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   9

11. Maintenance

Contents of this chapter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Maintenance intervals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Descriptions of symbols  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . 108
Recommended maintenance intervals after start-up  . . . . . . . . . . . . . . . . . . . . . . . . 108

Cabinet  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Heatsink   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Cleaning the interior of the heatsink  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Fans   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Replacing the circuit board compartment cooling fans . . . . . . . . . . . . . . . . . . . . . . . 111
Replacing the main cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Replacing the standard drive module  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Capacitors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Reforming the capacitors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Replacing the control unit battery  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Memory unit   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

12. Ordering information

Contents of this chapter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Output (du/dt) filters   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Sine filters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
FSO accessories kit   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Retrofit accessory kits  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

13. Technical data

Contents of this chapter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Ratings   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
When is derating needed  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Ambient temperature derating   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Altitude derating  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . . . . 122

Ex motor, sine filter, low noise  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

 Fuses (IEC)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Ultrarapid (aR) fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Fuses (UL)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Dimensions, weights and free space requirements   . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Units without full-size output cable connection terminals (+0H371) and with a 
common mode filter (+E208)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Terminal data for the control cables  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Electrical power network specification   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Brake resistor connection data  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
DC connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Control unit connection data (ZCU-14)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Summary of Contents for ACS880-04F

Page 1: ...ABB industrial drives Hardware manual ACS880 04F drive modules ...

Page 2: ...01 04 C132 marine type approved drives supplement 3AXD50000010521 Drive firmware manuals and guides ACS880 primary control program firmware manual 3AUA0000085967 Quick start up guide for ACS880 drives with primary control program 3AUA0000098062 Option manuals and guides DPMP 01 mounting platform for ACS AP control panel installation guide 3AUA0000100140 DPMP 02 03 mounting platform for ACS AP X co...

Page 3: ...anual ACS880 04F drive modules 3AXD50000034664 Rev A EN EFFECTIVE 2016 12 28 2016 ABB Oy All Rights Reserved 1 Safety instructions 5 Mechanical installation Table of contents 7 Electrical installation 9 Start up ...

Page 4: ......

Page 5: ...1 Terms and abbreviations 22 3 Operation principle and hardware description Contents of this chapter 25 Product overview 26 Layout 27 Standard drive module configuration 27 Drive module without full size output cable connection terminals option 0H371 and IP20 shrouds option 0B051 with common mode filter E208 29 Control unit 30 Control panel 30 Overview of power and control connections 31 External ...

Page 6: ...ar option H370 54 Attaching the external control unit 54 Attaching the external control unit to a mounting plate or wall 55 Attaching the external control unit vertically on a DIN rail 56 Attaching the control unit horizontally on a DIN rail 56 6 Guidelines for planning the electrical installation Contents of this chapter 57 Limitation of liability 57 Selecting the supply disconnecting device 58 E...

Page 7: ... against ground faults 69 Residual current device compatibility 69 Connecting drive modules to a common DC system 69 Implementing the Emergency stop function 70 Implementing the Safe torque off function 70 Implementing the ATEX certified Safe motor disconnection function option Q971 70 Implementing safety functions provided by the FSO safety functions module options Q972 and Q973 70 Declaration of...

Page 8: ...am 89 Notes 90 External power supply for the control unit 90 AI1 and AI2 as Pt100 Pt1000 PTC and KTY84 sensor inputs XAI XAO 91 DI6 XDI 6 as PTC sensor input 92 DIIL input XD24 1 92 Drive to drive link XD2D 92 Safe torque off XSTO 93 Safety functions X12 93 Installing the control panel holder back onto the external control unit 93 Connecting a control panel 94 Controlling several drives from one c...

Page 9: ...t filters 117 Sine filters 117 FSO accessories kit 118 Retrofit accessory kits 118 13 Technical data Contents of this chapter 119 Ratings 119 Definitions 120 When is derating needed 120 Ambient temperature derating 121 Altitude derating 122 Deratings for special settings in the drive control program 122 Ex motor sine filter low noise 122 High speed mode 124 Fuses IEC 125 Ultrarapid aR fuses 125 Fu...

Page 10: ...139 14 Dimension drawings Contents of this chapter 141 Standard configuration IP20 UL Open Type 142 Drive module with options E208 and H370 IP20 UL Open Type 143 Drive module with options 0B051 E208 0H371 IP00 UL Open Type 144 Drive module with options 0B051 E208 0H371 C217 IP00 UL Open Type 145 Drive module with options 0B051 0H371 IP00 UL Open Type 146 Mounting plate 147 External control unit 14...

Page 11: ...on 167 Placing the brake resistors 167 Protecting the system against thermal overload 167 Protecting the resistor cable against short circuits 168 Mechanical installation of external brake resistors 168 Electrical installation 168 Checking the insulation of the assembly 168 Connection diagram 168 Connection procedure 168 Start up 168 Technical data 169 Ratings 169 SAFUR resistors 169 Dimensions an...

Page 12: ...12 Further information Product and service inquiries 173 Product training 173 Providing feedback on ABB Drives manuals 173 Document library on the Internet 173 ...

Page 13: ...mage to the equipment They also tell you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment General warning tells about conditions other than those caused by electricity which can cau...

Page 14: ...ly Make sure that debris from borings and grindings does not enter the drive during the installation Electrically conductive debris inside the drive may cause damage or malfunction Make sure that there is sufficient cooling Before you connect voltage to the drive make sure that the cabinet doors are closed Keep the doors closed during the operation Obey the panel builder s instructions Before you ...

Page 15: ...rk 1 Clearly identify the work location 2 Disconnect all possible voltage sources Open the main disconnector of the drive Open the disconnector of the supply transformer as the main disconnector of the drive does not remove the voltage from the input busbars of the drive Make sure that reconnection is not possible Lock the disconnectors to open position and attach a warning notice to them Disconne...

Page 16: ...maximum speed We do not recommend that you secure the cabinet by arc welding Do not do insulation or voltage withstand tests on the drive or drive modules Note The motor cable terminals of the drive are at a dangerous voltage when the input power is on regardless of whether the motor is running or not The DC bus and brake resistor terminals UDC UDC R and R are at a dangerous voltage External wirin...

Page 17: ...g work Always ground the drive the motor and adjoining equipment This is necessary for the personnel safety Proper grounding also reduces electromagnetic emission and interference Make sure that the conductivity of the grounding conductors is sufficient See section Selecting the power cables on page 62 Obey the local regulations Connect the power cable shields to protective earth PE of the drive t...

Page 18: ... during work Make sure that no other system like hydraulic crawling drives can rotate the motor directly or through any mechanical connection like felt nip rope etc Measure that the installation is de energized Use a multimeter with an impedance of at least 1 Mohm Make sure that the voltage between the drive output terminals T1 U2 T2 V2 T3 W2 and the grounding PE busbar is close to 0 V Make sure t...

