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The Safe torque off function 199

Summary of Contents for ACS880-107

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 107 inverter units Hardware manual ...

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Page 3: ...ACS880 107 inverter units Hardware manual Table of contents 4 Electrical installation 6 Start up 3AUA0000102519 Rev F EN EFFECTIVE 2020 05 11 ...

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Page 5: ...ubicle with frame R1i R4i modules in their own compartments option C204 22 Inverter module frame size R5i 22 General 22 Module layout 22 Standard cabinet layout 23 Layout of cubicle with frame R5i modules in their own compartments option C204 25 Inverter module frame sizes R6i and R7i 25 Module layout 25 Cabinet layout 26 Motor cabling 27 Inverter module frame size R8i and multiples 28 Cooling fan...

Page 6: ...rd slot 53 Connector data 55 BCU x2 ground isolation diagram 56 ZCU 1x ground isolation diagram 4 Electrical installation 57 Contents of this chapter 57 Electrical safety precautions 59 General notes 59 Printed circuit boards 59 Optical components 59 Checking the insulation of the assembly 59 Measuring the insulation of the drive 59 Measuring the insulation of the motor and motor cable 61 Connecti...

Page 7: ...ce timers and counters 99 Cabinet 99 Cleaning the interior of the cabinet 99 Cleaning the door air inlets IP22 and IP42 100 Replacing the inlet door filters IP54 100 Replacing the outlet roof filters IP54 100 Cleaning the heatsink 101 Cooling fans 102 Module cooling fans 102 Replacing the R1i and R2i module cooling fan 103 Replacing the R3i and R4i module cooling fan 103 Replacing the R5i module m...

Page 8: ...ng the control panel battery 8 Technical data 131 Contents of this chapter 131 Ratings 134 Definitions 135 Derating 135 Surrounding air temperature derating 135 Altitude derating 136 Inverter modules used DC fuses DC capacitances 139 Noise and cooling characteristics 142 Sine output filter data 144 Input power DC connection 144 Motor AC connection 147 Typical power cable sizes 148 Control connecti...

Page 9: ...ze of output terminals 168 Units without common motor terminal cubicle 176 Units with common motor terminal cubicle H359 11 The Safe torque off function 183 Contents of this chapter 183 Description 184 Compliance with the European Machinery Directive 185 Wiring 185 Activation switch 185 Cable types and lengths 185 Grounding of protective shields 186 Dual channel connection with internal power supp...

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Page 11: ...A0000102301 English Read the software function specific warnings and notes before changing the default settings of a function For each function the warnings and notes are given in the section describing the related user adjustable parameters Read the task specific safety instructions before starting the task See the section describing the task Target audience This manual is intended for people who...

Page 12: ...ch the control program runs Control board Control board built in a housing often rail mountable Control unit One section of a cabinet installed drive A cubicle is typically behind a door of its own Cubicle DC circuit between rectifier and inverter DC link Frequency converter for controlling AC motors Drive Optional analog I O extension module FAIO 01 Optional CANopen adapter module FCAN Optional C...

Page 13: ...ion module RDCO Radio frequency interference RFI Safety integrity level 1 3 IEC 61508 SIL Safe torque off IEC EN 61800 5 2 STO Supply module s under control of one control board and related components Supply unit Uninterruptible power supply UPS Type of control unit ZCU Related documents Code Manual General manuals 3AUA0000102301 ACS880 multidrive cabinets and modules safety instructions 3AUA00001...

Page 14: ... type approved cabinet built drives supplement 3AUA0000085685 ACS AP x assistant control panels user s manual 3AUA0000094606 Drive composer start up and maintenance PC tool user s manual 3AXD50000210268 Converter module lifting device for drive cabinets hardware manual 3AXD50000332588 Lifter for air cooled drive modules user s guide Manuals for I O extension modules fieldbus adapters safety option...

Page 15: ...re description Contents of this chapter This chapter describes a typical drive system and the hardware of the inverter unit The information is valid for all ACS880 107 inverter units 2 Hardware description 15 ...

Page 16: ... 6 Brake unit brake resistors not shown 7 Motor s 8 The supply unit connects to the AC supply network and converts the AC voltage into DC The DC voltage is distributed through the DC bus to all inverter units The inverter unit consisting of one or more inverter modules converts the DC back to AC that rotates the motor The inverter units can be used for controlling asynchronous AC induction motors ...

