ABB ACS880-07LC Hardware Manual Download Page 25

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Terms and abbreviations

Description

Term/

Abbreviation

Type of control unit

BCU

Frequency converter for controlling AC motors

Drive

Electromagnetic compatibility

EMC

Electromagnetic interference

EMI

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 analog I/O extension module

FIO-11

Optional thermistor protection module

FPTC-01

Optional ATEX-certified thermistor protection module for potentially explosive atmospheres

FPTC-02

Physical size of the drive or power module

Frame, frame
size

Optional functional safety modules

FSO-12, FSO-
21

Insulated gate bipolar transistor

IGBT

Inverter module(s) under control of one control unit, and related components. One inverter
unit typically controls one motor.

Inverter unit

Common term for drive module, inverter module, supply module, brake chopper module etc.

Power module

Radio-frequency interference

RFI

Safe torque off (IEC/EN 61800-5-2)

STO

Supply module(s) under control of one control unit, and related components.

Supply unit

Related manuals

Code

Name

Drive hardware manuals and guides

3AXD50000569786

ACS880-07LC hardware manual

3AUA0000085685

ACX-AP-x assistant control panels user’s manual

Drive firmware manuals and guides

3AUA0000085967

ACS880 primary control program firmware manual

3AUA0000098062

Quick start-up guide for ACS880 drives with primary control program

3AUA0000103295

ACS880 diode supply control program firmware manual

3AXD50000126880

CIO-01 I/O module for distributed I/O bus control user's manual

Option manuals and guides

3AXD50000129607

ACS880-1007LC liquid cooling unit user's manual

3AUA0000094606

Drive composer start-up and maintenance PC tool user’s manual

3AXD50000015612

FSO-12 safety functions module user’s manual

3AXD50000015614

FSO-21 safety functions module user’s manual

3AUA0000145922

User’s manual for Prevention of unexpected start-up (+Q950) for ACS880-07/17/37
drives

3AUA0000119895

User’s manual for Emergency stop, stop category 0 (+Q951) for ACS880-07/17/37 drives

3AUA0000119896

User’s manual for Emergency stop, stop category 1 (+Q952) for ACS880-07/17/37 drives

Introduction to the manual 25

Summary of Contents for ACS880-07LC

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 07LC drives Hardware manual ...

Page 2: ......

Page 3: ...ACS880 07LC drives Hardware manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation 9 Start up 3AXD50000569786 Rev A EN EFFECTIVE 2020 07 02 ...

Page 4: ......

Page 5: ... Categorization by frame size and option code 24 Use of component designations 24 Quick installation commissioning and operation flowchart 25 Terms and abbreviations 25 Related manuals 3 Operation principle and hardware description 27 Contents of this chapter 27 Operation principle 28 Overview circuit diagram of the drive 29 Overview diagram of the rectifier bridge 29 12 pulse connection option A0...

Page 6: ... the transport package 50 Moving the unpacked drive cabinet 50 Lifting the cabinet with a crane 51 Moving the cabinet on rollers 51 Moving the cabinet on its back 52 Final placement of the cabinet 53 Attaching the cabinet to the floor and wall or roof 53 General rules 54 Attaching the cabinet non marine units 54 Alternative 1 Clamping 55 Alternative 2 Using the holes inside the cabinet 56 Attachin...

Page 7: ...e control cable ducts 76 Implementing short circuit and thermal overload protection 76 Protecting the input cabling and the drive upon a short circuit 76 Protecting the motor and motor cable in short circuits 76 Protecting the drive and the power cables against thermal overload 77 Protecting the motor against thermal overload 77 Protecting the drive against ground faults 77 Residual current device...

Page 8: ...a PC 98 Panel bus Control of several units from one control panel 101 Installing option modules 101 Mechanical installation of I O extension fieldbus adapter and pulse encoder interface modules 101 Installation of an FSO xx safety functions module onto BCU 103 Wiring of option modules 7 Control units of the drive 105 Contents of this chapter 106 BCU x2 layout 108 Default I O diagram of the supply ...

Page 9: ...ubicle fans options D150 and D151 136 Supply and inverter modules 136 Replacing the D8T supply module 140 Replacing an inverter module 141 Removing the module 142 Reinstalling the module 143 Capacitors 143 Reforming the capacitors 144 Fuses 144 Replacing the AC fuses 145 Replacing the supply module DC fuses 145 Checking and replacing the DC fuses 146 Replacing the inverter module DC fuses 147 Cont...

Page 10: ...frequency derating 164 Output frequency derating 164 Frame sizes and power module types 166 Fuses 166 Internal AC fuses 169 DC fuses 172 Brake chopper DC fuses 172 Dimensions and weights 172 Free space requirements 172 Cooling data noise 174 Typical power cable sizes 176 Terminal and lead through data for the power cables 176 Terminal data for the supply and inverter control units 176 Electrical p...

Page 11: ...verter module cubicle with two R8i modules bottom cable exit 198 Inverter module cubicle with three R8i modules bottom cable exit 199 Brake chopper cubicle 15 The Safe torque off function 201 Contents of this chapter 201 Description 202 Compliance with the European Machinery Directive 203 Wiring 203 Activation switch 203 Cable types and lengths 203 Grounding of protective shields 204 Dual channel ...

Page 12: ...16 Resistor braking Further information 12 Table of contents ...

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: ...Use the designated lifting 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 The lifting bars attached to large drive cabinets are heavy Be careful when removing or reinstalling the bars Whene...

Page 15: ...ut not limited to electric shock and arc protection Before you adjust the drive operation limits make sure that the motor and all driven equipment can operate throughout the set operation limits Before you activate the automatic fault reset or automatic restart functions of the drive control program make sure that no dangerous situations can occur These functions reset the drive automatically and ...

Page 16: ...eek medical advice Before the drive power up make sure that the internal cooling circuit is filled up with coolant and the cooling is in operation coolant circulates Make sure that coolant meets the ABB specification See the appropriate hardware manual of the drive unit To avoid breaking the coolant pipes do not overtighten the nuts of the unions Leave 2 to 3 millimeters 0 08 to 0 12 inches of thr...

Page 17: ...r from the drive 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 law...

Page 18: ...ble terminals of the drive are at a dangerous voltage 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 Option D150 Option D151 External wiring can supply dangerous voltages to the relay outputs of the control units of the drive T...

Page 19: ...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 20: ...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 21: ...ut 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 the load Motor overspeed causes overvoltage that can damage or destroy the capacitors in the intermediate circuit of the drive Safety in operation WARNING Make sure that the motor cannot run overspeed for example driven by th...

Page 22: ...22 ...

Page 23: ...n code Some instructions technical data and dimension drawings which concern only certain frame sizes are marked with the symbol of the frame size The frame size indicates the number of power modules that form the supply and inverter units respectively For example the marking 2 D8T 3 R8i refers to a drive that has a supply unit consisting of two frame D8T supply modules and an inverter unit consis...

Page 24: ...1 Ambient conditions page 178 Check the installation site Mechanical installation page 47 Unpack and check the drive only intact units may be started up Make sure that all necessary optional modules and equipment are present and correct Install the drive mechanically Routing the cables page 75 Route the cables Electrical installation page 83 Connect the power cables Connect the control cables Inst...

Page 25: ...orque off IEC EN 61800 5 2 STO Supply module s under control of one control unit and related components Supply unit Related manuals Code Name Drive hardware manuals and guides 3AXD50000569786 ACS880 07LC hardware manual 3AUA0000085685 ACX AP x assistant control panels user s manual Drive firmware manuals and guides 3AUA0000085967 ACS880 primary control program firmware manual 3AUA0000098062 Quick ...