Page 19: ... cabinet assembly of the drive module and install the module into a user defined cabinet plan the electrical installation of the drive cabinet make instructions for the end user of the drive concerning the mechanical installation of the drive cabinet connection of power and control cables to the cabinet installed drive and maintenance of the drive Read the manual before working on the drive You ar...

Page 20: ...enance contains maintenance instructions Ordering information gives ordering information on additional components available from ABB for the drive module installation Technical data contains the technical specifications of the drive module eg the ratings sizes and technical requirements provisions for fulfilling the requirements for CE and other markings Dimension drawings contains dimension drawi...

Page 21: ...f the cabinet to the floor Examining the installation site page 47 Ambient conditions page 132 Guidelines for planning the mechanical installation page 37 Route the cables Routing the cables page 66 Check the insulation of the supply cable the motor and the motor cable and the resistor cable if present Checking the insulation of the assembly page 78 Installing the drive module Install the drive mo...

Page 22: ...DDCS Distributed drives communication system a protocol used in optical fiber communication DTC Direct torque control EMC Electromagnetic compatibility EMI Electromagnetic interference FAIO 01 Optional analog I O extension module FCAN 01 Optional CANopen adapter module FCNA 01 Optional ControlNet fieldbus adapter module FDCO 0x Optional optical DDCS communication module FDIO 01 Optional digital I ...

Page 23: ...ed semiconductor type widely used in converters due to their easy controllability and high switching frequency I O Input Output IT system Type of supply network that has no low impedance connection to ground earth PLC Programmable logic controller RFI Radio frequency interference SAFUR Series of optional brake resistors STO Safe torque off SOIA Optical interface adapter board TN system Type of sup...

Page 24: ...24 Introduction to the manual ...

Page 25: ...peration principle and hardware description 25 3 Operation principle and hardware description Contents of this chapter This chapter describes the operating principle and construction of the drive module ...

Page 26: ...nt and voltage to direct current and voltage 3 DC link DC circuit between rectifier and inverter 4 Inverter Converts direct current and voltage to alternating current and voltage 5 Brake chopper option D150 Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary The chopper operates when the DC link voltage exceeds a certain maximum limit The vol...

Page 27: ...e module configuration is shown below A Front view 5 Heatsink cleaning hole cover B Back view 6 Flange 1 Drive module 7 Hood 2 Upper front cover 8 External control unit with control panel holder 3 Lower front cover 9 Control panel 4 Clear plastic shrouds attached See the part descriptions below 1 2 3 4 4 8 9 7 A B 6 5 ...

Page 28: ... back clear plastic shroud 14 External control unit The control unit can also be inside the drive module option P905 5 Lower back clear plastic shroud 15 Control panel 6 Front clear plastic shroud 16 Control cable clamp plate 7 Input power cable connection terminals option H370 17 Cables for connecting the control unit to the drive module 8 Output power cable connection terminals 18 Fiber optic ca...

Page 29: ... 2 Input cable connection busbars L1 U1 L2 V1 L3 W1 and DC and DC busbars UDC UCD with option H356 3 Circuit board compartment 4 Output cable connection busbars T1 U2 T2 V2 T3 W2 and brake resistor connection busbars R and R with option D150 5 Common mode filter option E208 6 Auxiliary cooling fans 7 Heatsink 8 PE busbar 9 Cover on heatsink cleaning hole 10 Main cooling fans 2 3 4 5 1 1 9 7 6 10 8...

Page 30: ...he external control unit The control panel can be mounted on the cabinet door using a DPMP 01 mounting platform option J410 or a DPMP 02 mounting platform option J413 For the use of the control panel see the firmware manual or ACS AP X assistant control panels user s manual 3AUA0000085685 English 1 ACS AP W bluetooth control panel 2 DPMP 01 door mounting kit option J410 3 DPMP 02 door mounting kit...

Page 31: ...y on page 35 4 Connector for the FSO xx safety functions module X12 The module can be installed on or above the control unit see page 95 5 Memory unit see page 116 6 I O terminal blocks See section External control connection terminals below and section Default I O connection diagram on page 89 7 Control panel see page 94 8 Brake resistor optional see page 165 9 du dt or sine filter optional see p...

Page 32: ...connection DIIL and 24 V output XDIO Digital input outputs XDI Digital inputs XSTO Safe torque off connection X12 Connector for optional safety functions modules X13 Control panel connection Slot 1 Optional module Slot 2 Optional module Slot 3 Optional module X205 Memory unit see page 116 J1 J2 Voltage Current selection jumpers J1 J2 for analog inputs J3 Drive to drive link termination jumper J6 C...

Page 33: ...g the drive module and control panel to the external control unit are shown below See sections Connecting the external control unit to the drive module page 86 and Connecting a control panel page 94 for the actual connections 3 m 9 8 ft BPOW 3 m 10 ft 2560 mm 8 4 ft CAT 5e cable ZBIB 8 0 3 1 5 ZCU ACS880 04F BGDR STO1 STO2 BPOW BGDR X3 SOIA ZINT V10 V20 ...

Page 34: ...designation key on page 35 2 Manufacturing address 3 Frame size 4 Cooling method 5 Degree of protection 6 Ratings see section Ratings on page 119 7 Short circuit withstand strength see section Electrical power network specification on page 127 8 Valid markings 9 Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturi...

Page 35: ...tion label as typical input voltage level 3 400 V AC 5 380 500 V This is indicated in the type designation label as typical input voltage levels 3 400 480 500 V AC Option codes plus codes Construction pedestal and cabling 0B051 No IP20 shrouds for cabling area H356 DC connection busbars H370 Full size input power cable connection terminals and PE busbar 0H371 No full size output power cable connec...

Page 36: ...le L521 FSE 31pulse encoder interface module Requires option Q972 L525 FAIO 01 analog I O extension module L526 FDIO 01 digital I O extension module L536 FPTC 01 thermistor protection module L537 FPTC 02 ATEX certified thermistor protection module Requires option Q971 Programmability N8010 Drive application programming CODESYS Safety Q971 ATEX certified Safe motor disconnection function using the ...

Page 37: ...al laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Installation alternatives The drive module can be installed from the flange onto a cabinet wall or a mounting plate with the heatsink degree of protection of IP55 in a cooling air channel or outdoors The control circuit compartment side of the module IP20...

Page 38: ...e cabinet Use a cabinet which has a frame sturdy enough to carry the weight of the drive components control circuitry and other equipment installed in it protects the user and drive module against contact and agrees with the requirements for dust and humidity has sufficient air inlet and outlet gratings that allow free flow of cooling air through the cabinet This is critical for proper cooling of ...