Page 17: ... motor At smaller inverter sizes a single cubicle may contain several inverter units each controlling a different motor On the other hand large inverter units consist of parallel connected modules and may occupy several cubicles Examples of the cabinet configurations are included below as well as in the dimensions and weights chapter The motor cabling direction is optionally up or down see below u...

Page 18: ...quipment is primarily installed on mounting plates in the same cubicle Module layout examples Frame R1i Frame R2i has a similar layout Explanation Item Power unit 1 DC input connections 2 Motor output connection obscured This has been wired to a separate terminal block in the lower part of the cubicle 3 ZCU 14 control unit mounted on top of the power unit 4 Grounding strain relief rail for control...

Page 19: ... 1 2 7 7 7 5 6 9 Standard cabinet layout Several inverter modules of frame sizes R1i R4i can be installed in one cubicle The standard cubicle width is 400 600 800 or 1000 mm depending on the size and number of inverter modules installed Each module has dedicated DC fuse disconnectors The motor output connections are located at the lower part of the cubicle depending on the power of the inverter mo...

Page 20: ...a door Up to three inverter modules of frame sizes R1i R4i can be installed in one 400 mm wide cubicle At the top of the cubicle there is another compartment which contains the common DC switch disconnector and fuses for all the modules in the cubicle The inverter modules are installed in an inclined position so that the cooling air flows from the cool area at the front of the cubicle through the ...

Page 21: ...nts an example of a 400 mm wide cubicle with three R1i to R4i modules Compartment doors open Compartment doors closed Explanation Item Main DC switch disconnector handle for all units in the cubicle 1 Compartments for inverter modules with DC switch disconnector handle 2 Output connections 3 Cable entries 4 Common DC fuses for all units in the cu bicle 5 Inverter module 6 Inverter control unit 7 M...

Page 22: ...ubicle 3 Control cable clamps 4 ZCU 12 control unit The control unit has three slots for optional modules 5 I O terminal blocks 6 Memory unit 7 Main cooling fan 8 Auxiliary cooling fan 9 5 1 8 3 2 4 6 7 9 Standard cabinet layout Several inverter modules of frame size R5i can be installed in one cubicle The standard cubicle widths are 300 check availability with ABB and 500 mm The number of modules...

Page 23: ...nt which contains the common DC switch disconnector and fuses for all the modules in the cubicle The inverter modules are installed in an upright position The cooling air is guided from the cool area at the front of the cubicle through the modules into the hot area at the back The hot air is exhausted through the roof of the cubicle Each module has a dedicated DC switch disconnector When the switc...

Page 24: ...ules in the cubicle Compartment for DC fuses 1 DC switch disconnectors with fuses for each individu al module 2 Inverter modules 3 Inverter control units 4 Output connections 5 Cable entries 6 3 1 2 4 5 6 2 3 4 5 Compartment doors closed 24 Hardware description ...

Page 25: ... the module and can be easily replaced Module layout Explanation Item DC input connection 1 Motor output connection 2 ZCU 14 control unit with slots for optional I O modules 3 I O terminal blocks 4 Control panel connector memory unit 5 Grounding clamping plates for control cables 6 Cooling fan holder with one R6i or two R7i fans 7 Lifting eyes 8 1 2 8 8 6 4 3 5 7 Cabinet layout Each inverter modul...

Page 26: ...tors R7i only optional 5 Common mode filters 6 Inverter module 7 Inverter module cooling fan s 8 Control unit 9 Control voltage circuit components install ation space for other equipment such as relays 10 Output busbars 11 Cable entries 12 3 1 7 10 9 11 8 2 4 5 6 12 Motor cabling The motor cables are connected to the output busbars at the bottom of the cubicle For top exit the depth of the cabinet...

Page 27: ...rect on line fan is available as option C188 4 Quick connector three phases The counterpart is fastened to the cabinet behind the module 5 Wheels 6 Type designation label 7 Terminal block X50 power supply for internal boards and module heating element option C183 DOL fan supply option C188 8 Connectors X51 X52 X53 9 The unpainted grounding point PE between module frame and cabinet frame 10 Lifting...

Page 28: ...erter module s The control electronics are typically located in a 300 mm wide control cubicle DCU which also may contain components of the auxiliary voltage circuit and optional features such as relays and circuit breakers The cubicle can also contain the control equipment of another inverter unit A 400 mm wide cubicle is optionally available Cabinet layout 1 3 inverter modules may be installed in...