Page 26: ...nterface Q965 for ACS880 07 17 37 drives 3AXD50000014979 User s manual for ATEX certified motor thermal protection functions L513 Q971 and L514 Q971 for cabinet built ACS880 drives 3AUA0000145920 User s manual for Emergency stop configurable stop category 0 or 1 Q978 for ACS880 07 17 37 drives 3AUA0000145921 User s manual for Emergency stop configurable stop category 0 or 1 Q979 for ACS880 07 17 3...

Page 27: ...dule s 1 to 8 inverter modules and optional equipment The actual arrangement of the cubicles varies from type to type and the selected options The supply modules of the drive contain a diode thyristor bridge The thyristors of the bridge are controlled at start up so that their firing angle approaches zero as the DC capacitors of drive get charged During normal operation the firing angle of the thy...

Page 28: ...upply module DC fuses 4 Inverter module DC fuses 5 Inverter modules 6 Motor 7 Brake chopper DC fuses 8 Brake chopper module 9 Brake resistors 10 Brake chopper D150 and resistors D151 are optional Auxiliary voltage switch Q21 with fuses connection for external supply is optional 11 Auxiliary voltage transformer 12 28 Operation principle and hardware description ...

Page 29: ...6 pulse connection is standard Some drive types are available as a 12 pulse version option A004 The 12 pulse supply connection eliminates the fifth and seventh harmonics which substantially reduces the harmonic distortion of the line current and the conducted emissions The 12 pulse connection requires a three winding transformer or two separate transformers There is a phase shift of 30 degrees bet...

Page 30: ... A B 6 pulse connection A 12 pulse connection B Supply transformer 1 Switching equipment 2 Diode supply modules 3 30 Operation principle and hardware description ...

Page 31: ...ist and drive types with four or more inverter modules have multiple inverter module cubicles D As standard the motor cables are run from each inverter module to the motor unless the drive is equipped with option H359 common motor terminal cubicle or H366 common output terminals CIO 01 I O module for cooling fan monitoring 1 BCU control units A51 for supply unit control A41 for inverter unit contr...

Page 32: ... module 2 14 Supply module cubicle fan 15 Inverter module DC fuses at the input of each inverter module 16 Inverter modules 17 Inverter module cooling fan A heat exchanger is located between the fan and the module 18 32 Operation principle and hardware description ...

Page 33: ...ves 2 Outlet manifold with stop and drain valves 3 Inlet pipes cold coolant from main pipe to modules and heat exchanger 4 Output pipes hot coolant to main pipe from modules and heat exchanger 5 Supply modules 6 Draining pipes inlet draining pipe and outlet draining pipe 7 Operation principle and hardware description 33 ...

Page 34: ... 1 2 3 Feedback interface modules 1 2 3 Fieldbus communication modules 4 RDCO xx DDCS communication option module standard equipment As standard a fiber optic link connects the supply and inverter control units 2 3 4 Additional modules can be installed on an optional FEA 03 extension adapter connected to an RDCO module on slot 4 Memory unit 5 Connection for FSO xx safety functions module 6 Control...

Page 35: ...nd lights Description Label in local language Label in Eng lish Ready light option G327 READY 1 Run light option G328 RUN 2 Fault light option G329 FAULT 3 Run enable signal switch for the supply unit ENABLE RUN 4 0 1 Run enable signal off starting the supply unit not allowed 0 Run enable signal on starting the supply unit allowed Close the main disconnecting device if present 1 Emergency stop res...

Page 36: ...nsformers The transformer feeds the control circuits inside the drive such as cooling fans relays and measuring equipment This switch is not present if optional connection for an external auxiliary voltage supply is selected Grounding earthing switch Q9 optional The grounding switch Q9 option F259 connects the main AC power bus to the PE busbar Units with 12 pulse connection option A004 as well so...

Page 37: ...e ACX AP x assistant control panel user s manual 3AUA0000085685 English and the firmware manual Control by PC tools There is a USB connector on the front of the panel that can be used to connect a PC to the drive When a PC is connected to the control panel the control panel keypad is disabled Operation principle and hardware description 37 ...

Page 38: ...of persons against access to hazardous parts with finger Marine construction option C121 The option includes the following accessories and features reinforced mechanics grab railings door flush bolt which allows the door to open 90 degrees and prevents it from slamming close self extinctive materials flat bars at base of the cabinet for fastening fastening brackets at the top of the cabinet Additi...

Page 39: ... provides terminals for connecting an external uninterruptible control voltage to the control unit and control devices when the drive is not powered See also Supplying power for the auxiliary circuits page 78 circuit diagrams delivered with drive for the actual wiring Halogen free wiring and materials option G330 The option provides halogen free cable ducts control wires and wire sleeves thus redu...

Page 40: ... connector individual wires are not marked Short obvious connections are not marked PE wires are not marked unless connected directly to components G340 class A3 9 7 7 Equipment designations and pin identifiers are marked with snap on markers or equivalent on conductors that connect to equipment terminal blocks or detachable plug type connectors or are part of the wiring between power modules Fibe...

Page 41: ...equired by Ex ATEX regulations For more information see ATEX certified motor thermal protection functions for cabinet built ACS880 drives options L513 Q971 and L514 Q971 user s manual 3AXD50000014979 English Options 2L505 and 2L513 duplicate options L505 and L513 respectively containing the relays and connections for two separate measurement circuits L536 L537 An alternative to a thermistor relay ...

Page 42: ...ring circuit See the circuit diagrams delivered with the drive Options 3L514 3 relays 5L514 5 relays and 8L514 8 relays are ATEX certified thermal protection functions that have the same external connectivity as nL506 In addition each monitoring relay has a 0 4 20 mA output that is available on the terminal block Option nL514 comes with Q971 ATEX certified safe disconnection function as standard a...

Page 43: ... selections are given thereafter separated by plus signs eg E202 Codes preceded by a minus sign eg J400 indicate the absence of the specified feature The main selections are described below Not all selections are available for all types For more information refer to the ordering instructions available separately on request Description Code Basic code Product series ACS880 Default configuration liq...

Page 44: ...e product certification issued by Lloyd s Register LR C207 Marine product certification issued by Bureau Veritas C209 Marine product certification issued by China Classification Society CCS C228 Marine product certification issued by Russian Maritime Register of Shipping RS C229 Brake choppers D150 Brake resistors D151 du dt filtering E205 EMC RFI filter for 2nd environment TN grounded or IT ungro...

Page 45: ...rmal protection with Pt100 relays 3 5 or 8 pcs See section Thermal protection with Pt100 relays options nL506 nL514 page 42 L506 ATEX certified thermal protection with PTC relays 1 or 2 pcs L513 ATEX certified thermal protection with Pt100 relays 3 5 or 8 pcs L514 FPTC 01 thermistor protection module L536 FPTC 02 ATEX certified thermistor protection module L537 IEC 61131 3 application programmabil...

Page 46: ...Description Code Emergency stop button monitoring Q984 FSPS 21 PROFIsafe safety functions module Q986 46 Operation principle and hardware description ...

Page 47: ...The floor that the drive cabinet is installed on is of non flammable material as smooth as possible and strong enough to support the weight of the unit Check the floor flatness with a spirit level The maximum allowed deviation from the surface level is 5 mm in every 3 meters Level the installation site if necessary as the cabinet is not equipped with adjustable feet Necessary tools The tools requi...

Page 48: ...ntrol unit s at the factory appropriate drive and optional module manuals delivery documents Make sure that there are no signs of damage Before attempting installation and operation see the information on the type designation labels of the drive to verify that the delivery is of the correct type 48 Mechanical installation ...

Page 49: ...d in the upright position The center of gravity of the cabinet is high Be therefore careful when moving the unit Avoid tilting Removing the transport package Remove the transport package as follows 1 Undo the screws that attach the wooden parts of the transport crate to each other 2 Remove the wooden parts 3 Remove the clamps with which the drive cabinet is mounted onto the transport pallet by und...