Page 39: ...ttach the cabinet to the floor or prop it up from the back The module has its center of gravity at the back and the cabinet easily topples over 2 Air inlet for the power cable connection and circuit board compartment part of drive module and for other equipment For losses and cooling data requirements see page 127 3 Air outlet for the he power cable connection and circuit board compartment part of...

Page 40: ...Cabinet back plate The maximum allowed depth of the back plate is 60 mm 2 36 in in order not to cover the air flow grate at the top off the heatsink 8 Drive module front part a drive module heatsink part b 2 Hood 9 Drive module control unit Note With an internal control unit option P905 the upper door air inlet is critical for proper cooling of the control board 3 Cabinet grounding busbar PE 10 Gr...

Page 41: ...he cabinet Fasten the cabinet to the floor from the front and to the floor or wall from the back Always fasten the drive module from its fastening points to the cabinet For details see the module installation instructions WARNING Do not fasten the cabinet by electric welding ABB does not assume any liability for damages caused by electric welding as the welding circuit can damage electronic circui...

Page 42: ...not possible we recommend to leave the seams between the panels unpainted and equipped with special conductive EMC strips to provide adequate galvanic connection Usually reliable strips are made of flexible silicon mass covered with a metal mesh The non tightened touch contact of the metal surfaces is not sufficient so a conductive gasket between the surfaces is required The maximum recommended di...

Page 43: ...he internal cooling fan of the drive module rotates at a constant speed thus blowing constant air flow through the module Whether the same amount of air must be replaced all the time in the facility depends on how much heat must be removed Leave enough free space around the components to ensure sufficient cooling Observe the minimum clearances given for each component For the required free space a...

Page 44: ...icient to keep the component temperatures low enough in IP22 cabinets In IP54 cabinets thick filter mats are used to prevent water splashes from entering the cabinet This requires the installation of additional cooling equipment such as a hot air exhaust fan Preventing the recirculation of hot air Prevent hot air circulation outside the cabinet by leading the out coming hot air away from the area ...

Page 45: ...on its back If you install the drive module on its back make sure that the hot cooling air that flows upwards from the module does not cause danger Planning the placement of the control panel The control panel can be mounted onto the cabinet door using a control panel mounting platform option J410 For the installation instructions refer to DPMP 01 mounting platform for ACS AP control panel 3AUA000...

Page 46: ...46 Guidelines for planning the mechanical installation ...

Page 47: ...he ambient conditions of the drive meet the specifications 1 The material onto which the drive module is mounted must be non flammable and strong enough to carry the weight of the module There is enough free space above the drive to enable cooling air flow service and maintenance The floor that the drive is installed on is of non flammable material as smooth as possible and strong enough to suppor...

Page 48: ...npack the package as follows see the package drawing on page 49 Cut the bands Lift the top lid If top boxes B1 are included lift them off and remove the lower lid Lift the inner and outer sheathings Remove the additional boxes and supports Insert lifting hooks to the drive module lifting eyes and lift the module to the installation place Note Before you lift the module horizontally remove the bott...

Page 49: ...es in the middle front cover of the drive module 7 Accessory sleeve Contains external control unit with control cable clamp plate and factory installed optional modules output cable connection terminal box B2 see below for the box contents input cable connection terminal box option H370 B3 see below for the box contents DPMP 02 door mounting kit option J413 8 If all options do not fit in the acces...

Page 50: ...plastic shroud 10 Clear plastic shroud for input cabling 11 Top clear plastic shroud 12 Clear plastic shroud for input cable lead through from side 13 Screws in a plastic bag 14 Metallic shroud without ground bar 15 Not in use 3AXD5000009515 2 6 7 5 4 3 1 Box B2 contains this box with standard drive module configuration 1 Paper fill 2 Output cable connection terminal T3 W2 3 Output cable connectio...

Page 51: ...drive to verify that the unit is of the correct type Attaching alternatives The drive module can be attached by its flange or back heatsink to a mounting plate or wall 33AXD5000009522 3 6 4 2 5 1 7 Box B3 contains additionally this box with option H370 1 Metallic shroud with ground bar 2 Paper fill 3 Input cable connection terminal L3 W1 4 Input cable connection terminal L2 V1 5 Input cable connec...

Page 52: ...ing plate hole dimensions A dimension drawing of a mounting plate for a Rittal TS 8 cabinet is also given 1 Make a hole to the mounting plate for the drive module heatsink penetration 2 Attach the drive module flange to the mounting plate with screws 3 For NEMA 12 installations and if otherwise needed Attach the hood 6 11 11 6 6 1 3 2 ...

Page 53: ...nical installation 53 Attaching the drive module by the heatsink 1 Attach the support brackets to the heatsink back 2 Attach the support brackets to the wall 1 1 2 2 2 2 Combi screw M8 20 20 N m 14 8 lbf ft ...

Page 54: ...ing the external control unit The drive control unit can be attached on a mounting plate or onto a DIN rail Note Connect the fiber optic power supply and BGDR cables from the drive module to the external control unit before you attach the control unit See section Connections to the control unit on page 87 ...

Page 55: ...chanical installation 55 Attaching the external control unit to a mounting plate or wall 1 Attach the mounting screws in the wall 2 Lift the unit onto the screws and tighten the screws 3aua0000130997 1 2 ...

Page 56: ...k of the control unit with three screws 2 Click the control unit to the rail as shown below B Attaching the control unit horizontally on a DIN rail 1 Attach the latches A to the back of the control unit with three screws 2 Click the control unit to the rail as shown below B 3aua0000130997 A A B B A A B B 3aua0000130997 ...

Page 57: ...ons cable routing and way of operation for the drive system Limitation of liability The installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not obeyed the drive can experience proble...

Page 58: ...nal voltage and current of the drive Examining the compatibility of the motor and drive Use an asynchronous AC induction motor permanent magnet motor AC induction servomotor or ABB synchronous reluctance motor SynRM motor with the drive Several induction motors can be connected at a time Select the motor size and drive type from the rating tables in chapter Technical data on basis of the AC line v...

Page 59: ...currents Insulated N end non drive end bearings protect the motor bearings Requirements table The following table shows how to select the motor insulation system and when optional ABB du dt filters insulated N end non drive end motor bearings and ABB common mode filters are required Failure of the motor to fulfill the following requirements or improper installation may shorten motor life or damage...

Page 60: ... output power of high output motors is higher than what is stated for the particular frame size in EN 50347 2001 This table shows the requirements for ABB random wound motor series for example M3AA M3AP and M3BP Additional requirements for non ABB high output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 2001 Th...

Page 61: ...nd substitute into equation t 0 8 ÛLL du dt Additional note for sine filters Sine filters protect the motor insulation system Therefore the du dt filter can be replaced with a sine filter The peak phase to phase voltage with the sine filter is approximately 1 5 UN Additional note for common mode filters Common mode filters are available as plus code option E208 Nominal AC supply voltage Requiremen...

