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ABB ACS880-04FXT, Hardware Manual

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Generic cabinet planning instructions

Contents of this chapter

This chapter contains generic cabinet planning instructions applicable to any user-defined
cabinet system. The topics discussed are essential for the safe and trouble-free use of 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 followed, the drive may experience problems that the warranty does not cover.

Cabinet construction

Basic requirements for the cabinet construction are listed below. Make sure that:

•

the cabinet frame is sturdy enough to carry the weight of the components, control circuitry
and other equipment installed in it

•

the cabinet protects the modules against contact and agrees with the requirements for
dust and humidity

•

the cabinet frame and doors are strong enough to provide adequate protection against
flames or pressure blast originating from inside the cabinet in case of arc flash or similar
failure

•

the cabinet has air inlet and outlet gratings that allow free flow of cooling air through
the modules inside the cabinet.

￭

Disposition of the devices

Plan a spacious layout to ensure easy installation and maintenance. Sufficient cooling air
flow, obligatory clearances, cables and cable support structures all require space.

4

Generic cabinet planning instructions 41

Summary of Contents for ACS880-04FXT

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 04FXT drive module packages Hardware manual ...

Page 2: ......

Page 3: ...ACS880 04FXT drive module packages Hardware manual Table of contents 1 Safety instructions 6 Mechanical installation 8 Electrical installation 11 Start up 3AXD50000274444 Rev B EN EFFECTIVE 2020 03 26 ...

Page 4: ......

Page 5: ...nce 21 Purpose of the manual 22 Related documents 23 Categorization by frame size and option code 23 Quick installation commissioning and operating flowchart 24 Terms and abbreviations 3 Operation principle and hardware description 25 Contents of this chapter 26 Product overview 27 Drive connection examples 29 Layout 29 Standard drive module configuration 30 Drive module configuration with IP20 sh...

Page 6: ... chapter 49 Installation alternatives 49 Channel installation 49 Basic requirements for the channel wall 50 Installation principle 51 Cabinet installation 51 Layout example outside view 52 Layout example inside view 52 Other installation positions than vertical 53 Required free space 6 Mechanical installation 55 Contents of this chapter 55 Examining the installation site 55 Moving and unpacking th...

Page 7: ... cables 72 Shielding 72 Signals in separate cables 72 Signals that can be run in the same cable 72 Relay cable 72 Control panel to drive cable 73 PC tool cable 73 Routing the cables 73 General guidelines IEC 73 General guidelines North America 74 Continuous motor cable shield conduit or enclosure for equipment on the motor cable 74 Separate control cable ducts 75 Implementing motor and motor cable...

Page 8: ...ction diagram 6 pulse with optional filters 89 Power cable connection diagram 6 pulse and 12 pulse with optional filters 91 Power cable connection diagram 6 pulse without optional filters 93 Power cable connection diagram 6 pulse and 12 pulse without optional filters 95 Preparing the cable ends and making 360 degree grounding at the cable entry 96 Power cable connection procedure 98 Connecting the...

Page 9: ...interior of the cabinet 125 Heatsink 126 Cleaning the interior of the heatsink 127 Fans 127 Replacing the circuit board compartment cooling fans 128 Replacing the main cooling fans 130 Replacing the standard drive module 130 Capacitors 130 Reforming the capacitors 130 Control panel 130 Replacing the real time clock battery 130 Replacing the memory unit 130 Replacing the SD SDHC memory card 131 Rep...

Page 10: ...l power network specification 150 Motor connection data 150 Brake resistor data 150 du dt and sine filters 151 Control unit connection data BCU 02 151 Control panel type 151 Efficiency 151 Protection classes 151 Ambient conditions 152 Materials 152 Color 152 Package 152 Disposal 153 Applicable standards 153 Markings 154 EMC compliance IEC EN 61800 3 2004 154 Definitions 154 Category C3 155 Categor...

Page 11: ...Acceptance test procedure 177 Use 178 Maintenance 178 Competence 179 Fault tracing 180 Safety data 180 Abbreviations 181 TÜV certificate 182 Declaration of conformity 19 Resistor braking 185 Contents of this chapter 185 When is resistor braking necessary 185 Operation principle and hardware description 185 Planning the braking system 185 Generic guidelines 186 Resistor cables 186 Resistor thermal ...

Page 12: ...0 Filters 193 Contents of this chapter 193 du dt filters 193 When is a du dt filter necessary 193 Selection table 194 Ordering codes 194 Description installation and technical data of the FOCH filters 194 Sine filters 194 When is a sine filter necessary 194 Selection table 194 Ordering codes 194 Derating 194 Description installation and technical data of the sine filters Further information 12 Tab...

Page 13: ...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 WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity which can cause injury or death or...

Page 14: ... points See the dimension drawings Incorrect lifting can cause danger or damage Obey the local laws and regulations applicable to lifting such as requirements for planning the lift for capacity and condition of lifting equipment and for training of personnel Attach the drive cabinet to the floor to prevent it from toppling over The cabinet has a high center of gravity When you pull out heavy compo...

Page 15: ...m make sure that no dangerous situations can occur These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY The maximum drive power cycles is five times in ten minutes Power cycling the drive ...

Page 16: ...rive always wait 5 minutes to let the intermediate circuit capacitors discharge before you continue 3 Protect any other energized parts in the work location against contact 4 Take special precautions when close to bare conductors 5 Measure that the installation is de energized If the measurement requires removal or disassembly of shrouding or other cabinet structures obey the local laws and regula...

Page 17: ...tage when the input power is on regardless of whether the motor is running or not When the input power is on the drive DC bus is at a dangerous voltage If brake chopper and resistor are in use they are at a dangerous voltage Options D150 and D151 External wiring can supply dangerous voltages to the relay outputs of the control units of the drive The Safe torque off function does not remove the vol...

Page 18: ...tions Connect the power cable shields to protective earth PE terminals of the drive to make sure of personnel safety Make a 360 grounding of the power and control cable shields at the cable entries to suppress electromagnetic disturbances In a multiple drive installation connect each drive separately to the protective earth PE busbar of the power supply Note You can use power cable shields as grou...

Page 19: ...lt or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY Note The maximum drive power cycles is five times in ten minutes Power cycling the drive too often can damage the charging circuit of the DC capacitors If you need to start or stop the drive use the control panel ke...

Page 20: ...tput terminals T1 U T2 V T3 W and the grounding PE busbar is close to 0 V Make sure that the voltage between the drive DC busbars and and the grounding PE busbar is close to 0 V Install temporary grounding to the drive output terminals T1 U T2 V T3 W Connect the output terminals together as well as to the PE During the start up Make sure that the motor cannot run overspeed for example driven by th...

Page 21: ...ned cabinet installations Target audience This manual is intended for people who plan the installation install start up and do maintenance work on the drive or create instructions for the end user of the drive concerning the installation and maintenance of the drive Read the manual before working on the drive You are expected to know the fundamentals of electricity wiring electrical components and...

Page 22: ...atform for control panels installation guide 3AUA0000136205 DPMP 02 03 mounting platform for control panels installation guide 3AXD50000308484 DPMP 04 and DPMP 05 mounting platform for control panels installation guide 3AUA0000132231 ACS880 ATEX certified Safe disconnection function application guide 3AUA0000127818 ACS880 01 drives and ACS880 04 drive modules common DC systems application guide 3A...