Page 50: ... units is 2 meters 6 7 Removing the transport package Remove the transport package as follows 1 Undo the screws that attach the wooden parts of the transport crate together 2 Remove the wooden parts 3 Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws 4 Remove the plastic wrapping Moving the unpacked drive cabinet Lifting the cabinet...

Page 51: ...e it carefully until close to its final location Remove the rollers by lifting the unit with a crane forklift pallet truck or jack Moving the cabinet on its back If the cabinet needs to be laid on its back support the cabinet from below alongside the cubicle seams 1 2 Cabinet back panel 1 Support 2 Mechanical installation 51 10 ...

Page 52: ...cement of the cabinet Move the cabinet into its final position with a slate bar spud bar Place a piece of wood between the edge of the cabinet and the bar to protect the cabinet frame 52 Mechanical installation ...

Page 53: ...inverter module replacement a b 120 w 250 mm 9 85 Note 1 Any height adjustment must be done before fastening the cabinet sections to the floor or to each other Height adjustment can be done by using metal shims between the cabinet bottom and floor Note 2 Depending on the size of the cabinet it has either bolt on lifting eyes or lifting bars with lifting holes If the cabinet is delivered with lifti...

Page 54: ...em to the floor with a bolt The recommended maximum distance between the clamps in the front edge is 800 mm 31 5 2 If floor mounting at the back is not possible fasten the top of the cabinet to the wall with L brackets not included in the delivery bolted to the lifting eye bar holes and suitable hardware Attaching top to wall Clamping bottom to floor M16 54 Mechanical installation ...

Page 55: ...bolts The recommended maximum distance between the front edge fastening points is 800 mm 31 5 2 If the back fastening holes are not accessible fasten the top of the cabinet to the wall with L brackets not included in the delivery bolted to the lifting eye bar holes Attaching to to wall Attaching bottom to floor M16 Mechanical installation 55 10 ...

Page 56: ...2 screws 2 If there is not enough room behind the cabinet for installation clamp a the rear edges of the flat bars c to the floor See the figure below 3 Attach corner brackets d to the lifting eye holes Fasten the corner brackets to the rear wall and or roof with suitable hardware such as U brackets e M16 3 e d a b c 2 Corner bracket included d Clamp not included a U bracket not included e Back pa...

Page 57: ...bicle The screws required for the joining are enclosed in a plastic bag inside the cabinet The threaded bushings are already mounted on the cabinet posts 1 Fasten the first section to the floor 2 Remove any plates covering the rear post of the joining cubicle 3 Slide Axilock connectors onto the coolant pipes at the joint 4 Align the two sections The coolant pipe ends must be aligned as shown 5 15 ...

Page 58: ...or screws to the torque indicated on the connector label 6 Fasten the front and rear posts of the joining cubicle to the posts of the other section with 14 screws 7 per post Tighten the screws to 5 N m 3 7 lbf ft 7 Fasten the second section to the floor 1 3 5 4 4 4 58 Mechanical installation ...

Page 59: ...rs using the M10 bolts included Tighten to 35 40 N m 25 30 lbf ft Side Above a b c a b c Plain washer a Spring washer b Bolt c 9 Remove the shroud covering the DC busbars in the joining cubicle Mechanical installation 59 10 ...

Page 60: ...chanically sprayed zinc coating c Nut d WARNING Make sure you install the washers in the correct order as shown For example placing an unpassivated zinc coated spring washer directly against the joint piece will cause corrosion WARNING Do not use any joining parts other than those delivered with the unit The parts are carefully selected to match the material of the busbars Other parts or materials...

Page 61: ...MC compliance 500 19 68 50 1 97 500 19 68 50 1 97 Arc welding ABB does not recommend attaching the cabinet by arc welding However if arc welding is the only option connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0 5 meters 1 6 of the welding point Note The thickness of the zinc plating of the cabinet frame is 100 200 micrometers 4 8 mil WARNING Make ...

Page 62: ...ting lugs and bars Certificate of conformity The certificate is available in ABB Library at www abb com drives documents document number 3AXD10001061361 Declaration of Conformity 62 Mechanical installation ...

Page 63: ...Mechanical installation 63 10 ...

Page 64: ...64 ...

Page 65: ...tallation 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 Selecting the supply disconnecting device The drive is equipped with a main disconnecting device as standard Depending on the size of the drive and the selected options the type of disconnecting device m...

Page 66: ... the appropriate parameters in the firmware manual Protecting the motor insulation and bearings The drive employs modern IGBT inverter technology Regardless of frequency the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time The pulse voltage can almost double at the motor terminals depending on the attenuation and reflection properties of the motor...

Page 67: ...andard 500 V UN 600 V or N CMF N Reinforced N du dt CMF N du dt du dt Reinforced 600 V UN 690 V cable length 150 m N CMF N Reinforced 600 V UN 690 V cable length 150 m PN 500 kW N CMF N CMF n a Standard 380 V UN 690 V Form wound HX_ and AM_ PN 500 kW N du dt CMF N du dt with voltages over 500 V CMF Check with the motor manu facturer 380 V UN 690 V Old1 form wound HX_ and modular N CMF Enamelled wi...

Page 68: ... 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 additional output filters are needed in the applied drive...

Page 69: ...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 kW PN 100 kW PN 268 hp 140 hp PN 268 hp PN 140 hp N CMF N Standard UN 500 V du dt N CMF du dt N du dt Standard 500 V UN 600 V or N CMF N Reinforced du dt N CMF du dt N du dt Reinfo...

Page 70: ...voltage with a sine filter is approximately 1 5 UN Selecting the power cables General guidelines Select the input power and motor cables according to local regulations Current Select a cable capable of carrying the maximum load current Temperature For an IEC installation select a cable rated for at least 70 C 158 F maximum permissible temperature of conductor in continuous use For North America se...

Page 71: ...L 61800 5 1 use a protective earth conductor with 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 ...

Page 72: ...Alternate power cable types Exception for ACS880 304LC A019 diode supply modules These power cable types are not allowed Use as motor cabling Use as input power cabling Cable type Yes with phase conductor smaller than 10 mm2 8 AWG Cu or motors up to 30 kW 40 hp Yes EMT Four conductor cabling in metal conduit three phase conductors and PE eg EMT or four conductor ar mored cable Yes with motors up t...

Page 73: ...ed 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 Power cable shield If the cable shield is used as the sole protective earth PE conductor make sure that its conductivity agrees with the PE conductor requirements To effectively suppress radiated and conducted radio frequency emission...

Page 74: ...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 75: ...cables with other cables Where control cables must cross power cables make sure that they are arranged at an angle as near to 90 degrees as possible 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 illustr...

Page 76: ...tect the input cabling in short circuit situations install fuses or a suitable circuit breaker at the supply side of the cabling The drive is equipped with internal AC fuses as standard In case of a short circuit inside the drive the AC fuses protect the drive restrict drive damage and prevent damage to adjoining equipment Protecting the motor and motor cable in short circuits The drive protects t...

Page 77: ...tional ground fault monitoring device Q954 is available for IT ungrounded systems The option includes a ground fault indicator on the drive cabinet door Residual current device compatibility The drive is suitable to be used with residual current devices of Type B Note As standard the drive contains capacitors connected between the main circuit and the frame These capacitors and long motor cables i...

Page 78: ...ake sure that a flying restart of the motor will not cause any danger If you are in doubt do not implement the power loss ride through function 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 s...

Page 79: ...h 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 output The switch is needed to isolate the motor from the drive during maintenance work on the drive Implementing the control of a contactor between drive and motor Implementing the control of the output contactor d...

Page 80: ...otective component 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 Implementing a motor temperature sensor connection WARNING IEC 60664 and IEC 61800 5 1 require double or reinforced insulation between live parts and accessible parts when the accessible parts are not...

Page 81: ...e digital and analog inputs 3 You can connect the sensor to the drive via an option module The sensor and the module must form a double or reinforced insulation between the motor live parts and the drive control unit See Connecting motor temperature sensor to the drive via an option module page 81 4 You can connect a sensor to a digital input of the drive via an external relay The sensor and the r...