Page 62: ...uit must have bonding at both ends A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended Compared to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation bearing currents and wear Unless local wiring regulations state otherwise the cross section...

Page 63: ...lowed power cable types to be used with the drive are presented below Recommended power cable types Drive type ACS880 04 IEC 1 US 2 Cu cable type Al cable type Cu cable type Al cable type mm2 mm2 AWG kcmil AWG kcmil UN 400 V 725A 3 3 3 185 4 3 185 3 500 MCM or 4 300 MCM 3 500 MCM or 4 300 MCM 820A 3 3 3 240 4 3 240 3 600 MCM or 4 400 MCM 3 700 MCM or 4 500 MCM 880A 3 3 3 240 4 3 240 3 600 MCM or 4...

Page 64: ... shielded power cable for the motor cables if metallic conduit is not used For the North American market 600 V AC cable is accepted for up to 500 V AC 1000 V AC cable is required above 500 V AC below 600 V AC For drives rated over 100 amperes the power cables must be rated for 75 C 167 F Conduit Couple separate parts of a conduit together bridge the joints with a ground conductor bonded to the con...

Page 65: ...ed pair cable for analog signals We recommend this type of cable for the pulse encoder signals also Employ one individually shielded pair for each signal Do not use common return for different analog signals A double shielded cable figure a below is the best alternative for low voltage digital signals but single shielded b twisted pair cable is also acceptable Signals in separate cables Run analog...

Page 66: ...e trays Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Do not install extra cables through the drive The cable trays must have good electrical bonding to each othe...

Page 67: ...t the shields of the cables otherwise together US Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding runs consistently without breaks from the drive to the motor Implementing thermal overload and short circuit protection Protecting the drive and input power cable in short circuits Protect the drive with fuses a and the input cable with fuses b or a circui...

Page 68: ...ence problems that the warranty does not cover Note Fuses must be used with circuit breakers in the USA 1 Maximum allowed rated conditional short circuit current IEC 61439 1 of the electrical power network 2 Contact your local ABB representative WARNING Due to the inherent operating principle and construction of circuit breakers independent of the manufacturer hot ionized gases can escape from the...

Page 69: ... feeding in additional motor and load data The most common temperature sensors are motor sizes IEC 180 225 thermal switch eg Klixon motor sizes IEC 200 250 and larger PTC or Pt100 See the firmware manual for more information on the motor thermal protection and the connection and use of the temperature sensors Protecting the drive against ground faults The drive is equipped with an internal ground ...

Page 70: ...afe disconnection function application guide 3AUA0000132231 English FPTC 02 ATEX certified thermistor protection module Ex II 2 GD option L537 user s manual 3AXD50000027782 English Implementing safety functions provided by the FSO safety functions module options Q972 and Q973 The drive can be equipped with an FSO xx safety functions module option Q971 or Q973 which enables the implementation of fu...

Page 71: ...s or harmonic filters to the motor cables between the drive and the motor They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves If there are power factor compensation capacitors in parallel with the three phase input of the drive 1 Do not connect a high power capacitor to the power line while the drive is connected The connection will cause voltage ...

Page 72: ...pen the output contactor while the drive controls the motor The DTC motor control operates extremely fast much faster than it takes for the contactor to open its contacts When the contactor starts opening while the drive controls the motor the DTC control will try to maintain the load current by immediately increasing the drive output voltage to the maximum This will damage or even burn the contac...

Page 73: ...ol mode 2 Open the main contactor of the drive with S11 3 Switch the motor power supply from the drive to direct on line with S40 4 Wait for 10 seconds to allow the motor magnetization to die away 5 Start the motor with S41 Q1 Drive main switch Q4 Bypass circuit breaker K1 Drive main contactor K4 Bypass contactor K5 Drive output contactor S11 Drive main contactor on off control S40 Motor power sup...

Page 74: ...contactors motors cause voltage transients when switched off The relay contacts on the drive control unit are protected with varistors 250 V against overvoltage peaks In spite of this it is highly recommended that inductive loads are equipped with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances m...

Page 75: ...odule See the table below for the sensor insulation requirement For sensor connection to the extension module see its manual 4 You can connect a sensor to an external thermistor relay the insulation of which is rated for the main circuit voltage of the drive Drive I O I O extension and encoder interface modules See section AI1 and AI2 as Pt100 Pt1000 PTC and KTY84 sensor inputs XAI XAO on page 91 ...

Page 76: ...use the FAIO 01 analog I O extension module option L525 Example circuit diagram See page 151 FPTC xx Reinforced insulation between sensor connector and other connectors including drive control unit connector X No special requirement Extension module Temperature sensor type Temperature sensor insulation requirement Type Insulation Isolation PTC KTY Pt100 Pt1000 ...

Page 77: ...If you are not a qualified electrician do not do the installation work described in this chapter Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur Installing the motor cable at the motor end Ground the motor cable shield 360 degrees at the lead through of the motor terminal box ...

Page 78: ...asure the insulation resistance between each phase conductor and then between each phase conductor and the Protective Earth conductor using a measuring voltage of 1000 V DC The insulation resistance of an ABB motor must exceed 100 Mohm reference value at 25 C or 77 F For the insulation resistance of other motors consult the manufacturer s instructions Note Moisture inside the motor casing will red...

Page 79: ...0 disconnect the filter grounding wire before connecting the drive to the supply network Insulate the end of the wire and attach it The wire is located behind the middle front cover WARNING If a drive with EMC filter E200 is installed on an IT system an ungrounded power system or a high resistance grounded over 30 ohm power system the system will be connected to earth potential through the EMC fil...

Page 80: ...rom its top back grounding hole to the cabinet frame or from the module PE terminal to the cabinet PE busbar Connecting the power cables WARNING Obey the safety instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur M10 ...

Page 81: ... a cable with a grounding conductor 2b 3 We recommend 360 degree grounding at the cabinet entry if a shielded cable is used Ground the other end of the input cable shield or PE conductor at the distribution board 4 We recommend 360 degree grounding at the cabinet entry see page 42 5 Use a separate grounding cable if the conductivity of the cable shield is 50 of the conductivity of the phase conduc...

Page 82: ...with cable lugs or by busbars Protect the power cable terminals and electrical parts against contact and ground the drive module correctly Cabinet installation 1 Run the motor cables from the motor to the cabinet Ground the cable shields 360 at the lead through plate 2 Twist the cable shields of the motor cables into bundles and connect them and any separate ground conductors or cables to the grou...