Page 29: ... 7 8 9 With DC switch disconnector and charging circuit Explanation Item Inverter modules 1 DC bus 2 DC fuses 3 Common mode filters 4 DC switch disconnector Q2 5 Charging resistors 6 Charging switch Q10 7 Charging controller 8 AC quick connector 9 Hardware description 29 ...

Page 30: ...r optional circuitry 8 10 Earthing switch of inverter unit output optional 11 Control cable lead through optionally on the roof of the cubicle 12 Front view 2 5 3 4 6 7 8 9 10 11 12 1 Motor cabling The motor cabling connects to the module via a quick connector at the back of the module By default each inverter module is cabled individually to the motor With an optional common motor terminal cubicl...

Page 31: ... X P O W J1J2 X A I X A O X D 2 D X S T O X D I X D I O J6 X D 2 4 X R O 1 J3 CLOSE 1 2 3 4 5 6 7 Option modules can be inserted into slots 1 2 and 3 as follows 1 Slots Modules 1 2 3 Analog and digital I O extension modules 1 2 3 Feedback interface modules 1 2 3 Fieldbus communication modules 2 X12 FSO xx safety functions module When installed into slot 3 of a ZCU 14 control unit the module will e...

Page 32: ...on modules can be inserted into slots 1 2 and 3 1 2 3 Fiber optic links to power modules inverter supply brake or converter 8 Memory unit 4 Ethernet port Not in use 9 Slot 4 for RDCO 0x 5 Safety option interface Only in use for the invert er units 10 Terminal blocks 6 The ACx AP x control panel The ACS AP W is the user interface of the inverter unit providing the essential controls such as Start S...

Page 33: ...r modules within that particular cubicle Each module is additionally fitted with DC fuse disconnectors or a switch disconnector If R1i R5i units are ordered in their own compartments option C204 the cubicle is equipped with a common DC switch disconnector and the modules with dedicated DC switch disconnectors as standard The status of the DC switch disconnector as well as module specific disconnec...

Page 34: ...t digits express the basic construction of the unit for example ACS880 107 0100A 3 The optional selections are given thereafter separated by plus signs for example E205 Quote the complete type designation and serial number when contacting technical support on the subject of an inverter unit Inverter module type designation label Each module has a type designation label attached to it The type desi...

Page 35: ...opper module BRAKE CHOPPER regenerative rectifier module REGENERATIVE RECTIFIER and DC DC converter module DC DC CONVERTER 4 Valid markings 5 Serial number The first digit refers to the manufacturing plant The next four digits indicate manufacturing year and week respectively yyww The remaining digits complete the serial number so that there are no two units with the same number 6 Hardware descrip...

Page 36: ...i R5i only standard wire markings ACS880 primary control program Safe torque off function coated circuit boards USB memory stick containing complete documentation in English ACS880 107 Size Refer to the rating tables xxxxx 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 lab...

Page 37: ...d module heating elements external supply G300 Cabinet lighting G301 Control auxiliary voltage 115 V AC G304 Terminals for connecting external control voltage 230 V AC or 115 V AC eg UPS G307 Output for motor space heater external supply G313 Aluminum busbars G314 Tin plated copper DC busbars G315 Control auxiliary voltage 230 V AC G320 Halogen free wiring and materials G330 Additional wire markin...

Page 38: ...1 Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols K473 FENA 21 Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols 2 port K475 Ethernet switch for PC tool or control network for max 6 inverter units K480 Ethernet switch with optical link for PC tool or control network for max 6 inverter units K483 FEIP 21 Ethernet IP adapter module 2 port K490 ...

Page 39: ...rake 115 V AC 0 40 0 63 A M661 Starter for electromagnetic motor brake 230 V AC 0 40 0 63 A M662 Starter for electromagnetic motor brake 400 V AC 3 phase 0 40 0 63 A M663 Control program Winder control program N5000 Crane control program N5050 Winch control program N5100 PCP Progressive Cavity Pump control program N5200 Test bench control program N5300 ESP Electrical Submersible Pump control progr...

Page 40: ...ncoder Q966 FSO 21 safety functions module Q972 FSO 12 safety functions module Q973 Emergency stop configurable for category 0 or 1 with FSO xx safety functions module by activating the Safe torque off function Q979 PROFIsafe with FSO xx safety functions module and FENA 21 Ethernet adapter module Q982 Full set of printed manuals in the selected language Note The delivery may include manuals in Eng...