Page 82: ...rs in cluding drive control unit connector FEN xx Basic insulation Connectors of op tion module other than sensor con nector must be left unconnected x x x Basic insulation between sensor connector and drive control unit connector No insulation between sensor connector and other I O connectors FAIO 01 No special requirement x Reinforced insulation between sensor connector and other connect ors inc...

Page 83: ...ring the safety instructions can cause injury or death Measuring the insulation Measuring the insulation of the drive WARNING Do not do any voltage withstand or insulation resistance tests on any part of the drive as testing can damage the drive Every drive has been tested for insulation between the main circuit and the chassis at the factory Also there are voltage limiting circuits inside the dri...

Page 84: ...cted 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 at 25 C 77 F For the insulation resistance of other motors refer to the manufacturer s instructions Note Moisture inside the motor casing red...

Page 85: ...l cables inside the cabinet page 87 4 Connect the control cables as described in section Connecting control cabling page 87 Grounding the outer shields of the control cables at the cabinet entry Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions as follows example constructions are shown below the actual hardware may vary 1 Loosen the tightening screws of the...

Page 86: ...ables going to the left into one group and the cables going to the right into another group to avoid unnecessary crossing of cables inside the cabinet 3 Sort the cables in each group according to size 4 Group the cables for each grommet as follows ensuring that each cable has a proper contact to the cushions on both sides Max number of cables per grommet Cable diameter in mm 4 13 3 17 2 25 1 25 5 ...

Page 87: ...nner twisted pair shields and all separate grounding wires to the grounding clamps closest to the terminals The drawing below represents the grounding of the control cabling when connecting to a terminal block inside the cabinet The grounding is done in the same way when connecting directly to a component such as the control unit Notes Do not ground the outer shield of the cable here since it is g...

Page 88: ...ground them indirectly via a high frequency capacitor with a few nanofarads 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 88 Electrical installation ...

Page 89: ...rive is equipped with a common motor terminal cubicle option H359 follow the instructions in section Connecting the motor cables units with common motor terminal cubicle page 92 Motor connection diagram without option H366 All parallel connected inverter modules are to be cabled separately to the motor 360 earthing is to be used at cable lead throughs U2 V2 W2 PE U2 V2 W2 M 3 U1 W1 V1 PE Inverter ...

Page 90: ... the cable entries for the cables to be connected Cut adequate holes into the rubber grommets Slide the grommets onto the cables Slide the cables into the cubicle through the conductive sleeves and attach the grommets to the holes 13 Attach the conductive sleeves to the cable shields with cable ties Tie up the unused conductive sleeves with cable ties 14 Connect the twisted shields of the cables t...

Page 91: ...a b c 4 a 8 b 16 18 PE PE 10 13 12 Electrical installation 91 11 ...

Page 92: ...the drive Connection diagram U2 V2 W2 PE M 3 U1 W1 V1 PE Inverter unit cubicle Common motor terminal cubicle The recommended cable types are given in chapter Technical data Procedure WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Electrical safety precautions page 16 before you start the...

Page 93: ...lectrical installation of custom brake resistors page 267 For the location of the terminals refer to the dimension drawings delivered with the unit or the dimension drawing examples in chapter Dimensions a b b 1 5 a Grommet 4 Cut the cables to suitable length Strip the cables and conductors 5 Twist the cable screens into bundles and connect the bundles to the PE busbar in the cubicle 6 Connect any...

Page 94: ...addition if the conductivity of the shields does not meet the requirement for the PE conductor Connection diagram 12 pulse units 1 2 1L1 1L2 1L3 PE 2L1 2L2 2L3 PE Fuses or other protection means for short circuit protection of the cable 1 Grounding of the cable shield at the cable entry 360 degree grounding 2 Additional information See the technical data for the dimensions of the cable entries and...

Page 95: ...page 16 before you start the work 2 Open the door of the incoming cubicle 3 Remove the shrouding covering the input terminals 4 Peel off 3 to 5 cm of the outer insulation of the cables above the lead through plate for 360 high frequency grounding 5 Prepare the ends of the cables WARNING Apply grease to stripped aluminum conductors before attaching them to non coated aluminum cable lugs Obey the gr...

Page 96: ...uctive sleeves to the cable shields with cable ties Tie up the unused conductive sleeves with cable ties 9 Connect the twisted shields of the cables to the PE busbar of the cabinet 10 Connect the phase conductors of the input cable to the L1 L2 and L3 terminals With 12 pulse connection the terminals are 1L1 1L2 and 1L3 for one 6 pulse supply line 2L1 2L2 and 2L3 for the other Tighten the screws to...

Page 97: ...11 Reinstall the shrouding removed earlier 12 Close the cubicle door Electrical installation 97 11 ...

Page 98: ... be used to control several drives or inverter units supply units etc by constructing a panel bus This is done by daisy chaining the panel connections of the drives Some drives 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 diag...

Page 99: ...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 100: ...With FDPI 02 modules OPEN TERMIN ATED 1 1 2 2 OPEN TERMINATED 3 100 Electrical installation ...

Page 101: ...he module It is essential for fulfilling the EMC requirements and for proper operation of the module 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 Th...

Page 102: ...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 103: ... Wiring of option modules See the appropriate optional module manual for specific installation and wiring instructions Electrical installation 103 11 ...

Page 104: ...104 ...

Page 105: ...e drive Contents of this chapter This chapter describes the connections of the control unit s used in the drive contains the specifications of the inputs and outputs of the control unit s 7 Control units of the drive 105 ...

Page 106: ...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 107: ...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 108: ...F RS485 connection X485 Cooling fan monitoring CIO module B 5 5 6 7 8 A 6 BGND 7 Shield 8 Relay outputs XRO1 XRO2 XRO3 XRO1 Running2 Energized running 250 V AC 30 V DC 2 A Norm closed NC 11 22 23 31 32 11 12 13 21 33 Common COM 12 Norm open NO 13 XRO2 Fault 1 2 Energized no fault 250 V AC 30 V DC 2 A Norm closed NC 21 Common COM 22 Norm open NO 23 XRO3 MCB ctrl3 Energized closes main contactor bre...

Page 109: ... 8 Digital input ground DICOM 2 24 V DC 200 mA5 24VD 3 Digital input output ground DIOGND 4 Ground selection switch6 DICOM DIOGND ON OFF Analog inputs reference voltage output XAI 10 V DC RL 1 10 kohm VREF 1 5 6 7 1 2 3 4 10 V DC RL 1 10 kohm VREF 2 Ground AGND 3 Not in use by default 0 2 10 V Rin 200 kohm7 AI1 4 AI1 5 Not in use by default 0 4 20 mA Rin 100 ohm8 AI2 6 AI2 7 AI1 current voltage se...

Page 110: ...tions such as a supply or brake unit de energizing the IN1 and or IN2 terminal will stop the unit but not constitute a true safety function 5 Total load capacity of these outputs is 4 8 W 200 mA at 24 V minus the power taken by DIO1 and DIO2 6 Determines whether DICOM is separated from DIOGND ie common reference for digital inputs floats ON DICOM connected to DIOGND OFF DICOM and DIOGND separate 7...

Page 111: ...puts XDI Stop 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 i...

Page 112: ...ntrol unit Additional information on the connections 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 kept operational during input power break...

Page 113: ...hey are in the same ground line with no significant voltage drop between the end points AI1 AI1 AO1 AGND 2 1 3 T T T One two or three Pt100 Pt1000 or PTC sensors or one KTY84 sensor 1 Set the input type to voltage with the appropriate switch or jumper on the control unit Make the corres ponding setting in the control program in parameter group 12 Standard AI 2 Select the excitation mode in paramet...