Page 83: ...of the drive module For the tightening torques see page 127 DC connection The UDC and UDC terminals are intended for common DC configurations of a number of drives allowing regenerative energy from one drive to be utilized by the other drives in the motoring mode See ACS880 01 drives and ACS880 04 drive modules common DC systems application guide 3AUA0000127818 English Overview of control cable co...

Page 84: ...ing the control panel holder from the external control unit 1 Disconnect the control panel cable from connector X13 on the control unit 2 Loosen the mounting screws of the control panel holder and take the holder off 1 X13 X13 2 2 2 2 ...

Page 85: ...Electrical installation 85 Attaching the control cable clamp plate Attach the control cable clamp plate either to the top or base of the control unit with four screws as shown below 0 7 N m 6 2 lbf in ...

Page 86: ...ule through the slot in the middle front cover at the front or left side or from below or above When routing through the middle front cover remove the plate which covers the slot Then install the rubber grommet into the slot from the accessories box no 6 in the package drawing on page 49 Connections to the drive module 1 Connect power supply cable of the control unit to the BPOW connector and the ...

Page 87: ...of the control unit 2 Connect the cables to the ZBIB board terminals 3 Connect the BPOW cable grounding wire to the grounding terminal at the back top or bottom of the control unit BPOW ZBIB SOIA ZBIB X3 1 X3 1 V10 V1 X3 2 X3 2 V20 V2 X3 3 not used X3 3 not used BGDR ZBIB X7 STO1 X7 STO1 X8 STO2 X8 STO2 TXD transmitter V1 V2 BPOW 2 ZBIB 1 3 X3 3 X3 2 X7 X8 SOIA BGDR X3 1 STO2 RXD receiver STO1 ...

Page 88: ...d fastened with a screw at the clamp plate Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacitor eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points Tighten the screws to secure the connection 3 Connect the conductors to the app...

Page 89: ...2D Drive to drive link termination 6 ON OFF Drive to drive link Shield 4 BGND 3 A 2 B 1 Safe torque off XSTO Safe torque off Both circuits must be closed for the drive to start IN2 4 IN1 3 SGND 2 OUT 1 Digital inputs XDI By default not in use DI6 6 Constant speed 1 select 1 on 5 DI5 5 Acceleration deceleration select 4 DI4 4 Reset DI3 3 Forward 0 Reverse 1 DI2 2 Stop 0 Start 1 DI1 1 Digital input ...

Page 90: ...ined by parameter 22 26 6 Must be set to ON when the drive is the last unit on the drive to drive XD2D link 7 Determines whether DICOM is separated from DIOGND ie common reference for digital inputs floats See also Ground isolation diagram on page 131 DICOM connected to DIOGND DICOM and DIOGND separate 8 See section DIIL input XD24 1 on page 92 External power supply for the control unit External 2...

Page 91: ...t insulated according to IEC 60664 the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfill the requirement the I O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I O terminals 1 Set the input typ...

Page 92: ...ication with one master drive and multiple followers Set termination activation jumper J3 next to this terminal block to the ON position on the drives at the ends of the drive to drive link On intermediate drives set the jumper to the OFF position Use shielded twisted pair cable 100 ohm for example PROFIBUS compatible cable for the wiring For best immunity high quality cable is recommended Keep th...

Page 93: ...que off function on page 153 Safety functions X12 See section Installing the FSO safety functions module options Q972 and Q973 on page 95 and FSO 12 safety functions module user s manual 3AXD50000015612 English Installing the control panel holder back onto the external control unit Install the control panel holder back onto the external control unit in reverse order to removing it see section Remo...

Page 94: ...nglish 1 Connect the panel to one drive using an Ethernet eg CAT5E cable Use Menu Settings Edit texts Drive to give a descriptive name to the drive Use parameter 49 01 to assign the drive with a unique node ID number Set other parameters in group 49 if necessary Use parameter 49 06 to validate any changes Repeat the above for each drive 2 With the panel connected to one drive link the drives toget...

Page 95: ...nected b Note 1 When a PC is connected to the control panel the control panel keypad is disabled In this case the control panel acts as a USB RS485 adapter Installing optional modules Installing the FSO safety functions module options Q972 and Q973 Install the FSO safety functions module in Slot 2 of the control unit Note Install the FSO safety functions module before you install any other optiona...

Page 96: ...ernative bottom plate from the FSO package to module 3 Connect the FSO data cable to connector X12 on the control unit 4 Put the FSO module into its position 5 Tighten the FSO module electronics grounding screw to 0 8 N m Note The screw tightens the connections and grounds the module It is essential for fulfilling the EMC requirements and for proper operation of the module 6 Fasten the module with...

Page 97: ...top the drive and do the steps in section Precautions before electrical work on page 15 before you start work 2 Insert the module carefully into its position on the control unit 3 Tighten the grounding screw torque of 0 8 N m Note The screw tightens the connections and grounds the module It is essential for fulfilling the EMC requirements and for proper operation of the module Wiring the optional ...

Page 98: ...structions If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Precautions before electrical work on page 15 before you start work 2 Insert the memory unit to the X205 terminal on the control unit 3 Fasten the memory unit with one screw X205 ...

Page 99: ...jury or death or damage to the equipment can occur Check that Cabinet construction The drive module is fastened properly to the cabinet See chapters Guidelines for planning the mechanical installation Mechanical joints are tightened and not broken Parts are clean and painted surfaces not scratched The cabinet frame and parts which are in metal to metal contact with the frame for example seams comp...

Page 100: ... insufficient clearance or loss of shielding against contact The control unit is wired properly to the drive module The control panel cable is connected properly Cables are not lying against sharp edges or bare live parts Bending radius of fiber optic cables is at least 3 5 cm 1 38 in The type markings insulation plates and cross connections of terminal blocks are correct Grounding and protection ...

Page 101: ...e matches the nominal input voltage of the drive Check the type designation label The input power cable has been connected to the appropriate terminals the phase order is right and the terminals have been tightened Pull the conductors to check Appropriate AC fuses and a main disconnector have been installed The motor cable has been connected to the appropriate terminals the phase order is right an...

Page 102: ...102 Installation checklist ...

Page 103: ...ate start up guide or firmware manual If you need more information on the use of the control panel see ACS AP x Assistant control panels user s manual 3AUA0000085685 English For drives with resistor braking option D151 see also section Start up on page 168 For option N7502 see also ACS880 drives with SynRM motors option N7502 supplement 3AUA0000145506 English For drives with ABB du dt filter check...

Page 104: ...ncluding acceptance test on page 159 7 For drive modules with an FSO xx safety functions module option Q972 and Q973 Test and validate the operation of the safety functions See the delivery specific circuit diagrams and FSO 12 safety functions module user s manual 3AXD50000015612 English or FSO 21 safety functions module user s manual 3AXD50000015614 English English ...