Page 41: ...oard contained in a plastic housing The control unit is mounted on the inverter module The BCU x2 control unit is used with frame size R8i and multiples The BCU x2 consists of a BCON 12 control board and a BIOC 01 I O connector board and power supply board built in a metal housing The control unit is connected to the inverter module s by fiber optic cables In this manual the name BCU x2 represents...

Page 42: ...ction XSTO Connection for FSO xx safety functions module X12 Control panel connection X13 Option slot 1 X202 Option slot 2 X203 Option slot 3 X204 Memory unit connection memory unit inser ted in the picture X205 Voltage Current selection jumpers J1 J2 for analog inputs J1 J2 Drive to drive link termination switch J3 J3 Common digital input ground selection switch J6 J6 X13 X12 X202 X203 X204 X205 ...

Page 43: ...nit When the ZCU is controlling a supply unit de energizing the inputs will stop the unit but will not constitute a true safety function XSTO Connection for FSO xx safety functions module inverter unit only X12 Control panel connection X13 Option slot 1 X202 Option slot 2 X203 Option slot 3 X204 Memory unit connection memory unit inser ted in the drawing X205 Voltage Current selection jumpers J1 J...

Page 44: ...r speed rpm 0 20 mA RL 500 ohm AGND 2 AO1 1 Drive to drive link XD2D Drive to drive link 3 Shield 4 BGND 3 A 2 B 1 Drive to drive link termination 3 J3 Safe torque off XSTO Safe torque off Both circuits must be closed for the drive to start 4 IN2 4 IN1 3 SGND 2 OUT 1 Digital inputs XDI By default not in use DI6 6 Constant speed 1 select 1 on 5 DI5 5 Acceleration deceleration select 6 DI4 4 Reset D...

Page 45: ...e off function page 183 5 Constant speed 1 is defined by parameter 22 26 6 0 Acceleration deceleration ramps defined by parameters 23 12 23 13 in use 1 Acceleration deceleration ramps defined by parameters 23 14 23 15 in use 7 Determines whether DICOM is separated from DIOGND ie common reference for digital inputs floats in practice selects whether the digital inputs are used in current sinking or...

Page 46: ...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 47: ...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 48: ...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 49: ...trol 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 breaks...

Page 50: ... 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 J1 for analog input AI1 or with J2 for analog input AI2 Set the appropriate analog input unit to V volt in parameter group 12 Standard AI 2 Select the excitation mode in parameter group 13 Standard AO 3 1 Set the input type to voltage with the appropriate switc...

Page 51: ...e 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 immunity ABB recommends high quality cable Keep the cable as short as possible Avoid unnecessary loops and parallel runs near power cables such as motor cables The follo...

Page 52: ... true safety function FSO xx safety functions module connection X12 See the user manual of the FSO xx module Note that the FSO xx safety functions module is not in use in supply DC DC converter or brake units SDHC memory card slot The BCU x2 has an on board data logger that collects real time data from the power modules to help fault tracing and analysis The data is stored onto the SDHC memory car...

Page 53: ...tch 5 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...

Page 54: ...ns must be 1 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 183 ...

Page 55: ...2 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 vo...

Page 56: ...OM 3 24VD 4 DIOGND 5 XDIO DIO1 1 DIO2 2 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 XSTO OUT1 1 GND 2 IN1 3 IN2 4 Common mode voltage between channels 30 V Ground selector J6 settings ZCU 12 ZCU 14 All digital inputs share a common ground DICOM connected to DIOGND This is the default setting ZCU 12 ZCU 14 Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO signal ground DIOGND Isolati...

Page 57: ...ve cabinets and modules 3AUA0000102324 English WARNING Only qualified electricians are allowed to carry out the work described in this chapter Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English before you install commission use or service the drive The tightening torques for the electrical connections are listed in the techni...

Page 58: ...you have a permanent magnet motor connected to the drive disconnect the motor from the drive with a safety switch or by other means Disconnect any dangerous external voltages from the control circuits After you disconnect power 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 again...

Page 59: ...bles too tightly The minimum allowed bend radius is 35 mm 1 4 Checking the insulation of the assembly 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 c...

Page 60: ...r 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 reduces the insulation resistance If you think that there is moisture in the motor dry the motor and do the measurement again 1000 V DC 10...