Page 23: ... and correct Electrical installation page 83 If the drive module has been non operational for more than one year the converter DC link capacitors need to be reformed Reforming the capacitors page 130 Only intact units can be started up Examining the installation site page 55 Check the installation site Fasten the base of the cab inet to the floor Technical data page 137 Guidelines for planning the...

Page 24: ... FAIO 01 Optional TTL incremental encoder interface module FEN 01 Optional TTL absolute encoder interface module FEN 11 Optional resolver interface module FEN 21 Optional HTL incremental encoder interface module FEN 31 Optional digital I O extension module FIO 01 Optional analog I O extension module FIO 11 Optional thermistor protection module FPTC 01 Physical size of the drive or power module Fra...

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

Page 26: ...ether See the connection diagrams in Connecting the power cables frame size 2 x R11 page 87 Note All motor cables must be of equal type and length The DC links of the drive modules are to be connected together to make sure that the drive operates correctly The main circuit of the drive module is shown below L1 U1 L2 V1 L3 W1 T1 U2 T2 V2 T3 W2 R R 4 2 1 3 UDC UDC PE 5 ACS880 04F P943 AC choke 1 Rec...

Page 27: ...on for the input and motor cables against thermal overload is needed WARNING Make sure that both contactors close at the same time Otherwise the charging current will flow through one module only and damage the module 1 2 3 1 2 3 4 1 2 3 1 2 3 4 Drive module 1 Brake chopper option D150 2 External brake resistors 3 DC connection 4 Operation principle and hardware description 27 ...

Page 28: ...tactors close at the same time Otherwise the charging current will flow through one module only and damage the module WARNING Make sure that both contactors close at the same time Otherwise the charging current will flow through one module only and damage the module 1 2 3 1 2 3 4 1 2 3 1 2 3 4 Drive module 1 Brake chopper option D150 2 External brake resistors 3 DC connection 4 28 Operation princi...

Page 29: ...2 V2 T3 W2 and brake resistor connection busbars R and R with option D150 4 Common mode filter E208 as standard 5 Auxiliary cooling fans 6 Heatsink 7 PE busbar 8 Cover on heatsink cleaning hole 9 Main cooling fans 10 Hood for UL Type 12 installations 11 External control unit 12 Cables for connecting the control unit to the drive modules 13 Fibre optic cables 14 Support brackets 15 Flange 16 Operat...

Page 30: ...2 3 4 4 8 7 A B 6 5 Front view A Back view B Drive module 1 Upper front cover 2 Lower front cover 3 Clear plastic shrouds attached 4 Heatsink cleaning hole cover 5 Flange 6 Hood for UL Type 12 installations 7 External control unit 8 See the part descriptions below 30 Operation principle and hardware description ...

Page 31: ...p of the drive module entry for top cabling 3 External control unit 13 Upper back clear plastic shroud 4 Cables for connecting the control unit to the drive module 14 Lower back clear plastic shroud 5 Fiber optic cables 15 Front clear plastic shroud 6 Support brackets 16 Full size input power cable connection terminals 7 Lifting lugs 17 Full size output power cable connection terminals 8 Flange 18...

Page 32: ... 1 2 ZINT V10 V20 V1 V2 2 1 2 1 2 SOIA ZINT V10 V20 V1 V2 1 2 FXX FXX FXXX CLOSE XPOW 1 2 V1T V1R V2T V2R L3 ACS880 04F xxxx x P943 ACS880 04F xxxx x P943 FSO 1 2 3 5 4 6 7 8 9 11 12 10 11 12 13 14 Analog and digital I O extension modules feedback interface modules and fieldbus communication modules can be inserted into slots 1 2 and 3 See section Type designation key page 37 1 2 3 Slot 4 for RDCO...

Page 33: ...stor braking page 185 11 du dt or sine filter optional see chapter Filters page 193 12 XSTO OUT terminals are wired to BGDR connectors if Safe torque off function is taken into use See chapter The Safe torque off function page 167 13 The BCU control unit can be powered from one or both drive modules or from an external uninter ruptible power source 14 Operation principle and hardware description 3...

Page 34: ...s Connecting the control unit to the drive module page 98 and Connecting a control panel page 100 for the actual connections BPOW BCU ACS880 04F BGDR BPOW BGDR XPOW SOIA ZINT V10 V20 BPOW ACS880 04F BGDR BPOW BGDR ZINT XSTO OUT SOIA V10 V20 2 1 1 1 1 These cables are included in the delivery as standard 1 CAT 5e cable must be ordered separately 2 34 Operation principle and hardware description ...

Page 35: ... designation key page 37 1 Manufacturer s address 2 Frame size 3 Cooling method 4 Degree of protection 5 Ratings see section Ratings page 137 6 Short circuit withstand strength See section Electrical power network specification page 149 7 Maximum input voltage UL CSA See section Electrical power network specification page 149 8 Valid markings 9 Serial number The first digit of the serial number re...

Page 36: ...s see section Ratings page 137 6 Short circuit withstand strength See section Electrical power network specification page 149 7 Maximum input voltage UL CSA See section Electrical power network specification page 149 8 Valid markings Note The ACS880 04F modules are UL marked 9 Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the uni...

Page 37: ... program Safe torque off function coated boards memory stick containing all manuals with all available languages 04FXT Size Refer to the rating tables xxxxA Voltage range 380 415 V AC This is indicated in the type designation label as typical input voltage level 3 400 V AC 3 380 500 V AC This is indicated in the type designation label as typical input voltage levels 3 400 480 500 V AC 5 525 690 V ...

Page 38: ...s xxxxA Voltage range 380 415 V AC This is indicated in the type designation label as typical input voltage level 3 400 V AC 3 380 500 V AC This is indicated in the type designation label as typical input voltage levels 3 400 480 500 V AC 5 525 690 V AC This is indicated in the type designation label as typical input voltage levels 3 525 600 690 V AC 7 Option codes plus codes These codes are print...

Page 39: ...Specialties Extended warranty 24 30 P904 Extended warranty 36 42 P909 Extended warranty 60 66 P911 Drive module for parallel connection only modules with P943 can be connected in parallel and used as spare parts for ACS880 04FXT P943 Operation principle and hardware description 39 ...

Page 40: ...40 ...

Page 41: ...Basic requirements for the cabinet construction are listed below Make sure that the cabinet frame is sturdy enough to carry the weight of the components control circuitry and other equipment installed in it the cabinet protects the modules against contact and agrees with the requirements for dust and humidity the cabinet frame and doors are strong enough to provide adequate protection against flam...

Page 42: ...xide layer and apply suitable anti oxidant joint compound Shrouds The installation of shrouds touch protection to fulfill applicable safety regulations is the responsibility of the drive system builder Ready made shrouding parts are available from ABB for some cabinet designs see the ordering information Tightening torques Unless a tightening torque is specified in the text the following torques c...

Page 43: ...chnical data leave enough free space around the components to ensure sufficient cooling Observe the minimum clearances given for each component see the technical data Air inlets and outlets Equip the air inlets and outlets with gratings that are large enough to allow sufficient air flow in and out of the cabinet critical for correct cooling of the module guide the air flow protect against contact ...

Page 44: ... and other additional equipment must also be ventilated The internal cooling fans of the converter modules and filters are usually sufficient to keep the component temperatures low enough in IP20 and IP42 cabinets Additional fans are present in the example designs as needed If you install additional heat generating components to the cabinet make sure to upgrade the cooling system accordingly In IP...