Page 114: ...ws the wiring between control units BCU x2 XD2D XD2D XD2D 1 2 3 4 B A BGND SHIELD 1 2 3 4 B A BGND SHIELD 1 2 3 4 B A BGND SHIELD Termination ON Termination ON Termination OFF Safe torque off XSTO XSTO OUT See chapter The Safe torque off function page 201 Note The XSTO input only acts as a true Safe torque off input on the inverter control unit De energizing the IN1 and or IN2 terminals of other u...

Page 115: ... mm wire size 2 5 mm2 Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 As inputs 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Fil tering 1 ms Input output mode selection by paramet ers As outputs Total output current from 24VD is limited to 200 mA 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 othe...

Page 116: ... This applies to all control units including drive inverter supply brake DC DC converter etc control units but true Safe torque off functionality is only achieved through the XSTO connector of the drive inverter control unit Current consumption 66 mA continuous per STO channel per R8i module EMC immunity according to IEC 61326 3 1 See also chapter The Safe torque off function page 201 Connector pi...

Page 117: ... DIOGND 3 DIOGND 4 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 DIIL 7 XSTO OUT 1 SGND 2 IN1 3 IN2 4 XSTO OUT IN1 5 SGND 6 IN2 7 SGND 8 Ground selector DICOM DIOGND settings DICOM DIOGND ON All digital inputs share a common ground DICOM connected to DIOGND This is the default setting DICOM DIOGND OFF Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO signal ground DIOGND Isolation vol...

Page 118: ...118 ...

Page 119: ... WARNING Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work Make sure that The ambient operating conditions meet the drive ambient conditions specification and enclosure rating IP code or UL enclosure type The supply voltage matches the nominal input voltage of the drive See the type designation label The insulation resistance of the input po...

Page 120: ... conductor between the brake resistor and the drive and the conductor is connected to the correct terminal and the terminals are tightened to the correct torque Proper grounding has also been measured according to the regulations If an external brake resistor is connected to the drive The brake resistor is connected to the correct terminals and the terminals are tightened to the correct torque If ...

Page 121: ...customized drive Always refer to the delivery specific circuit diagrams when proceeding with the start up WARNING Only qualified electricians are allowed to do the work described in this chapter Note For certain options such as functional safety options Q950 Q951 Q952 Q957 Q963 Q964 Q978 Q979 additional start up instructions are given in their separate manuals Action Safety WARNING Obey the safety...

Page 122: ...the machine is at maximal load in the maximum environmental temperature We recommend to set the operating temperatures of the relay typically for example as follows 120 140 C when only tripping is in use alarm 120 140 C and trip 130 150 C when both alarm and tripping are used Powering up the auxiliary circuit of the drive Make sure that it is safe to connect voltage Ensure that nobody is working o...

Page 123: ...ection and the air flows upwards Check that the motor starts stops and follows the speed reference in the correct direction when controlled with the control panel Check that the motor starts stops and follows the speed reference in the correct direction when controlled through the customer specific I O or fieldbus Drives in which the Safe torque off control circuit is in use Test and validate the ...

Page 124: ...124 ...

Page 125: ...low 2 8 V the battery is missing or the control unit is not powered Internal voltage OK Green PWR OK The control program indicates that the equipment is faulty See the appropriate firmware manual Red FAULT Writing to SD card in progress Yellow WRITE Control panel and panel platform holder LEDs The ACS AP control panel has a status LED The control panel mounting platform or holder has two status LE...

Page 126: ...ive converter inverter Blinking red The Bluetooth interface is enabled in discoverable mode and ready for pairing Blinking blue ACS AP W only Data is being transferred through the Bluetooth interface of the control panel Flickering blue ACS AP W only There is an active fault in the unit Red Control panel mounting platform or holder with the control panel removed Power supply for the control unit i...

Page 127: ...representative www abb com searchchannels Years from start up Maintenance task object 12 11 10 9 8 7 6 5 4 3 2 1 0 Coolant P P P P P P P P P P P P P Checking coolant antifreeze concentration P P P P P P Checking coolant quality R R Coolant draining and replacement See ACS880 1007LC liquid cooling unit user s manual 3AXD50000129607 English ABB cooling unit if present Cooling fans R Supply module cu...

Page 128: ...ess corrosion temperature I I I I I I I I I I I I I Checking coolant pipe connections 3AXD10000578918 F 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 equipment is operated within the specified r...

Page 129: ... 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 Power connections and quick connectors Retightening the power connections WARNING Obey the safety instructions of the drive If you ignore them injury or death or dama...

Page 130: ...temperature and dust concentration See the firmware manual for the actual signal which indicates the running time of the cooling fan Reset the running time signal after fan replacement Replacement fans are available from ABB Do not use other than ABB specified spare parts 130 Maintenance ...

Page 131: ...afety precautions page 16 before you start the work 2 Remove the shrouding in front of the fan if any 3 Disconnect the fan wiring Remove the CIO module 4 Remove the two screws and slide the fan unit out 5 Remove the four screws to detach the fan from the fan unit 6 Remove the eight screws surrounding the fan unit 7 Install a new fan in reverse order 4 5 6 Maintenance 131 ...

Page 132: ...replace the fan 6 Install the new fan in reverse order 4 Replacing the cooling fan of a D8T supply module WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges 1 Repeat the steps described in section Electrical safety precautions page 16 2 Remove any shrouding in front of the cooling fan 3 Remove the support bracket of the fan 4 ...

Page 133: ...section Electrical safety precautions page 16 2 Remove any shrouding in front of the cooling fan 3 Disconnect the fan wiring 4 Undo the two retaining screws a 5 Pull the fan outwards to separate it from the heat exchanger housing 6 Install new fan in reverse order Align the guide pins b at the rear of the fan cowling with the slots c in the module bottom guide then reinstall the retaining screws a...

Page 134: ...p edges 1 Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work 2 Remove any shrouding in front of the cooling fan 3 Disconnect the fan wiring 4 Undo the fastening screws 5 Pull the fan housing up and out 6 Install a new fan in reverse order to the above 134 Maintenance ...

Page 135: ... Replacing the brake chopper and resistor cubicle fans options D150 and D151 See chapter Resistor braking page 219 Maintenance 135 ...

Page 136: ...47447 Make sure that the drive cabinet is attached to the floor to prevent it from toppling over The cabinet has a high center of gravity When you pull out heavy components or power modules there is a risk of overturning 1 Stop the motors connected to the drive 2 Repeat the steps described in section Electrical safety precautions page 16 3 Open the cubicle door 4 Close the inlet and outlet valve 5...

Page 137: ...ep the weight constantly on the lifting device 16 Lower the module on a pallet Keep the lifting chain attached to the module and attach the module safely to the pallet 17 Remove the lifting chains from the old module and move the pallet out of the way 18 Install the new module a Attach the lifting hooks to the module lift the module and place it on the module guide plate Keep the weight on the lif...

Page 138: ...8 9 138 Maintenance ...

Page 139: ...11 12 12 6 10 Maintenance 139 ...

Page 140: ...ype code as the old module WARNING Beware of hot coolant Do not work on the liquid cooling system until the pressure is lowered down by stopping the pumps and draining the coolant High pressure warm coolant 6 bar max 50 C is present in the internal cooling circuit when it is in operation WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have ...

Page 141: ... cable ties to keep the wiring out of the way 5 Remove the L shaped DC busbars at the top of the module Make note of the orientation of the screws as well as the order of the washers 6 Close the inlet valve a and outlet valve located on the right hand side of the cubicle Lead the drain hoses b on both sides of the cubicle into a suitable container Open the drain valves c on both sides of the cubic...

Page 142: ...le lifting device for drive cabinets hardware manual 3AXD50000210268 English Reinstalling the module 1 Push the module carefully into its bay 2 Fasten the retaining screws at the top and the bottom of the module 3 Reinstall the DC busbars at the top of the module 4 Reconnect the coolant pipes to the module 5 Reconnect the control wiring to the module 6 Fill up the cooling system For instructions s...