Page 61: ...d in creases bearing currents and causes extra wear Motor cable connection procedure WARNING Read and follow the instructions given in Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English Ignoring the instructions can cause physical injury or death or damage to the equipment Refer to the diagram above Also refer to the wiring diagrams delivered with the unit for th...

Page 62: ...ounding cable if the conductivity of the cable shield is less than 50 of the conductivity of the phase conductor in a cable with no symmetrically constructed grounding conductor see the document ACS880 multidrive cabinets and modules Electrical planning instructions 3AUA00000102324 English Note If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conduc...

Page 63: ...it with tape 5 Crimp suitable lug terminals onto the phase conductors and the ground conductor The dimensions of the output busbars are shown in the technical data 6 Connect the shield and any grounding conductors of the cable to the PE busbar close to the cable entries 7 Connect the phase conductors of the motor cable to the U2 V2 and W2 terminals 8 Secure the cable mechanically It is recommended...

Page 64: ...2 4 5 6 7 8 11 10 3 a b a b b 1 5 a 64 Electrical installation ...

Page 65: ...e s page 67 Especially in the case of multiple inverter modules in the same cubicle you can consider only removing the fan carriage of each module This is faster than removing the entire module but allows less room for the connecting work For instructions see section Removing the fan carriage of an inverter module page 71 Motor connection diagram without option H366 All parallel connected inverter...

Page 66: ...to use a number of cables that could not otherwise be evenly distributed between the inverter modules PE U2 V2 W2 U2 V2 W2 M 3 U1 W1 V1 PE Bridging busbars Inverter unit cubicle s The recommended cable types are given in chapter Technical data WARNING The bridging can carry the nominal output of one inverter module In case of three parallel modules ensure that the load capacity of the bridging is ...

Page 67: ...ultidrive cabinets and modules 3AUA0000102301 English If you ignore them injury or death or damage to the equipment can occur Note The illustrations represent a frame 2 R8i inverter cubicle with option F286 DC switch disconnector On units without F286 the DC busbars are oriented differently but the procedure is otherwise the same 1 Do the steps in section Electrical safety precautions page 57 befo...

Page 68: ...evel or chock the wheels of the module 10 Remove the two retaining screws at the top front of the module 11 Pull the module carefully out along the ramp While pulling on the handle with your right hand keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back 12 Move the module into a safe location outside the immediate work area and make sure ...

Page 69: ...Electrical installation 109 5 6 4 3 Electrical installation 69 11 ...

Page 70: ...7 a b d c 110 Electrical installation 7 8 8 8 9 9 70 Electrical installation ...

Page 71: ...nd modules 3AUA0000102301 English If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Electrical safety precautions page 57 before you start the work 2 Open the inverter module cubicle door 3 Remove the screws holding the front cover plate Lift the cover plate somewhat to release it 4 Disconnect the wiring at the top of the fan carriage Electrical inst...

Page 72: ...crews to 22 N m 16 lbf ft Note Units with marine or seismic design have an additional transverse bracket that is attached to the module with these screws At this point loosen the retaining screws of the bracket at the left and the right ends and remove it During reassembly tighten the bracket retaining screws to 9 N m 6 6 lbf ft 7 Pull the fan carriage out 8 Repeat the procedure for other fan carr...

Page 73: ...ven in Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Electrical safety precautions page 57 before you start the work 2 Remove the shroud in front of the output busbars Electrical installation 73 11 ...

Page 74: ...c insulators b between the busbars to make the connecting work easier WARNING The plastic insulators b between the busbars must be in place when the inverter is powered 7 Connect the shield and any grounding conductors of the cable to the PE busbar close to the cable entries 8 Secure the cable mechanically 9 Repeat the procedure for other modules if any 10 Refit the shroud removed earlier 11 At th...

Page 75: ...2 11 b PE 10 7 5 6 8 a 360 grounding detail Electrical installation 75 11 ...

Page 76: ...he ramp and back into the cubicle Keep your fingers away from the edge of the module front plate to avoid pinching Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back 4 Secure the top front of the module with two screws Tighten to 22 N m 16 lbf ft 5 Secure the bottom front of the module with two screws Tighten to 22 N m 16 lbf ft 6 Remove...

Page 77: ...the wiring and fiber optic cables to the terminals on the front of the module 11 Repeat the procedure for the other inverter modules 12 Reinstall the shroud near the top of the cubicle Electrical installation 77 11 ...