Page 45: ...better the interference attenuation The maximum recommended diameter of a hole in galvanic metal contact in the covering cabinet structure is 100 mm 3 94 in Pay special attention to the cooling air inlet and outlet gratings The best galvanic connection between the steel panels is achieved by welding them together as no holes are necessary If welding is not possible ABB recommends to leave the seam...

Page 46: ...ABB recommends 360 high frequency grounding of the motor cable shields at their entries The grounding can be implemented by a knitted wire mesh screening as shown below 3 1 6 4 5 2 Cable 1 Cable tie 2 Strain relief 3 Bare cable shield 4 Knitted wire mesh 5 Cabinet entry plate 6 ABB recommends 360 high frequency grounding of the control cable shields at their entries The shields can be grounded by ...

Page 47: ...el into the cabinet Cabinet side view with a bottom plate The supporting structure on a cable channel Cubicle heaters Use a cubicle heater if there is a risk of condensation in the cabinet Although the primary function of the heater is to keep the air dry it may also be required for heating at low temperatures Mounting the control panel on the cabinet door You can use a mounting platform to mount ...

Page 48: ...01 IP66 inside and outside the cabinet door IP65 UL Type 12 when panel is mounted IP54 UL Type 12 when panel is mounted IP20 when panel is not mounted IP20 when panel is not mounted 48 Generic cabinet planning instructions ...

Page 49: ...nk degree of protection of IP55 in a cooling air channel or outdoors The control circuit compartment side of the module IP20 degree of protection is to be placed in clean air The drive module can also be installed from the heatsink with mounting brackets which are included in the delivery as standard The drive module can be cabled from top or bottom to cable connection terminals or sideways with b...

Page 50: ... Installation principle 3 3 1 4 2 Cool air in max 40 C 104 F 1 Hot air out 2 Air guide 3 Air flow in the cooling air channel 4 50 Guidelines for planning the mechanical installation ...

Page 51: ...ment part of drive module and for other equipment For losses and cooling data requirements see the technical data 2 Air outlet for the power cable connection and circuit board compartment part of drive module and other equipment 3 Drive control panel with DPMP 01 mounting platform The control panel is connected to the drive module control unit inside the cabinet 4 Contactor control switch and emer...

Page 52: ... 12 Input power cable including the protective ground conductor PE of the drive 4 Motor cable including the protective ground con ductor of the drive module 13 Disconnector and fuses 5 External control cables 14 Contactor 6 Air flow 15 AC fuses 7 Input power cable connection terminals busbars 8 Note The power cable shields can also be grounded to the drive module grounding terminals Note See also ...

Page 53: ...cient cooling air flows through the module and the module cools correctly The required free space at the top and bottom of the drive module is shown below The modules can be installed side by side Min 200 mm 7 87 in Min 200 mm 7 87 in Guidelines for planning the mechanical installation 53 ...

Page 54: ...54 ...

Page 55: ...a The ambient conditions of the drive meet the specifications See the technical data Moving and unpacking the unit WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Move the transport package by pallet truck to the installation site Unpacking Unpack the package as follows see section Package drawings page 56 Cut the bands Lift...

Page 56: ...rol unit cable entry holes in the middle front cover of the drive module 6 Accessory sleeve containing 7 external control unit output cable connection terminal box B2 see below for the box contents input cable connection terminal box B3 see below for the box contents control panel door mounting kit If all options do not fit in the accessory sleeve the rest are packed in this space on the drive mod...

Page 57: ...lear plastic shroud 11 Clear plastic shroud for input cable entry from side 12 Screws in a plastic bag 13 Metallic shroud without ground bar 14 Not in use 15 1 12 13 7 9 8 11 2 14 4 3AXD50000009484 15 3 5 10 6 Box B2 contents option Full size output cable connection terminals Paper fill 1 Output cable connection terminal T3 W2 2 Output cable connection terminal T2 V2 3 Output cable connection term...

Page 58: ...plastic bag 7 3AXD5000009522 3 6 4 2 5 1 7 Examining the delivery Make sure that all items listed in section Moving and unpacking the unit page 55 are present Make sure that there are no signs of damage Before attempting installation and operation see the information on the type designation label of the drive to verify that the unit is of the correct type Lifting Insert lifting hooks to the drive ...

Page 59: ... point and mounting plate opening dimensions 1 Make an opening to the mounting plate for the drive module heatsink penetration 2 Attach the drive module flange to the mounting plate with screws 3 For UL Type 12 installations and if otherwise needed Attach the hood 6 11 11 6 6 1 3 2 Mechanical installation 59 10 ...

Page 60: ...ernal 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 Connecting the control unit to the drive module page 98 See BCU 02 12 22 control units hardware manual 3AUA0000113605 English 60 Mechanical install...

Page 61: ...ver Selecting the main supply disconnecting device You must equip the drive with a main supply disconnecting device which meets the local safety regulations You must be able to lock the disconnecting device to the open position for installation and maintenance work European Union To meet the European Union Directives according to standard EN 60204 1 Safety of Machinery the disconnecting device mus...

Page 62: ...of the AC line voltage and motor load You can find the rating table in the appropriate drive or inverter unit hardware manual You can also use the DriveSize PC tool Make sure that the motor withstands the maximum peak voltage in the motor terminals See Requirements table page 63 For basics of protecting the motor insulation and bearings in drive systems see Protecting the motor insulation and bear...

Page 63: ...ltage Motor type ABB du dt and common mode filters insulated N end motor bearings Motor insula tion system PN 350 kW or frame size IEC 400 100 kW PN 350 kW or IEC 315 frame size IEC 400 PN 100 kW and frame size IEC 315 PN 469 hp or frame size NEMA 580 134 hp PN 469 hp or NEMA 500 frame size NEMA 580 PN 134 hp and frame size NEMA 500 N CMF N Standard UN 500 V Random wound M2_ M3_ and M4_ N du dt CM...

Page 64: ...CMF du dt N or CMF du dt Reinforced ÛLL 1600 V 500 V UN 600 V or N CMF N or CMF Reinforced ÛLL 1800 V N du dt CMF du dt N du dt Reinforced ÛLL 1800 V 600 V UN 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 micro second rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if addit...

Page 65: ...rs is higher than what is stated for the particular frame size in EN 50347 2001 This table shows the requirements for protecting the motor insulation and bearings in drive systems for ABB random wound motor series for example M3AA M3AP and M3BP Requirement for Nominal AC supply voltage ABB du dt and common mode filters insulated N end motor bearings Motor insulation system PN 200 kW 100 kW PN 200 ...

Page 66: ...rcuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed in the applied drive operation range Additional data for calculating the rise time and the peak line to line voltage The diagrams below show the relative peak line to line voltage and rate of change of voltage as a functio...

Page 67: ...ermissible temperature of conductor in continuous use For North America select a cable rated for at least 75 C 167 F Voltage 600 V AC cable is accepted for up to 500 V AC 750 V AC cable is accepted for up to 600 V AC 1000 V AC cable is accepted for up to 690 V AC To comply with the EMC requirements of the CE mark use one of the preferred cable types See Preferred power cable types page 68 Symmetri...

Page 68: ...ith a minimum cross sectional area of 10 mm2 Cu or 16 mm2 Al as an alternative when aluminum cables are permitted or use a second protective earth conductor of the same cross sectional area as the original protective earth conductor or use a device that automatically disconnects the supply if the protective earth conductor is damaged If the protective earth conductor is separate that is it does no...