Page 105: ...ith options J410 Warning and fault messages See the firmware manual for the descriptions causes and remedies of the control program warning and fault messages Where LED Color When the LED is lit Control panel mounting platform POWER Green Control unit is powered and 15 V is supplied to the control panel FAULT Red Drive in fault state ...

Page 106: ...106 Fault tracing ...

Page 107: ...B recommends annual drive inspections to ensure the highest reliability and optimum performance Note Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components Consult your local ABB Service representative for additional maintenance recommendations The tables below shows the maintenance tasks which can be done by th...

Page 108: ... work 2 When necessary clean the interior of the cabinet with a soft brush and a vacuum cleaner Action Description I Visual inspection and maintenance action if needed P Performance of on off site work commissioning tests measurements or other work R Replacement of component Action Target I IP22 and IP42 air inlet and outlet meshes on the cabinet doors R IP54 air filters on the cabinet doors P Qua...

Page 109: ...pment can occur WARNING Use a vacuum cleaner with antistatic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Stop the drive and do the steps in section Precautions before electrical work on page 15 before you start the work 2 Undo the attaching screws of the cover plate on the service opening 3 Remove the plate 4 Blow clean compressed air n...

Page 110: ...ature and dust concentration See the firmware manual for the actual signal which indicates the running time of the cooling fan For resetting the running time signal after a fan replacement please contact ABB Replacement fans are available from ABB Do not use other than ABB specified spare parts ...

Page 111: ... to the equipment can occur 1 Stop the drive and do the steps in section Precautions before electrical work on page 15 before you start the work 2 Remove the cover 3 Undo the fastening screw of the fan enclosure 4 Unplug the power supply cable of the fan 5 Install the new fan in reverse order to the above 6 Reset the counter if used in group 5 in the primary control program 4 3 2 ...

Page 112: ...s from the front side 1 Stop the drive and do the steps in section Precautions before electrical work on page 15 before you start the work 2 If motor cables are connected to the output terminals disconnect them 3 Undo the mounting screws of the fan cassette cover and remove the cover 4 Disconnect the power supply wires of the fans 5 Pull the fan cassette out 6 Install the new fan cassette in rever...

Page 113: ...ical work on page 15 before you start the work 2 Undo the locking screw 3 Push the fan cassette to the left 4 Take the cassette down 5 Disconnect the power supply wires of the fans see the previous page 6 Install the new fan cassette in reverse order to the above 7 Reset the counter if used in group 5 in the primary control program 2 3 4 ...

Page 114: ... preferably with help from another person 8 Install the new module in reverse order to the above Capacitors The drive intermediate circuit employs several electrolytic capacitors Their lifespan depends on the operating time of the drive loading and ambient temperature The lifespan of the capacitor can be prolonged by lowering the ambient temperature It is not possible to predict a capacitor failur...

Page 115: ... before electrical work on page 15 before you start the work To replace the control unit battery 1 Remove the M4x8 T20 screws at the ends of the control unit 2 To see the battery remove the XD2D terminal block 3 Carefully lift the edge of the control unit cover on the side with the I O terminal blocks 4 Carefully pull the battery out of the battery holder 5 Carefully put a new CR2032 battery into ...

Page 116: ... unit is located in the control unit see page 31 WARNING Do not remove or insert the memory unit when the drive module is powered After power up the drive scans the memory unit If a different control program or different parameter settings are detected they are copied to the drive This can take several minutes To remove the memory unit 1 Remove the fastening screw 2 Pull the memory unit out ...

Page 117: ...he installation accessories available from ABB All other parts must be sourced from a third party by the system integrator For a listing refer to the kit specific installation instructions available at https www151 abb com spaces lvacdrivesengineeringsupport content For access contact your local ABB representative Output du dt filters See section du dt filters on page 171 Sine filters See section ...

Page 118: ...ut and motor cabling area as standard The shrouds can be excluded with option 0B051 Kit code Ordering code Illustration A X X 279 3AXD50000025495 Instruction code 3AXD50000025583 Kit Option code Ordering code Common mode filter kit E208 3AXD50000026145 Full size cable connection terminals for input power cables H370 3AXD50000019542 Full size cable connection terminals for output power cables 3AXD5...

Page 119: ...N ILd PLd IHd PHd A A A A kW kVA A kW A kW UN 400 V 504A 3 R11 504 560 671 504 250 349 485 250 361 200 584A 3 R11 584 730 828 584 315 405 575 315 429 250 649A 3 R11 649 730 954 649 355 450 634 355 477 250 725A 3 R11 725 1020 1100 725 400 502 715 400 566 315 820A 3 R11 820 1020 1100 820 450 568 810 450 625 355 880A 3 R11 880 1100 1100 880 500 610 865 500 725 400 UN 500 V 459A 5 R11 459 560 671 459 ...

Page 120: ...rive temperature 140 200 of IHd depending on power rating Imax_start Maximum output current at start Available for two seconds only at start every five seconds if start current limit is activated by parameter 30 15 Maximum start current I2 Continuous rms output current No overload capability at 40 C 104 F PN Typical motor power in no overload use ILd Continuous rms output current allowing 10 overl...

Page 121: ...ge 40 55 C 104 131 F the rated output current is derated by 1 for every added 1 C 1 8 F as follows Calculate the output current by multiplying the current given in the rating table by the derating factor 1 00 0 85 40 C 55 C 104 F 131 F Derating factor Ambient temperature ...

Page 122: ... filter low noise Table below gives the deratings for these cases drive is used with an ABB motor for explosive atmospheres Ex and EX motor in Parameter 95 15 Special HW settings is enabled sine filter given in the selection table on page 172 is used and ABB sine filter in Parameter 95 15 Special HW settings is enabled Low noise optimization is selected in Parameter 97 09 Switching freq mode Derat...

Page 123: ... 315 562 431 880A 3 809 450 570 450 785 450 760 600 630 355 600 500 UN 500 V 459A 5 437 250 427 316 430 250 419 311 357 250 345 265 502A 5 478 315 458 345 470 315 450 340 390 250 370 290 582A 5 531 355 509 364 514 355 487 347 400 250 380 298 634A 5 579 400 553 419 560 400 530 400 410 250 392 298 715A 5 657 450 641 522 637 450 620 507 462 315 428 362 820A 5 753 500 734 576 730 500 710 560 530 355 4...

Page 124: ...z A kW A A UN 400 V 504A 3 120 504 250 485 361 500 390 200 370 290 584A 3 120 584 315 575 429 500 437 250 419 311 649A 3 120 649 355 634 477 500 485 250 466 346 725A 3 120 725 400 715 566 500 519 250 496 390 820A 3 120 820 450 810 625 500 587 315 562 431 880A 3 120 880 500 865 725 500 630 355 600 500 UN 500 V 459A 5 120 459 315 450 330 500 357 250 345 265 502A 5 120 502 355 483 361 500 390 250 370...