Page 143: ...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 reformed if the drive has not been powered either in storage or unused for a year or more The manufacturing date is on the type designation label For information on reforming the capacitors se...

Page 144: ...orrect order of the washers Remove the screws and nuts from the L shaped busbars Remove the DC fuses and the L shaped busbars 6 Remove the screw nut and washer in the middle 7 Remove the screws 3 pcs 1 per each phase from the L shaped busbars above the fuses 8 Remove the screws that attach the L shape busbars below the fuses to the module AC busbars There is one screw and busbar for each AC phase ...

Page 145: ...ors connected to the drive 2 Repeat the steps described in section Electrical safety precautions page 16 3 Open the cubicle door 4 Remove any shrouding in front of the DC fuses 5 Remove the screws nuts and washers from the old fuses Write down the correct order of the washers Pull the fuses out 6 Install the new fuses in reverse order Make sure that the washers are in the correct order If necessar...

Page 146: ...ath or damage to the equipment can occur WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Repeat the steps described in section Electrical safety precautions page 16 before you start the work 2 Open the door of the module cubicle 3 Remove the shrouding in front of the fuses if any 146 Maintenance ...

Page 147: ...ses and 46 N m 34 lbf ft for Ferraz Shawmut fuses 5 Attach the shrouding if any and close the door 4 Control panel For detailed information on the control panel see ACx AP x assistant control panels user s manual 3AUA0000085685 English Cleaning the control panel Use a soft damp cloth to clean the control panel Avoid harsh cleaners which could scratch the display window Replacing the control panel ...

Page 148: ...rom the defective control unit to the new control unit WARNING Do not remove or insert the memory unit when the control unit is powered 1 Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work 2 Make sure that the control unit is not powered 3 Remove the fastening screw and pull the memory unit out 4 Install a memory unit in reverse order Replaci...

Page 149: ...4 Dispose of the old battery according to local disposal rules or applicable laws 5 Set the real time clock Maintenance 149 ...

Page 150: ...150 ...

Page 151: ...ability The information in this chapter is applicable to cabinet built ACS880 liquid cooled drives Except where otherwise indicated the information is also applicable to drives built out of ACS880 liquid cooled multidrive modules Internal cooling system Each cubicle has an inlet and an outlet manifold fitted with a stop valve and a drain valve The stop valves can be closed to isolate all modules i...

Page 152: ...upply unit each module has a dedicated air to liquid exchanger as shown for item 2 1 Inverter modules 2 To From cooling unit 3 Air to liquid heat exchanger A L Heat sink HS Inlet valve a Inlet side drain valve b Outlet valve c Outlet side drain valve d The coolant used with ACS880 liquid cooled drive systems is Antifrogen L 25 or 50 mixture See Coolant specification page 156 152 Internal cooling c...

Page 153: ...he limits specified in Technical data page 156 Install a pressure regulator to make sure that the maximum permissible operating pressure is not exceeded Install a bleed valve at the highest point of the cooling circuit and a drain valve at the lowest point The materials that can be used are listed in Cooling circuit materials page 158 Coolant temperature control The temperature of the coolant in t...

Page 154: ...on for the valve is usually near or at the cooling unit Observe the instructions given by the manufacturer of the cooling unit Pay special attention to filling up and bleeding the pumps properly as they may be damaged if operated when dry Draining coolant into the sewer system is not allowed 1 Open the bleed valve at the cooling unit 2 Open the inlet valve and the outlet side drain valve of one cu...

Page 155: ... stop the pump or block the coolant flow with a valve 15 Re check the pressure and add coolant if necessary 16 Repeat steps 13 to 15 a few times until all air is let out of the cooling circuit Listen for a humming sound and or feel the piping for vibration to find out if there is still air left in the circuit Internal cooling circuit 155 ...

Page 156: ...ed under Coolant specification page 156 drain the cooling circuit again Maintenance intervals As a general rule the quality of the coolant should be checked at intervals of two years This can be done by distributors of Antifrogen L see www clariant com if a 250 milliliter sample is provided Technical data Coolant specification Coolant type Antifrogen L by Clariant International Ltd www clariant co...

Page 157: ...mperature increase as shown by curve a 45 50 C 113 122 F If components with a maximum operating temperature of 55 C 131 F are installed in the same space as the drive modules drive output current must be derated by 6 percentage points per 1 C 1 8 F temperature increase as shown by curve c If there are no components with a maximum operating temperature of 55 C 131 F installed in the same space as t...

Page 158: ...system compared with the atmospheric pressure when the cooling circuit is filled with coolant Air counterpressure in expansion vessel with ACS880 1007LC cooling unit 80 kPa Design pressure PS 600 kPa Nominal pressure difference 120 kPa with Antifrogen L 25 coolant solution 140 kPa with Antifrogen L 50 coolant solution This has to be taken into account when dimensioning the liquid cooling circuit M...

Page 159: ...umstances Even minor dissolution of copper can cause copper precipitation on aluminum and subsequent galvanic corrosion The liquid cooling system must not contain any zinc eg galvanized pipes If the plant incorporates normal iron pipes or cast iron accessories eg motor housings a cooling unit with a heat exchanger such as the ACS880 1007LC must be used to separate the systems Internal cooling circ...

Page 160: ...160 ...

Page 161: ...kVA hp kW A A A UN 690 V 6 pulse connection 300 250 292 350 355 374 466 400 355 585 390 357 0390A 7 300 250 322 450 355 413 514 450 400 645 430 394 0430A 7 350 315 359 450 400 461 574 500 450 720 480 439 0480A 7 400 355 396 500 450 509 633 550 500 795 530 485 0530A 7 450 400 449 600 560 576 717 600 560 900 600 549 0600A 7 500 450 501 700 630 643 801 700 630 1005 670 613 0670A 7 600 500 561 700 710...

Page 162: ...49 0600A 7 A004 500 450 599 700 630 643 801 700 630 1005 670 613 0670A 7 A004 600 500 670 700 710 720 896 800 710 1125 750 686 0750A 7 A004 600 560 760 900 800 816 1016 900 800 1275 850 778 0850A 7 A004 800 710 921 1000 900 989 1231 1000 1000 1545 1030 943 1030A 7 A004 900 800 1046 1250 1100 1123 1398 1250 1100 1755 1170 1071 1170A 7 A004 1000 900 1171 1250 1200 1258 1566 1250 1200 1965 1310 1199 ...

Page 163: ...d A AC A DC A DC kVA A AC kW DC A DC kW DC A DC kW DC UN 690 V 0820A 7 A019 820 1000 1400 980 1143 932 960 895 800 745 1540A 7 A019 1540 1880 2632 1840 2149 1752 1805 1682 1504 1401 2290A 7 A019 2290 2805 3927 2737 3206 2614 2693 2509 2244 2091 3040A 7 A019 3040 3720 5208 3633 4252 3466 3571 3328 2976 2773 3AXD00000601909 XLS Nominal ratings UN Nominal input voltage For U1 see Electrical power net...

Page 164: ...7 E205 1 0780A 7 A018 1 1 D8T 1 R8i 0670A 7 0750A 7 E205 1 0780A 7 A018 1 1 D8T 1 R8i 0750A 7 0850A 7 E205 1 0780A 7 A018 1 1 D8T 1 R8i 0850A 7 0530A 7 E205 2 1060A 7 A018 1 1 D8T 2 R8i 1030A 7 0600A 7 E205 2 1060A 7 A018 1 1 D8T 2 R8i 1170A 7 0670A 7 E205 2 0780A 7 A018 2 2 D8T 2 R8i 1310A 7 0750A 7 E205 2 0780A 7 A018 2 2 D8T 2 R8i 1470A 7 0850A 7 E205 2 0780A 7 A018 2 2 D8T 2 R8i 1660A 7 0670A ...