Page 69: ...10 mm2 8 AWG Cu or motors up to 30 kW 40 hp Yes with phase conductor smaller than 10 mm2 8 AWG Cu PVC Note Shielded or armored cable or cabling in metal conduit is always recommended to minimize radio fre quency interference Four conductor cabling in PVC con duit or jacket three phase conduct ors and PE Yes with phase conductor smaller than 10 mm2 8 AWG Cu or motors up to 30 kW 40 hp Yes EMT Four ...

Page 70: ...nbalance between the phases Not allowed power cable types Use as motor cabling Use as input power cabling Cable type No No PE Symmetrical shielded cable with in dividual shields for each phase conductor Additional guidelines North America ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor s Due to the variety of application needs metallic and non me...

Page 71: ...se installations inherently have an increased chance for nuisance problems due to the potential for water moisture in the conduit Water moisture in the conduit increases the likelihood of VFD faults or warnings Proper installation is required to make sure there is no intrusion of water moisture Metal conduit Couple separate parts of a metal conduit together bridge the joints with a ground conducto...

Page 72: ...pair cable is also acceptable a b Signals in separate cables Run analog and digital signals in separate shielded cables Do not mix 24 V DC and 115 230 V AC signals in the same cable Signals that can be run in the same cable If their voltage does not exceed 48 V relay controlled signals can be run in the same cables as digital input signals The relay controlled signals should be run as twisted pair...

Page 73: ...ossible Do not run extra cables through the drive Make sure that the cable trays have good electrical bonding to each other and to the grounding electrodes Aluminum tray systems can be used to improve local equalizing of potential The following figure illustrates the cable routing guidelines with an example drive min 200 mm 8 in 90 min 500 mm 20 in 1 2 3 3 2 1 4 min 300 mm 12 in 2 4 3 min 300 mm 1...

Page 74: ...trical shielded cable or install the cabling in a metal conduit Make sure that there is a good and continuous galvanic connection in the shield conduit between drive and motor Connect the shield conduit to the protective ground terminal of the drive and the motor Separate control cable ducts Put 24 V DC and 230 V AC 120 V AC control cables in separate ducts unless the 24 V DC cable is insulated fo...

Page 75: ... Depending on a drive parameter value the function either monitors a calculated temperature value based on a motor thermal model or an actual temperature indication given by motor temperature sensors The motor thermal protection model supports thermal memory retention and speed sensitivity The user can tune the thermal model further by feeding in additional motor and load data The most common temp...

Page 76: ...ng the breaker type when the supply network characteristics are known WARNING Due to the inherent operating principle and construction of circuit breakers independent of the manufacturer hot ionized gases can escape from the breaker enclosure in case of a short circuit To ensure safe use pay special attention to the installation and placement of the breakers Obey the manufacturer s instructions Ci...

Page 77: ...lly extra low voltage circuits must be protected against contact and insulated with basic insulation from other low voltage circuits The insulation must be rated for the same voltage level as the drive main circuit Note Extra low voltage circuits for example 24 V DC typically do not meet these requirements As an alternative you can connect the sensor with basic insulation to the analog digital inp...

Page 78: ...drive control unit con nector FPTC xx1 1 Suitable for use in safety functions SIL2 PL c rated Protecting the drive against ground faults The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable This function is not a personnel safety or a fire protection feature See the firmware manual for more information Residu...

Page 79: ... trip the drive 3 Make sure that the power factor compensation unit is suitable for use in systems with AC drives ie harmonic generating loads In such systems the compensation unit should typically be equipped with a blocking reactor or harmonic filter Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive ou...

Page 80: ...increasing the drive output voltage to the maximum This will damage or even burn the contactor completely Implementing a bypass connection If bypassing is required employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line Make sure with interlocking that the contactors cannot be closed simultaneously The installation must be...

Page 81: ...as close to the inductive load as possible Do not install protective components at the relay outputs 230 V AC 230 V AC 24 V DC 1 2 3 4 Relay output 1 Varistor 2 RC filter 3 Diode 4 Guidelines for planning the electrical installation 81 ...

Page 82: ...82 ...

Page 83: ...ssional do not do installation or maintenance work Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Grounding the motor cable shield at the motor end For minimum radio frequency interference ground the cable shield 360 degrees at the cable entry of the motor terminal box 8 Electrical installation 83 11 ...

Page 84: ...ce work 1 Do the steps in section Electrical safety precautions page 15 before you start the work 2 Make sure that the motor cable is disconnected from the drive output terminals 3 Measure the insulation resistance between each phase conductor and the protective earth conductor Use a measuring voltage of 1000 V DC The insulation resistance of an ABB motor must be more than 100 Mohm reference value...

Page 85: ...MC filter connected can be installed to a symmetrically grounded TN S system If you install the drive to another system you may need to disconnect the EMC filter and ground to phase varistors See ACS880 frames R1 to R11 EMC filter and ground to phase varistor disconnecting instructions 3AUA0000125152 English WARNING Do not install the drive with EMC filter option E200 to a system that the filter i...

Page 86: ...M10 86 Electrical installation ...

Page 87: ...meet the requirements for the PE conductor 1 ABB recommends 360 degree grounding if shielded cable is used Ground the other end of the input cable shield or PE conductor at the distribution board 2 ABB recommends 360 degree grounding 3 Line contactor 4 Common mode filter 5 du dt filter or sine filter optional see Filters page 193 6 Use a separate grounding cable if the shield does not meet the req...

Page 88: ...or ends Do not use an asymmetrically constructed motor cable Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear The minimum allowed motor cable length without optional output filters is 20 m or 2 m with derating see derating rules in Deratings for special settings in the drive control program page 140 Maximum cable length of the DC cables is 4 m In th...

Page 89: ...R R U2 V2 W2 9 4 2 8 T1 T2 T3 R R L1 L2 L3 U1 V1 W1 U2 V2 W2 9 UDC UDC UDC UDC 4 L1 L2 L3 U1 V1 W1 U2 V2 W2 6 5 10 2 L 1 L L3 PE PE PE 1b 1a 10 L1 L2 L3 Use a separate grounding PE cable 1a or a cable with a separate PE conductor 1b if the conductivity of the shield does not meet the requirements for the PE conductor 1 Electrical installation 89 11 ...

Page 90: ...witch fuse see Selecting the main supply disconnecting device page 61 10 Note If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield connect the grounding conductor to the grounding terminal at the drive and motor ends Do not use an asymmetrically constructed motor cable Connecting its fourth conductor at the motor end increases bearing ...

Page 91: ...ding is recommended if shielded cable is used Ground the other end of the input cable shield or PE conductor at the distribution board 2 360 degree grounding is required 3 Line contactor 4 Drive module 5 Switch disconnector and separate fuses or switch fuse see Selecting the main supply disconnecting device page 61 6 Use a separate grounding cable if the shield does not meet the requirements of IE...

Page 92: ...cting its fourth conductor at the motor end increases bearing currents and causes extra wear The minimum allowed motor cable length without optional output filters is 20 m or 2 m with derating see derating rules in Deratings for special settings in the drive control program page 140 Maximum cable length of the DC cables is 4 m In this connection the drive protects the input cables against thermal ...