Page 125: ...CS880 04F Input current A Fuse A A2 s V Manufacturer Type DIN 43620 Size UN 400 V 504A 3 505 800 490000 690 Bussmann 170M6812D 3 584A 3 585 1000 985000 690 Bussmann 170M6814D 3 649A 3 650 1000 985000 690 Bussmann 170M6814D 3 725A 3 725 1250 2150000 690 Bussmann 170M8554D 3 820A 3 820 1600 4150000 690 Bussmann 170M8557D 3 880A 3 880 1600 4150000 690 Bussmann 170M8557D 3 UN 500 V 459A 5 460 630 4900...

Page 126: ...pace around the drive module see page 45 715A 5 715 800 600 Ferraz L A4BY800 820A 5 820 900 600 Ferraz L A4BY900 880A 5 880 1000 600 Ferraz L A4BY1000 Standard drive module configuration including flange and shrouds Frame size Height1 Width Depth2 Weight mm in mm in mm in kg lb R11 1733 68 23 620 24 41 477 18 78 224 494 Optional selection 0B051 0H371 without shrouds full size output power cable co...

Page 127: ...A 3 R11 1400 120 7400 750 75 ACS880 04F 725A 3 R11 1400 120 7950 850 75 ACS880 04F 820A 3 R11 1400 120 8950 950 75 ACS880 04F 880A 3 R11 1400 120 9600 1000 75 UN 500 V ACS880 04F 459A 5 R11 1400 120 3900 550 75 ACS880 04F 502A 5 R11 1400 120 5050 600 75 ACS880 04F 582A 5 R11 1400 120 5750 700 75 ACS880 04F 634A 5 R11 1400 120 7350 800 75 ACS880 04F 715A 5 R11 1400 120 7900 900 75 ACS880 04F 820A 5...

Page 128: ...s reluctance motors SynRM motors Voltage U2 0 to U1 3 phase symmetrical Umax at the field weakening point Frequency f2 0 500 Hz For drives with du dt filter 200 Hz For drives with sine filter 120 Hz Frequency resolution 0 01 Hz Current See section Ratings Switching frequency 3 kHz typically Maximum recommended motor cable length DTC control Scalar control 500 m 1640 ft 500 m 1640 ft Note Motor cab...

Page 129: ...nd XDIO 2 Input output mode selection by parameters DIO1 can be configured as a frequency input 0 16 kHz with hardware filtering of 4 microseconds for 24 V level square wave signal sinusoidal or other wave form cannot be used DIO2 can be configured as a 24 V level square wave frequency output See the firmware manual parameter group 11 Connector pitch 5 mm wire size 2 5 mm2 As inputs 24 V logic lev...

Page 130: ... XSTO Connector pitch 5 mm 0 2 in wire size 2 5 mm2 14 AWG Input voltage range 3 30 V DC Logic levels 0 5 V 1 19 V For the drive to start both connections must be closed OUT1 to IN1 and IN2 Current consumption 50 mA 24 V DC continuous per STO channel EMC immunity according to IEC 61326 3 1 Control panel PC connection X13 Connector RJ 45 Cable length 3 m ...

Page 131: ... 2 NO 3 NC 1 COM 2 NO 3 XD24 DIIL 1 24VD 2 DICOM 3 24VD 4 DIOGND 5 XDIO DIO1 1 DIO2 2 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 XSTO OUT1 1 GND 2 IN1 3 IN2 4 Ground Common mode voltage between channels 30 V Ground selector J6 settings ZCU 14 All digital inputs share a common ground DICOM connected to DIOGND This is the default setting ZCU 14 Ground of digital inputs DI1 DI5 and DIIL DICOM is isolate...

Page 132: ...T and IT corner grounded network systems 0 to 2000 m 6561 ft above sea level Above 1000 m 3281 ft see page 120 Air temperature 15 to 55 C 5 to 131 F No frost allowed See page 120 40 to 70 C 40 to 158 F 40 to 70 C 40 to 158 F Relative humidity 5 to 95 Max 95 Max 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases Contamination levels IEC EN 60721 3 ...

Page 133: ...d materials should be dismantled and separated Generally all metals such as steel aluminum copper and its alloys and precious metals can be recycled as material Plastics rubber cardboard and other packaging material can be used in energy recovery Printed circuit boards and DC capacitors C1 1 to C1 x need selective treatment according to IEC 62635 guidelines To aid recycling plastic parts are marke...

Page 134: ...mpliance with the European RoHS Directive The RoHS Directive defines the restriction of the use of certain hazardous substances in electrical and electronic equipment Compliance with the European Machinery Directive The drive is an electronic product which is covered by the European Low Voltage Directive However the drive includes the Safe torque off function and can be equipped with other safety ...

Page 135: ...Technical data 135 Declaration of Conformity ...

Page 136: ...136 Technical data ...

Page 137: ...ltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment Drive of category C4 drive of rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Category C3 The drive complies with the standard with the following provisions 1 The drive is equipped wi...

Page 138: ...tive dust See page 132 The maximum ambient air temperature is 40 C 104 F at rated current The current is derated for 40 to 50 C 104 to 122 F The drive module is suitable for use in a circuit capable of delivering not more than 100 000 rms symmetrical amperes 600 V maximum when the input cable is protected with class T fuses The ampere rating is based on tests done according to UL 508C The cables l...

Page 139: ...erface It is Customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to...

Page 140: ...140 Technical data ...

Page 141: ...Dimension drawings 141 14 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules ...

Page 142: ...142 Dimension drawings Standard configuration IP20 UL Open Type ...

Page 143: ...Dimension drawings 143 Drive module with options E208 and H370 IP20 UL Open Type ...

Page 144: ...144 Dimension drawings Drive module with options 0B051 E208 0H371 IP00 UL Open Type ...

Page 145: ...Dimension drawings 145 Drive module with options 0B051 E208 0H371 C217 IP00 UL Open Type ...

Page 146: ...146 Dimension drawings Drive module with options 0B051 0H371 IP00 UL Open Type ...

Page 147: ...Dimension drawings 147 Mounting plate 3AXD50000038119 ...

Page 148: ...148 Dimension drawings 3AXD50000038119 ...

Page 149: ...Dimension drawings 149 External control unit 3axd50000011687 ...

Page 150: ...150 Dimension drawings ...

Page 151: ...Example circuit diagram 151 15 Example circuit diagram Contents of this chapter This chapter shows an example circuit diagram for a cabinet installed drive module ...

Page 152: ...a basic delivery plus code options other options to be acquired by the customer Motor temperature supervision ACS CP W control panel Switch fuse disconnector Main contactor Supply Alarm Brake resistor Drive module ZCU control unit 3 Motor Cabinet Common mode filter du dt filter or Input and output signals see page 89 360 degree grounding recommended V20 V10 SOIA sine filter BGDR X7 1 2 ...