Page 165: ...0A 7 A018 2 2 D8T 2 R8i 1660A 7 A004 0670A 5 E205 3 1060A 7 A018 2 2 D8T 3 R8i 1940A 7 A004 0750A 7 E205 3 1060A 7 A018 2 2 D8T 3 R8i 2180A 7 A004 0850A 7 E205 3 0780A 7 A018 4 4 D8T 3 R8i 2470A 7 A004 0750A 7 E205 4 0780A 7 A018 4 4 D8T 4 R8i 2880A 7 A004 0850A 7 E205 4 0780A 7 A018 4 4 D8T 4 R8i 3260A 7 A004 0750A 7 E205 5 1060A 7 A018 4 4 D8T 5 R8i 3580A 7 A004 0850A 7 E205 5 1060A 7 A018 4 4 D...

Page 166: ...0A 7 0530A 7 170M6416 Bussmann 690 1250 3 1 0600A 7 0670A 7 0750A 7 0850A 7 170M6413 Bussmann 690 900 6 2 1030A 7 1170A 7 170M6416 Bussmann 690 1250 6 1 1310A 7 1470A 7 1660A 7 170M6413 Bussmann 690 900 12 2 1940A 7 2180A 7 170M6413 Bussmann 690 900 18 2 2470A 7 2880A 7 3260A 7 170M6413 Bussmann 690 900 24 2 3580A 7 4050A 7 170M6413 Bussmann 690 900 30 2 4840A 7 170M6413 Bussmann 690 900 36 2 5650...

Page 167: ... 7 170M6416 Bussmann 690 1250 3 1 0600A 7 0670A 7 0750A 7 0850A 7 170M6904 Bussmann 1800 3 1 1030A 7 1170A 7 170M6416 Bussmann 690 1250 6 1 1310A 7 1470A 7 1660A 7 170M6904 Bussmann 1800 6 1 1940A 7 2180A 7 170M6904 Bussmann 1800 9 1 2470A 7 2880A 7 3260A 7 170M6904 Bussmann 1800 12 1 3580A 7 4050A 7 170M6904 Bussmann 1800 15 1 4840A 7 170M6904 Bussmann 1800 18 1 5650A 7 6460A 7 UN 690 V 12 pulse ...

Page 168: ...anufacturer V A Qty total Qty per phase 170M6416 Bussmann 690 1250 12 1 2470A 7 A004 2880A 7 A004 3260A 7 A004 170M6904 Bussmann 1800 12 1 3580A 7 A004 4050A 7 A004 170M6904 Bussmann 690 1800 18 1 4840A 7 A004 5650A 7 A004 6460A 7 A004 168 Technical data ...

Page 169: ...ann 1250 800 4 2 0600A 7 0670A 7 0750A 7 0850A 7 170M6549 Bussmann 1000 1100 4 2 1030A 7 1170A 7 170M6546 Bussmann 1250 800 8 2 1310A 7 1470A 7 1660A 7 170M6549 Bussmann 1000 1100 8 2 1940A 7 2180A 7 170M6549 Bussmann 1000 1100 12 2 2470A 7 2880A 7 3260A 7 170M6549 Bussmann 1000 1100 16 2 3580A 7 4050A 7 170M6549 Bussmann 1000 1100 20 2 4840A 7 170M6549 Bussmann 1000 1100 24 2 5650A 7 6460A 7 UN 6...

Page 170: ...1250 2200 2 1 1030A 7 1170A 7 170M6792 Bussmann 900 1600 4 1 1310A 7 1470A 7 1660A 7 170M6827 Bussmann 1250 2200 4 1 1940A 7 2180A 7 170M6827 Bussmann 1250 2200 6 1 2470A 7 2880A 7 3260A 7 170M6827 Bussmann 1250 2200 8 1 3580A 7 4050A 7 170M6827 Bussmann 1250 2200 10 1 4840A 7 170M6827 Bussmann 1250 2200 12 1 5650A 7 6460A 7 UN 690 V 12 pulse connection 170M6549 Bussmann 1000 1100 4 1 0530A 7 A004...

Page 171: ...ussmann 1000 1100 4 1170A 7 170M6500 Bussmann 1100 1250 4 1310A 7 170M6501 Bussmann 1100 1400 4 1470A 7 1660A 7 170M6500 Bussmann 1100 1250 6 1940A 7 170M6501 Bussmann 1100 1400 6 2180A 7 2470A 7 170M6501 Bussmann 1100 1400 8 2880A 7 3260A 7 170M6501 Bussmann 1100 1400 10 3580A 7 4050A 7 170M6501 Bussmann 1100 1400 12 4840A 7 170M6501 Bussmann 1100 1400 14 5650A 7 170M6501 Bussmann 1100 1400 16 64...

Page 172: ...d weights See chapter Dimensions Free space requirements The values are as required by cooling maintenance and or operation of the pressure relief if present Also obey the general mechanical installation instructions Above Sides Front in mm in mm in mm 9 85 250 0 0 59 1500 Cooling data noise Noise Heatdissipa tion Coolant flow Coolant volume ACS880 07LC dB A kW US gal min l min US gal l UN 690 V 6...

Page 173: ... 5 74 5 1 19 4 0530A 7 A004 67 15 1 19 5 74 5 1 19 4 0600A 7 A004 67 16 8 19 5 74 5 1 19 4 0670A 7 A004 67 19 0 19 5 74 5 1 19 4 0750A 7 A004 67 22 19 5 74 5 1 19 4 0850A 7 A004 69 24 23 8 90 5 95 22 6 1030A 7 A004 69 27 23 8 90 5 95 22 6 1170A 7 A004 69 30 23 8 90 5 95 22 6 1310A 7 A004 69 35 23 8 90 5 95 22 6 1470A 7 A004 69 40 23 8 90 5 95 22 6 1660A 7 A004 71 44 28 0 106 6 85 25 9 1940A 7 A004...

Page 174: ...9 1376 1637 1881 2237 2740 3229 262 318 368 425 486 572 659 1182 1492 1776 2042 2422 2967 3478 210 256 297 343 392 462 533 2 32 2 38 2 41 2 44 2 49 2 54 2 58 2 3 70 21 Cu 2 3 95 29 Cu 2 3 120 41 Cu 2 3 150 41 Cu 2 3 185 57 Cu 2 3 240 72 Cu 2 3 300 88 Cu 1881 2237 2740 3229 638 728 859 989 2042 2422 2967 3478 514 588 693 800 3 44 3 49 3 54 3 58 3 3 150 41 Cu 3 3 185 57 Cu 3 3 240 72 Cu 3 3 300 88 C...

Page 175: ...820 3329 4073 4779 274 334 386 446 510 602 696 2 32 2 38 2 41 2 44 2 50 2 55 2 58 2 3 70 35 2 3 95 50 2 3 120 70 2 3 150 70 2 3 185 95 2 3 240 120 2 3 300 150 1859 2139 2525 3099 3636 723 837 957 1128 1304 2441 2820 3329 4073 4779 579 669 765 903 1044 3 41 3 44 3 50 3 55 3 58 3 3 120 70 3 3 150 70 3 3 185 95 3 3 240 120 3 3 300 150 2139 2525 3099 3636 1116 1276 1504 1304 2820 3329 4073 4779 892 10...

Page 176: ... The drive is suitable for use on a circuit capable of delivering not more than 100 000 rms symmetrical amperes at 600 V maximum when the input cable is protected with class T fuses Short circuit current protec tion UL 508A CSA C22 2 No 14 13 To be defined Short circuit current protec tion UL 508A CSA C22 2 No 14 13 Connection Dy 11 d0 or Dyn 11 d0 Transformer specification for 12 pulse supply IEC...