Page 93: ... W2 5 4 2 8 T1 T2 T3 R R L1 L2 L3 U1 V1 W1 U2 V2 W2 5 UDC UDC UDC UDC 4 L1 L2 L3 U1 V1 W1 9 6 2 L 1 L L3 PE PE PE 1b 1a 6 L1 L2 L3 U1 V1 W1 3 M 3 7 Use a separate grounding PE cable 1a or a cable with a separate PE conductor 1b if the conductivity of the shield does not meet the requirements for the PE conductor 1 Electrical installation 93 11 ...

Page 94: ...185 8 Common mode filter 9 Note If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield connect the grounding conductor to the grounding terminal at the drive and motor ends Do not use an asymmetrically constructed motor cable Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear The minimum all...

Page 95: ...pare the ends of the cables PE PE WARNING Apply grease to stripped aluminum conductors before attaching them to non coated aluminum cable lugs Obey the grease manufacturer s instructions Aluminum aluminum contact can cause oxidation in the contact surfaces 3 If fire insulation is used make an opening in the mineral wool sheet according to the diameter of the cable 4 Put the cables through the entr...

Page 96: ...ds Power cable connection procedure Stop the drive and do the steps in section Electrical safety precautions page 15 before you start the work 1 Connect the cable shields of the motor cables and any separate ground conductors or cables to the ground terminal of the drive module or to the cabinet ground bar 2 Connect the phase conductors of the motor cables to terminals T1 U2 T2 V2 and T3 W2 of the...

Page 97: ...2 T1 T2 T3 U2 V2 W2 UDC UDC L1 L2 L3 U1 V1 W1 L1 L2 L3 U1 V1 W1 UDC UDC 5 Connect the cable shields of the input cables and any separate ground conductors or cables to the drive module ground terminal or to the cabinet PE busbar 6 Connect the phase conductors of the input cables to terminals L1 U1 L2 V1 and L3 W1 of the drive module For the tightening torques see the technical data Electrical inst...

Page 98: ...onnection cables to the drive module through the slot in the middle front cover at the front or left side First remove the plate which covers the slot Then install the rubber grommet from the accessories box item 2 in the package drawing Connections to the drive module 1 Connect power supply cable of the control unit to the BPOW connector 2 Connect the BGDR cable to the BGDR connector 3 Connect th...

Page 99: ...he outer shield strands into a bundle crimp a lug onto it and connect it to the nearest chassis grounding point 3 Connect the conductors to the appropriate detachable terminals of the control unit see section Default I O connection diagram page 110 Note Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by ind...

Page 100: ...have the necessary twin panel connectors in the control panel holder those that do not require the installation of an FDPI 02 module available separately For further information see the hardware description and FDPI 02 diagnostics and panel interface user s manual 3AUA0000113618 English The maximum allowed length of the cable chain is 100 m 328 ft 1 Connect the panel to one drive using an Ethernet...

Page 101: ...TERMINATED position Make sure that bus termination is off on all other drives 4 On the control panel switch on the panel bus functionality Options Select drive Panel bus The drive to be controlled can now be selected from the list under Options Select drive If a PC is connected to the control panel the drives on the panel bus are automatically displayed in the Drive composer tool With twin connect...

Page 102: ...02 modules OPEN TERMIN ATED 1 1 2 2 OPEN TERMINATED 3 Connecting a PC WARNING Do not connect the PC directly to the control panel connector of the control unit as this can cause damage 102 Electrical installation ...

Page 103: ...U 02 12 22 control units hardware manual 3AUA0000113605 English Installation of an FSO xx safety functions module onto BCU WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur This procedure describes the installation of an FSO xx safety functions module onto the BCU control unit The FSO xx can alternatively be install...

Page 104: ...ews 4 Tighten the FSO xx electronics grounding screw 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 5 Connect the FSO xx data cable between FSO xx connector X110 and BCU x2 connector X12 6 To complete the installation refer to the instructions in the User s manual delivered with the FSO xx 12...

Page 105: ...rail nearby the control unit or onto the grounding clamping plate of a ZCU 14 used in frames R1i R4i control unit The kit also contains longer cables for connecting the FSO xx to the control unit Refer to instruction 3AXD50000025583 for installation details Mounting on DIN rail Mounting on ZCU 14 grounding clamping plate with frames R1i R4i Connecting the memory unit See BCU 02 12 22 control units...

Page 106: ...106 ...

Page 107: ...s the control unit used in the drive module package See BCU 02 12 22 control units hardware manual 3AUA0000113605 English for the following information hardware description mechanical installation maintenance technical data dimension drawings 9 Control unit of the drive 107 ...

Page 108: ...ut AI2 I current U voltage AI2 Termination switch for drive to drive link D2D D2D TERM Ground selection Determines whether DICOM is separated from DIOGND ie the common reference for the digital inputs floats See the ground isolation diagram DICOM DIOGND 7 segment display Multicharacter indications are displayed as repeated se quences of characters U is indicated briefly before o Control program ru...

Page 109: ...to modules 1 and 2 VxT transmitter VxR receiver V1T V1R V2T V2R Fiber optic connection to modules 3 7 BCU 12 22 only VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to modules 8 12 BCU 22 only VxT transmitter VxR receiver V8T V8R V12T V12R Data logger memory card for inverter module communication SD CARD Real time clock battery voltage is higher than 2 8 V If the LED is off whe...

Page 110: ...op 0 Start 1 DI1 1 Forward 0 Reverse 1 DI2 2 Reset DI3 3 Acceleration deceleration select 3 DI4 4 Constant speed 1 select 1 on 4 DI5 5 By default not in use DI6 6 Run enable 5 DIIL 7 Digital input outputs XDIO Output Ready DIO1 1 Output Running DIO2 2 Digital input output ground DIOGND 3 Digital input output ground DIOGND 4 Auxiliary voltage output XD24 24 V DC 200 mA 6 24VD 5 Digital input ground...

Page 111: ... Rin 200 kohm input selected by switch AI2 Change of setting requires reboot of control unit External power supply for the control unit XPOW The control unit is powered from a 24 V DC 2 A supply through terminal block XPOW With a type BCU control unit a second supply can be connected to the same terminal block for redundancy Using an external supply is recommended if the control unit needs to be k...

Page 112: ...and output as shown below Alternatively you can connect the KTY to an FIO 11 or FAIO 01 analog I O extension module or FEN xx encoder interface module At the sensor end of the cable leave the shields unconnected or ground them indirectly via a high frequency capacitor with a few nanofarads for example 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground...

Page 113: ...n programming See the firmware manual of the drive for the related parameter settings Enable bus termination on the units at the ends of the drive to drive link Disable bus termination on the intermediate units Use shielded twisted pair cable with a twisted pair for data and a wire or another pair for signal ground nominal impedance 100 to 165 ohm for example Belden 9842 for the wiring For best im...

Page 114: ...FSO xx safety functions module connection X12 See the user manual of the FSO xx module 114 Control unit of the drive ...

Page 115: ...rk Make sure that Cabinet construction The drive module is attached correctly to the cabinet 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 component fixing points on assembly plates back of control unit mounting plate are not finished with non conduct...

Page 116: ...es for pigtails Connections of PE cables and busbars are tight enough Pull the cable to test that it does not loosen No long routes for pigtails Doors equipped with electrical equipment are grounded No long grounding routes From EMC standpoint best result is achieved with a flat copper braid Fans that can be touched are shrouded Live parts inside the doors are protected against direct contact to a...