Page 153: ...e drive output stage A see diagram below thus preventing the drive from generating the torque required to rotate the motor If the motor is running when Safe torque off is activated it coasts to a stop The Safe torque off function has a redundant architecture that is both channels must be used in the safety function implementation The safety data given in this manual is calculated for redundant use...

Page 154: ...contacts of the switch or relay must open close within 200 ms of each other An FSO xx safety functions module can also be used For more information see the FSO xx module documentation Cable types and lengths We recommend double shielded twisted pair cable see page 65 IEC 61508 1 2010 Functional safety of electrical electronic programmable electronic safety related systems Part 1 General requiremen...

Page 155: ...inals of the control unit must be at least 17 V DC to be interpreted as 1 Grounding of protective shields Ground the shield in the cabling between the activation switch and the control unit at the control unit Ground the shield in the cabling between two control units at one control unit only Single drive internal power supply Dual channel connection 24 V OUT1 SGND IN2 T1 U2 T2 V2 T3 W2 Control lo...

Page 156: ...to the activation switch Otherwise no SIL PL classification is given Pay special attention to avoiding any potential failure modes for the wiring For example use shielded cable For measures for fault exclusion of wiring see eg EN ISO 13849 2 2012 table D 4 24 V OUT1 SGND IN2 K IN1 ACS880 04F Control unit ...

Page 157: ...orque off function 157 Multiple drives internal power supply 24 V OUT1 SGND IN1 IN2 ACS880 04F OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 ACS880 04F ACS880 04F K XSTO Control unit XSTO Control unit XSTO Control unit ...

Page 158: ...orque off function Multiple drives external power supply OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 ACS880 04F 24 V ACS880 04F Control unit ACS880 04F 24 V DC K XSTO Control unit XSTO Control unit XSTO ...

Page 159: ...ce test of the safety function must be carried out by a competent person with adequate expertise and knowledge of the safety function as well as functional safety as required by IEC 61508 1 clause 6 The test procedures and report must be documented and signed by this person Acceptance test reports Signed acceptance test reports must be stored in the logbook of the machine The report shall include ...

Page 160: ...the motor is running Open the STO circuit The motor should stop The drive generates an indication if one is defined for running state in parameter 31 22 see the firmware manual Reset any active faults and try to start the drive Ensure that the motor stays at a standstill and the drive operates as described above in testing the operation when the motor is stopped Close the STO circuit Reset any act...

Page 161: ...tenance After the operation of the circuit is validated at start up the STO function shall be maintained by periodic proof testing In high demand mode of operation the maximum proof test interval is 20 years In low demand mode of operation the maximum proof test interval is 5 or 2 years see section Safety data page 162 It is assumed that all dangerous failures of the STO circuit are detected by th...

Page 162: ... The safety data is calculated for redundant use and does not apply if both STO channels are not used According to Table E1 EN ISO 13849 1 The following temperature profile is used in safety value calculations 670 on off cycles per year with T 71 66 C 1340 on off cycles per year with T 61 66 C 30 on off cycles per year with T 10 0 C 32 C board temperature at 2 0 of time 60 C board temperature at 1...

Page 163: ...ailures during a particular measurement interval under stated conditions PFDavg IEC 61508 Average probability of failure on demand PFH IEC 61508 Probability of dangerous failures per hour PL EN ISO 13849 1 Performance level Levels a e correspond to SIL SC IEC 61508 Systematic capability SFF IEC 61508 Safe failure fraction SIL IEC 61508 Safety integrity level 1 3 SILCL IEC EN 62061 Maximum SIL leve...

Page 164: ...164 Safe torque off function ...

Page 165: ...by the control program Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected Planning the braking system Selecting the default brake circuit components 1 Calculate the maximum power generated by the motor during braking Pmax 2 Select a suitable drive brake chopper and brake resistor combination for the application from the rating table on page 119 The ...

Page 166: ...ltage by the chopper where Selecting and routing the external brake resistor cables Use the same cable type for the resistor cabling as for the drive input cabling to ensure that the input fuses also protect the resistor cable Alternatively a two conductor shielded cable with the same cross sectional area can be used R Resistance of the custom resistor WARNING Never use a brake resistor with a res...

Page 167: ...dule in a place where they will cool Arrange the cooling of the resistor in a way that no danger of overheating is caused to the resistor or nearby materials the temperature of the room the resistor is located in does not exceed the allowed maximum Supply the resistor with cooling air water according to the resistor manufacturer s instructions WARNING The materials near the brake resistor must be ...

Page 168: ...r cables If a shielded three conductor cable is used cut the third conductor and ground the twisted shield of the cable protective earth conductor of the resistor assembly at both ends Connect the thermal switch of the brake resistor as described in section Protecting the system against thermal overload on page 167 Start up Set the following parameters ACS880 primary control program Disable the ov...

Page 169: ...The ratings apply at an ambient temperature of 40 C 104 F SAFUR resistors The degree of protection of SAFUR resistors is IP00 The resistors are not UL listed The thermal time constant of the resistors is 555 seconds Drive type Internal brake chopper Example brake resistor s Pbrcont Rmin Type R ER PRcont kW ohm ohm kJ kW UN 400 V ACS880 04F 504A 3 250 2 0 2xSAFUR125F500 2 00 7200 18 ACS880 04F 584A...

Page 170: ... lead through data See section Terminal and lead through data for the power cables on page 127 Brake resistor type ABB ordering code SAFUR125F500 68759285 SAFUR200F500 68759340 234 300 1320 Ø 7 345 1270 Brake resistor type Weight SAFUR125F500 25 kg 55 lb SAFUR200F500 30 kg 66 lb ...

Page 171: ...ve page 58 Selection table du dt filter types for the drive modules are given below Drive module type ACS880 04F du dt filter type Drive module type ACS880 04F du dt filter type UN 400 V UN 500 V 504A 3 FOCH0610 70 459A 5 FOCH0610 70 584A 3 FOCH0610 70 502A 5 FOCH0610 70 649A 3 FOCH0610 70 582A 5 FOCH0610 70 725A 3 FOCH0875 70 634A 5 FOCH0610 70 820A 3 FOCH0875 70 715A 5 FOCH0875 70 880A 3 FOCH087...

Page 172: ... for special settings in the drive control program on page 128 Description installation and technical data of the sine filters See Sine filters hardware manual 3AXD50000016814 English For more information contact ABB Filter type ABB ordering code FOCH 0610 70 68550483 FOCH 0875 70 3AUA0000125245 Basic drive module type ACS880 04F Sine filter type Drive module type ACS880 04F Sine filter type UN 40...

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