Page 177: ...ycles ABB drive products in general utilize 5 and 10 MBd megabaud optical components from Avago Technologies Versatile Link range Note that the optical component type is not directly related to the actual communication speed Note The optical components transmitter and receiver on a fiber optic link must be of the same type Plastic optical fiber POF cables can be used with both 5 MBd and 10 MBd opt...

Page 178: ...nvironmental paramet ers and their severities Stationary use of weather protected locations Contamination Chemical gases Class 2C2 Solid particles Class 2S2 Chemical gases Class 1C2 Solid particles Class 1S3 packing must support this otherwise 1S2 Chemical gases Class 3C2 Solid particles Class 3S2 No conductive dust al lowed 2 Pollution degree IEC EN 60721 3 2 1997 IEC EN 60721 3 1 1997 IEC EN 607...

Page 179: ...binets are attached to the pallet with screws and braced from the top end to the package walls to prevent swaying inside the package Package elements are at tached to each other with screws The main parts of the drive can be recycled to preserve natural resources and en ergy Product parts and materials should be dismantled and separated Generally all metals such as steel aluminum copper and its al...

Page 180: ...ved mark functional safety Product contains Safe Torque Off and possibly other optional safety functions which are certified by TÜV according to the relevant functional safety standards Applicable to drives and inverters not applicable to supply brake or DC DC converter units or modules EAC Eurasian Conformity mark Product complies with the technical regulations of the Eurasian Customs Union EAC m...

Page 181: ...an 1000 V and intended to be installed and started up only by a professional when used in the first environment Note A professional 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...

Page 182: ...English 3 The motor and 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...

Page 183: ...Technical data 183 ...

Page 184: ...184 Technical data ...

Page 185: ...8 10 N m 7 4 lbf ft M6 Strength class 8 8 24 N m 17 7 lbf ft M8 Insulation supports Note Max torque Size Strength class 8 8 5 N m 44 lbf in M6 Strength class 8 8 9 N m 6 6 lbf ft M8 Strength class 8 8 18 N m 13 3 lbf ft M10 Strength class 8 8 31 N m 23 lbf ft M12 Cable lugs Note Max torque Size Strength class 8 8 15 N m 11 lbf ft M8 Strength class 8 8 32 N m 23 5 lbf ft M10 Strength class 8 8 50 N...

Page 186: ... 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 187: ...ta given is preliminary ABB reserves the right to modify the design at any time without notice Consult ABB for up to date drive specific information Weight Width ACS880 07LC lbs kg mm UN 690 V 6 pulse connection 3260 1480 1700 0390A 7 3260 1480 1700 0430A 7 3260 1480 1700 0480A 7 3260 1480 1700 0530A 7 3260 1480 1700 0600A 7 3260 1480 1700 0670A 7 3260 1480 1700 0750A 7 3260 1480 1700 0850A 7 3550...

Page 188: ...A004 4920 2230 2300 0670A 7 A004 4920 2230 2300 0750A 7 A004 4920 2230 2300 0850A 7 A004 5200 2360 2500 1030A 7 A004 5200 2360 2500 1170A 7 A004 5200 2360 2500 1310A 7 A004 5200 2360 2500 1470A 7 A004 5200 2360 2500 1660A 7 A004 5580 2530 2700 1940A 7 A004 5580 2530 2700 2180A 7 A004 5580 2530 3100 2470A 7 A004 7140 3240 3400 2880A 7 A004 7140 3240 3400 3260A 7 A004 7520 3410 3600 3580A 7 A004 752...

Page 189: ... Dimension drawing examples ACS880 07LC 0850A 7 Dimensions 189 ...

Page 190: ...ACS880 07LC 1660A 7 6 pulse 190 Dimensions ...

Page 191: ...ACS880 07LC 1660A 7 A004 12 pulse Dimensions 191 ...

Page 192: ...ACS880 07LC 3260A 7 192 Dimensions ...

Page 193: ...Cabinet height and depth Marine construction option C121 IP42 side view Non marine IP42 side view Dimensions 193 ...

Page 194: ...Location and size of input terminals 600 mm with main breaker single busbar bottom cable entry 194 Dimensions ...

Page 195: ... 600 mm with main breaker double busbar bottom cable entry Dimensions 195 ...

Page 196: ...Location and size of output terminals Units without common motor terminal cubicle Inverter module cubicle with one R8i module bottom cable exit 196 Dimensions ...

Page 197: ...Inverter module cubicle with two R8i modules bottom cable exit Dimensions 197 ...

Page 198: ...Inverter module cubicle with three R8i modules bottom cable exit 198 Dimensions ...

Page 199: ...Brake chopper cubicle Dimensions 199 ...

Page 200: ...200 ...

Page 201: ...ts 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 Safe torque off is activated it coasts to a stop The Safe torque ...

Page 202: ...ed 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 programmable electronic control systems IEC 62061 2005 A1 2012 A2 20...

Page 203: ... drive control unit 60 m 200 ft between multiple drives 60 m 200 ft between external power supply and first control unit 30 m 100 ft between BCU control unit and last inverter module in the chain 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 including wiring diagnostics or a wiring method shield ...

Page 204: ... CH1 STO IN X52 24VDC CH2 FE GND CH2 24VDC CH1 GND CH1 STO OUT X51 24VDC CH2 FE GND CH2 24VDC CH1 GND CH1 STO IN X52 24VDC CH2 FE GND CH2 24VDC CH1 GND CH1 STO OUT X51 24VDC CH2 FE GND CH2 1 2 2 3 Drive control unit 1 Inverter module s 2 To remaining inverter modules 3 Activation switch K 204 The Safe torque off function ...

Page 205: ...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 205 ...

Page 206: ...power supply 24 V OUT SGND IN1 IN2 OUT SGND IN1 IN2 OUT SGND IN1 IN2 K XSTO XSTO XSTO 1 1 1 2 2 2 Drive 1 Control unit 2 Activation switch K Terminal designation may vary depending on drive type 206 The Safe torque off function ...

Page 207: ... OUT SGND IN1 IN2 OUT SGND IN1 IN2 OUT SGND IN1 IN2 24 V 24 V DC K XSTO XSTO XSTO 1 2 1 2 1 2 Drive 1 Control unit 2 Activation switch K Terminal designation may vary depending on drive type The Safe torque off function 207 ...

Page 208: ... 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 209: ... validate its operation as follows Note If the drive is equipped with safety option L536 L537 Q950 Q951 Q952 Q957 Q963 Q964 Q978 or Q979 do the procedure shown in the documentation of the option Note All inverter modules of the drive must be powered and connected to the STO circuit during the acceptance test Action WARNING Obey the safety instructions If you ignore them injury or death or damage t...

Page 210: ...rcuit 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 211: ...ply control unit or the brake control unit The Safe torque off function is supported by any ACS880 inverter or drive control program It is not supported by supply DC DC converter or brake firmware WARNING With permanent 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 moto...

Page 212: ...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 213: ...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 214: ...ions 670 on off cycles per year with ΔT 71 66 C 1340 on off cycles per year with ΔT 61 66 C 30 on off cycles per year with ΔT 10 0 C 32 C board temperature at 2 0 of time 60 C board temperature at 1 5 of time 85 C board temperature at 2 3 of time The STO is a type B safety component as defined in IEC 61508 2 Relevant failure modes The STO trips spuriously safe failure The STO does not activate whe...

Page 215: ...a safety related system to perform the specified safety function over a given period of time IEC 61508 PFH Performance level Levels a e correspond to SIL EN ISO 13849 1 PL Systematic capability IEC 61508 SC Safe failure fraction 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 ...

Page 216: ... Declaration of conformity 216 The Safe torque off function ...

Page 217: ...The Safe torque off function 217 ...

Page 218: ...218 ...

Page 219: ...Resistor braking The ACS880 07LC employs ACS880 607LC 1 phase brake units For more information refer to ACS880 607LC 1 phase brake units hardware manual 3AXD50000481491 English 16 Resistor braking 219 ...

Page 220: ...220 ...

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