Page 117: ...Pull on the conductors to check The brake resistor if present has been connected to the appropriate terminals and the terminals have been tightened Pull on the conductors to check The motor cable and brake resistor cable if present has been routed away from other cables No power factor compensation capacitors have been connected to the motor cable The control cables if any have been connected to t...

Page 118: ...118 ...

Page 119: ...icians are allowed to start up the drive 1 Make sure that the installation of the drive module has been done according to the checklist in chapter Installation checklist page 115 and that the motor and driven equipment are ready for start 2 Perform the start up tasks instructed by the cabinet installer of the drive module 11 Start up 119 12 ...

Page 120: ...ilter the list using parameter 95 30 Parallel type list filter Reboot the control unit either by cycling the power or by parameter 96 08 Control board boot For drives with resistor braking option D150 See also section Start up page 190 For drives with ABB du dt filter Make sure that bit 13 of parameter 95 20 HW options word 1 is switched on For drives with sine filter Make sure that parameter 95 1...

Page 121: ...dule with option DPMP 01 When the LED is lit Color LED Where Control unit is powered and 15 V is supplied to the control panel Green POWER Control panel mounting platform Drive in fault state Red FAULT Warning and fault messages See the firmware manual for the descriptions causes and remedies of the control program warning and fault messages 12 Fault tracing 121 ...

Page 122: ...122 ...

Page 123: ...s Maintenance intervals The table below shows the maintenance tasks which can be done by the end user The complete maintenance schedule is available on the Internet www abb com drivesservices For more information consult your local ABB Service representative www abb com searchchannels 13 Maintenance 123 ...

Page 124: ...rts I I I I I I I I I I I I I Spare part stock P P P P P P P P P P P P P Reforming DC circuit capacitors spare modules and spare capa citors Symbols Inspection visual inspection and maintenance action if needed I Performance of on off site work commissioning tests measurements or other work P Replacement R Maintenance and component replacement intervals are based on the assumption that the equipme...

Page 125: ...charges which can damage circuit boards 1 Stop the drive and do the steps in section Electrical safety precautions page 15 before you start the work 2 Open the cabinet door 3 Clean the interior of the cabinet Use a vacuum cleaner and a soft brush 4 Clean the air inlets of the fans and air outlets of the modules top 5 Clean the air inlet gratings if any on the door 6 Close the door Heatsink The dri...

Page 126: ...es which can damage circuit boards 1 Stop the drive and do the steps in section Electrical safety precautions 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 not humid or oily upwards from the opening and at the same time vacuum from the top of the drive module Note If there is a risk of dust ent...

Page 127: ...ied spare parts Replacing the circuit board compartment cooling fans WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Electrical safety precautions 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 o...

Page 128: ... 1 Stop the drive and do the steps in section Electrical safety precautions 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 reverse order to the above 7 Reset...

Page 129: ... 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 Maintenance 129 ...

Page 130: ...erating time load and surrounding air temperature have an effect on the life of the capacitors Capacitor life can be extended by decreasing the surrounding air temperature Capacitor failure is usually followed by damage to the unit and an input cable fuse failure or a fault trip If you think that any capacitors in the drive have failed contact ABB Reforming the capacitors The capacitors must be re...

Page 131: ...4 V DC power supply ABB recommends using an external power supply with parallel connected drive modules 3 Disconnect all cables from the module to be serviced and remove it from its bay See section Replacing the standard drive module page 130 4 Switch on the power to the remaining drive module 5 Enter the number of drive modules present into parameter 95 13 Reduced run mode 6 Reset all faults and ...

Page 132: ...132 ...

Page 133: ...ctions available at https www151 abb com spaces lvacdrivesengineeringsupport content For access contact your local ABB representative Control panel The control panel is not included with the drive module but must be ordered separately One control panel is required for the commissioning of an ACS880 drive system even if the Drive composer PC tool is used The control panel can be flush mounted on th...

Page 134: ...anel DDPI 01 board cover and M4 8 combi screw for the cover EMC shield control panel mounting platform grounding wire Ethernet cable 3 m DPMP 01 mounting platform for ACS AP control panel installation guide 3AUA0000100140 English Brake resistors See section SAFUR resistors page 191 Output du dt filters See section du dt filters page 193 Sine filters See section Sine filters page 194 134 Ordering i...

Page 135: ... Ordering code Kit 3AXD50000024518 Full size input cable connection terminals and PE busbar 3AXD50000024519 Full size output cable connection terminals 3AXD50000019538 IP20 shrouds for covering the input and motor cabling area 3AXD50000303533 Support brackets for attaching the drive module by the heatsink Ordering information 135 ...

Page 136: ...136 ...

Page 137: ...t duty use Nominal use PHd IHd PLd ILd Sn PN I2 Imax_start Imax I1 kW A kW A kVA kW A A A A UN 400 V 400 746 560 997 698 560 1008 1441 1270 1008 2 R11 1008A 3 500 878 630 1167 823 630 1188 1755 1343 1188 2 R11 1188A 3 560 1041 710 1316 921 710 1330 2024 1886 1330 2 R11 1330A 3 710 1334 900 1570 1115 900 1610 2024 2024 1610 2 R11 1610A 3 UN 500 V 500 720 710 997 873 710 1008 1441 1270 1008 2 R11 10...

Page 138: ...75 V 700 630 678 800 710 791 966 1356 1017 808 2 R11 0808A 7 800 800 837 1000 900 929 1147 1674 1260 960 2 R11 0960A 7 1000 900 929 1000 1000 1051 1291 1858 1472 1080 2 R11 1080A 7 1000 1000 1051 1250 1200 1297 1578 2024 1509 1320 2 R11 1320A 7 3AXD10000363510 Nominal voltage of the drive For input voltage range see Type designation key page 37 UN Nominal input current rms at 40 C 104 F I1 Apparen...

Page 139: ...us output current of the drive if ambient temperature exceeds 40 C 104 F or drive is installed higher than 1000 m 3280 ft above sea level switching frequency is other than default the minimum requirements of motor cable length are not met see chapter Filters page 193 Note The final derating factor is a multiplication of all applicable derating factors Ambient temperature derating In the temperatur...

Page 140: ...l program can require output current derating Ex motor sine 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 see section Sine filters page 194 is used and ABB sine filter in parameter 95 15 Special HW settings is enable...

Page 141: ...N Continuous rms output current allowing 10 overload for 1 minute every 5 minutes Continuous rms output current allowing 40 overload for 1 minute every 5 minutes Continuous rms output current allowing 44 overload for 1 minute every 5 minutes ILd Continuous rms output current allowing 50 overload for 1 minute every 5 minutes IHd Note To achieve the rated motor power given in the table the rated cur...

Page 142: ...50 500 1041 1297 916 1310 120 1310A 5 754 938 736 1012 500 1282 1570 1153 1610 120 1610A 5 UN 690 V 445 528 471 546 375 678 791 752 808 120 0808A 7 482 534 460 552 375 837 929 920 960 120 0960A 7 552 607 580 626 375 929 1051 1025 1080 120 1080A 7 644 791 736 828 375 1051 1297 1300 1320 120 1320A 7 3AXD10000363510 Output frequency f Maximum output frequency with High speed mode fmax Nominal voltage...

Page 143: ...080A 7 2 R11 ACS880 04F 721A 7 P943 ACS880 04FXT 1320A 7 3AXD10000363510 Fuses IEC aR fuses by Cooper Bussmann for protection against short circuit in the input power cable of the drive are listed below Ultrarapid aR fuses per drive module Fuse Input current A Drive type Size Type DIN 43620 V A2s A UN 400 V 3 170M8554D 690 2150000 1250 1008 ACS880 04FXT 1008A 3 3 170M8554D 690 2150000 1250 1188 AC...

Page 144: ...odule are listed below Make sure that the operating time of the fuse is below 0 1 seconds The operating time depends on the fuse type supply network impedance and the cross sectional area material and length of the supply cable The fuses must be of the non time delay type Obey local regulations Fuse Fuse Input current A Drive type Type UL class Manufacturer V A UN 400 V A4BY800 L Ferraz 600 800 10...

Page 145: ...nd the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table Circuit breakers Circuit breakers must not be used without fuses 1 Maximum allowed rated conditional short circuit current IEC 61439 1 of the electrical power network 2 Contact your local ABB representative Dimensions weights and free space requirements Standard drive module configuration includin...

Page 146: ...AXD10000363510 The cooling air temperature rises 30 degrees Celsius when it goes through the drive module if the temperature of the input cooling air is 40 degrees Celsius Typical power cable sizes The table below gives copper and aluminum cable types with concentric copper shield for the drive modules with nominal current See also Terminal and entry data for the power cables page 149 IEC1 input a...

Page 147: ...880 04FXT Al cable type Cu cable type mm2 mm2 UN 400 V 2 3 185 2 3 120 1008A 3 2 3 185 2 3 150 1188A 3 2 3 185 2 3 185 1330A 3 2 3 240 2 3 240 1610A 3 UN 500 V 2 3 185 2 3 120 1008A 5 2 3 185 2 3 150 1158A 5 2 3 185 2 3 185 1310A 5 2 3 240 2 3 240 1610A 5 UN 690 V 2 3 120 2 3 95 0808A 7 2 3 185 2 3 120 0960A 7 2 3 185 2 3 150 1080A 7 2 3 185 2 3 185 1320A 7 The cable sizing is based on max 9 cable...

Page 148: ...6 300 3 600 or 4 400 3 500 or 4 300 1320A 7 The cable sizing is based on max 9 cables laid on a cable ladder side by side three ladder type trays one on top of the other ambient temperature 30 C 86 F PVC insulation surface temperature 70 C 158 F EN 60204 1 and IEC 60364 5 52 For other conditions dimension the cables according to local safety regulations appropriate input voltage and the load curre...

Page 149: ...w size for connecting busbars to the drive module input and output busbars M12 tightening torque 50 75 N m Units without full size output cable connection terminals and with a common mode filter E208 It is possible to use the maximum cable size 4 3 240 mm2 or 4 3 500 AWG only with special cable lugs and additional insulation For more information contact your local ABB representative Terminal data ...

Page 150: ... in the type designation label as typical output voltage level 3 0 U1 Voltage U2 0 500 Hz Frequency f2 For drives with du dt filter 200 Hz For drives with sine filter 120 Hz 0 01 Hz Frequency resolution See section Ratings page 137 Current 3 kHz typically Switching frequency DTC control 500 m 1640 ft Maximum recommended motor cable length Scalar control 500 m 1640 ft Note With motor cables longer ...

Page 151: ...ent Transportation Storage Operation in the protective package in the protective package installed for stationary use For TN and TT neutral grounded network systems and IT non corner groun ded network systems 0 to 4000 m 13123 ft above sea level Installation site altitude For TN TT and IT corner grounded network sys tems 0 to 2000 m 6561 ft above sea level Above 1000 m 3281 ft see section When is ...

Page 152: ...ht over 100 kg 220 lb 100 mm 4 in for weight over 100 kg 220 lb Not allowed Free fall Materials See Recycling instructions and environmental information for ACS880 04 ACS880 04F ACS880 14 ACS880 34 ACS580 04 ACH580 04 ACH580 34 ACQ580 04 and ACQ580 34 drives 3AXD50000137688 English Color RAL 9002 Package Plywood and cardboard bands PP 3AXD50000040437 Disposal The main parts of the drive can be rec...

Page 153: ...ctrical Code Part II CSA C22 2 No 0 10 Industrial control equipment CSA C22 2 No 14 13 Adjustable Speed Drives CSA 22 2 No 274 13 Markings These markings are attached to the drive CE mark Product complies with the applicable European Union legislation For fulfilling the EMC requirements see the additional information concerning the drive EMC compliance IEC EN 61800 3 TÜV Safety Approved mark funct...

Page 154: ...onal is a person or organization having necessary skills in installing and or starting up power drive systems including their EMC aspects Drive of category C3 drive of rated voltage 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 ...

Page 155: ...nd control cables are selected and routed according to the electrical planning guidelines of the drive The EMC recommendations are obeyed 4 The drive is installed according to its installation instructions The EMC recommendations are obeyed WARNING A drive of category C4 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expe...

Page 156: ...lsewhere in this chapter The ampere rating is based on tests done according to the appropriate UL standard The cables located within the motor circuit must be rated for at least 75 C 167 F in UL compliant installations The input cable must be protected with fuses The fuses must provide branch circuit protection in accordance with the national regulations National Electrical Code NEC or Canadian El...

Page 157: ... 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 protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information ABB and its affiliates are not liable for dama...

Page 158: ...158 ...

Page 159: ...Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules 16 Dimension drawings 159 ...

Page 160: ...Standard configuration IP00 UL Type Open 160 Dimension drawings ...

Page 161: ...Drive module with optional support brackets IP00 UL Type Open Dimension drawings 161 ...

Page 162: ...Drive module with optional full size input and output power cable terminals and IP20 shrouds 162 Dimension drawings ...

Page 163: ...Mounting plate opening 3AXD50000038119 Dimension drawings 163 ...

Page 164: ...3AXD50000038119 164 Dimension drawings ...

Page 165: ...ram for a cabinet installed drive module package Example circuit diagram This diagram is an example for the main wiring of a drive cabinet Note that the diagram includes components which are not included in a basic delivery option to be acquired by the customer 17 Example circuit diagram 165 ...

Page 166: ... 4 Motor temperature supervision 5 Switch fuse disconnector 6 Common mode filter 7 du dt filter or sine filter 8 Drive module 9 Alarm 10 Supply 11 360 degree grounding recommended 12 Brake resistor 13 For BCU input and output signals see the Default I O connection diagram page 110 166 Example circuit diagram ...

Page 167: ...intenance operations like cleaning or work on non electrical parts of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage of the power semiconductors of the drive output stage A see the diagrams below thus preventing the drive from generating the torque required to rotate the motor If the motor is running when S...

Page 168: ...s for electrical electronic program mable electronic safety related systems IEC 61508 2 2010 Functional safety Safety instrumented systems for the process industry sector IEC 61511 1 2016 Adjustable speed electrical power drive systems Part 5 2 Safety require ments Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related electrical elec tronic and pro...

Page 169: ...ed twisted pair cable is recommended Maximum cable lengths 300 m 1000 ft between activation switch K and drive control unit 60 m 200 ft between multiple drives or inverter units 60 m 200 ft between external power supply and first control unit Note A short circuit in the wiring between the switch and an STO terminal causes a dangerous fault Therefore it is recommended to use a safety relay includin...

Page 170: ... With internal power supply Dual channel connection K 1 1 2 Drive module 1 Control unit 2 Activation switch K 170 The Safe torque off function ...

Page 171: ...he 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 Drive 1 Control unit 2 Activation switch K The Safe torque off function 171 ...

Page 172: ... With external power supply K 24 V DC 2 1 1 Drive module 1 Control unit 2 Activation switch K 172 The Safe torque off function ...

Page 173: ... Safe torque off function not in use If STO is not in use close the circuit as shown Otherwise the drive will not start 1 1 2 Drive module 1 Control unit 2 The Safe torque off function 173 ...

Page 174: ... this occurs Note This parameter does not affect the operation of the STO function itself The STO function will operate regardless of the setting of this parameter a running drive will stop upon removal of one or both STO signals and will not start until both STO signals are restored and all faults reset Note The loss of only one STO signal always generates a fault as it is interpreted as a malfun...

Page 175: ...d into the logbook Acceptance test procedure After wiring the Safe torque off function validate its operation as follows Note If an FSO xx safety functions module or an FPTC 0x module is installed refer to its documentation Action WARNING Obey the safety instructions If you ignore them injury or death or damage to the equipment can occur Make sure that the drive can be run and stopped freely durin...

Page 176: ...o IN1 If the motor was running it should coast to a stop The drive generates a FA81 Safe Torque Off 1 loss fault indication see the firmware manual Give a start command to verify that the STO function blocks the drive s operation The motor should not start Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Open the 2nd channel of the STO circuit ...

Page 177: ...ent magnet or synchronous reluctance SynRM motors only In case of a multiple IGBT power semiconductor failure the drive can produce an alignment torque which maximally rotates the motor shaft by 180 p degrees with permanent magnet motors or 180 2p degrees with synchronous reluctance SynRM motors regardless of the activation of the Safe torque off function p denotes the number of pole pairs Notes I...

Page 178: ...tegrity requirement for the safety function is SIL 2 HFT 1 or PL d cat 3 the proof test for the function must be performed at least every 12 months The STO function of the drive does not contain any electromechanical components In addition to proof testing it is a good practice to check the operation of the function when other maintenance procedures are carried out on the machinery Include the Saf...

Page 179: ...function is performed and the drive trips on an STO hardware failure fault An attempt to use the STO in a non redundant manner for example activating only one channel will trigger the same reaction See the firmware manual of the drive control program for the indications generated by the drive and for details on directing fault and warning indications to an output on the control unit for external d...

Page 180: ... failure mode short circuit on printed circuit board has been made EN 13849 2 table D 5 The analysis is based on an assumption that one failure occurs at one time No accumulated failures have been analyzed STO response times STO reaction time shortest detectable break 1 ms STO response time 2 ms typical 25 ms maximum Fault detection time Channels in different states for longer than 200 ms Fault re...

Page 181: ...ion IEC 61508 SFF Safety integrity level 1 3 IEC 61508 SIL Maximum SIL level 1 3 that can be claimed for a safety function or subsystem IEC EN 62061 SILCL Safe torque off IEC EN 61800 5 2 STO Proof test interval T1 is a parameter used to define the probabilistic failure rate PFH or PFD for the safety function or subsystem Per forming a proof test at a maximum interval of T1 is required to keep the...

Page 182: ... Declaration of conformity 182 The Safe torque off function ...

Page 183: ...The Safe torque off function 183 ...

Page 184: ...184 ...

Page 185: ... as add on kits The brake chopper handles the energy generated by a decelerating motor The extra energy increases the DC link voltage The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected Planning t...

Page 186: ... has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling The customer must consider the EMC compliance of the complete installation Protecting the resistor cable against short circuits The input fuses of the drive will also protect the resistor cable when it is identical with the input cable Resistor thermal switch Use a resistor with a thermal switch stand...

Page 187: ...lculate the maximum power generated by the motor during braking 2 Select a suitable drive brake chopper and brake resistor combination for the application from the brake ratings table below The braking power of the chopper must be greater than or equal to the maximum power generated by the motor during the braking 3 Make sure that the resistor selection is correct The energy generated by the motor...

Page 188: ... of the default resistor Rmin WARNING Never use a brake resistor with a resistance smaller than Rmin This will cause overcurrent that will damage the brake chopper and the drive 2 make sure that the resistance of the custom resistor does not restrict the braking capability needed ie where Maximum power generated by the motor during braking Pmax Drive intermediate DC circuit voltage 1 35 1 2 415 V ...

Page 189: ...te DC circuit by the chopper where Instantaneous load capacity of the custom resistor PR inst Drive intermediate DC circuit voltage 1 35 1 2 415 V DC when supply voltage is 380 to 415 V AC 1 35 1 2 500 V DC when supply voltage is 440 to 500 V AC or 1 35 1 2 690 V DC when supply voltage is 525 to 690 AC UDC Resistance of the custom resistor R Mechanical installation of resistors All brake resistors...

Page 190: ...thermal switch is wired to the DIIL input an overheating resistor will by default remove the Run enable signal from the drive See also parameters 20 11 Run enabe stop mode 20 12 Run enable 1 source and 95 20 HW options word 1 If the thermal switch is wired to another digital input input set the following parameters 1 Set the source of parameter 31 01 External event 1 source to point to the digital...

Page 191: ...200F500 0 7 400 2 R11 880A 5 P943 1610A 5 UN 690 V 13 3600 2 7 SAFUR200F500 2 2 285 2 R11 429A 7 P943 0808A 7 18 7200 2 0 2 SAFUR125F500 2 0 350 2 R11 522A 7 P943 0960A 7 18 7200 2 0 2 SAFUR125F500 1 8 400 2 R11 590A 7 P943 1080A 7 18 7200 2 0 2 SAFUR125F500 1 8 400 2 R11 721A 7 P943 1320A 7 3AXD10000363510 3AXD00000588487 Maximum continuous braking power The braking is considered continuous if th...

Page 192: ...1320 Ø 7 345 1270 ABB ordering code Weight Brake resistor type 68759285 25 kg 55 lb SAFUR125F500 68759340 30 kg 66 b SAFUR200F500 Terminals and cable entry data See section Terminal and entry data for the power cables page 149 192 Resistor braking ...

Page 193: ...le currents See also section Motor connection data page 150 for the minimum motor cable length If there is no du dt filter and the motor cable length from each drive module is less than 20 m 65 ft the nominal values of the drive must be de rated by 15 Selection table du dt filter types for the drive modules are given below du dt filter type Drive module type ACS880 04F du dt filter type Drive modu...

Page 194: ...module type ACS880 04F Sine filter type Drive module type ACS880 04F UN 690 V UN 500 V UN 400 V NSIN0485 6 429A 7 NSIN0900 6 582A 5 NSIN0900 6 584A 3 NSIN0900 6 522A 7 NSIN0900 6 634A 5 NSIN0900 6 649A 3 NSIN0900 6 590A 7 NSIN0900 6 715A 5 NSIN0900 6 725A 3 NSIN0900 6 721A 7 NSIN0900 6 880A 5 NSIN0900 6 880A 3 3AXD10000363510 Ordering codes ABB ordering code Filter type 64254936 NSIN0485 6 6425496...

Page 195: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

Page 196: ...www abb com drives 3AXD50000274444B 2020 ABB All rights reserved Specifications subject to change without notice 3AXD50000274444 Rev B EN EFFECTIVE 2020 03 26 ...

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