Page 78: ... WARNING Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Electrical safety precautions page 57 before you start the work 2 Open the door of the cubicle and remove the shrouding 3 Lead the cables into the cubicle Make the 360 e...

Page 79: ...e torques specified under Tightening torques page 152 8 Refit any shrouding removed earlier and close the cubicle doors 9 At the motor connect the cables according to instructions from the motor manufacturer Pay special attention to the phase order For minimum radio frequency interference ground the cable shield 360 degrees at the lead through of the motor terminal box or ground the cable by twist...

Page 80: ...tes for mounting on different units For mounting on the ZCU 14 the mounting points should be located at the short edges of the module as shown Replace the bottom plate of the FSO xx if necessary For mounting on the ZCU 12 the mounting points should be located at the long edges Replace the bottom plate of the FSO xx if necessary 3 Connect the data cable to connector X12 on the control unit 4 Put th...

Page 81: ... 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 installed beside the control unit which is the standard with factory installed FSO xx modules For instructions see the FSO xx manual 1 Stop the drive and do the steps in section Electrical safety precautions page 57 before you start the work 2 The FSO ...

Page 82: ...rews 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 1...

Page 83: ...e equipment can occur Pay attention to the free space required by the cabling or terminals coming to the option modules 1 Repeat the steps described in Electrical safety precautions page 57 2 Pull out the lock Note The location of the lock depends on the module type 3 Install the module to a free option module slot on the control unit 4 Push in the lock Electrical installation 83 11 ...

Page 84: ...lfilling the EMC requirements and for proper operation of the module WARNING Do not use excessive force or leave the screw too loose Over tightening can damage the screw or module A loose screw can cause an operation failure 6 Connect the wiring to the module Obey the instructions given in the documentation of the module 84 Electrical installation ...

Page 85: ...ushions can press on the bare shield If the outer surface of the shield is non conductive turn the shield inside out and wrap copper tape around the cable to keep the shielding continuous Do not cut the grounding wire if any 6 Push the cushions firmly together so that they press on the exposed cable shields Tighten the locking screws 7 When connecting to the inverter control unit remove the outer ...

Page 86: ...rews 1 A B C 2 2 3 4 5 Stripped cable A Conductive surface of the shield exposed B Stripped part covered with copper foil C Cable shield 1 Copper foil 2 Shielded twisted pair 3 Grounding wire 4 Copper cable 5 86 Electrical installation ...

Page 87: ...n USB cable Type A to Type Mini B between the USB connector on the control panel 3a and a free USB port on the PC 3b 4 The panel will display an indication whenever the connection is active 5 See the documentation of the PC tool for setup instructions Start Stop Loc Rem Start Stop Loc Rem USB connected 3a 4 3b 2 2 Panel bus Control of several units from one control panel One control panel or PC ca...

Page 88: ...DC converter units Repeat the above for each drive 2 With the panel connected to one unit link the units using Ethernet cables 3 Switch on the bus termination on the drive that is farthest from the control panel in the chain With drives that have the panel mounted on the front cover move the terminating switch into the outer position With an FDPI 02 module move termination switch S2 into the TERMI...

Page 89: ...With FDPI 02 modules OPEN TERMIN ATED 1 1 2 2 OPEN TERMINATED 3 Electrical installation 89 11 ...

Page 90: ...90 ...

Page 91: ...aintenance work WARNING Stop the drive and do the steps in section Electrical safety precautions page 57 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 ...

Page 92: ...able is connected to the correct terminals the phase order is correct and the terminals are tightened to the correct torque The motor cable is routed away from other cables No power factor compensation capacitors are connected to the motor cable Proper grounding has also been measured according to the regulations The control cables are connected to the correct terminals and the terminals are tight...

Page 93: ...connector Q1 The same device designations are also used in the circuit diagrams These instructions cannot and do not cover all possible start up tasks of a 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 safet...

Page 94: ...e trip level can be set for example 10 C higher than what the temperature of 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...

Page 95: ...rque off function See section Acceptance test procedure page 192 Drives with an emergency stop circuit options Q951 Q952 Q963 Q964 Q978 Q979 Test and validate the operation of the emergency stop circuit See the delivery specific circuit diagrams and wiring start up and operating instructions of the option Drives with the Prevention of unexpected start up with safety relay option Q957 Test and vali...

Page 96: ...96 ...

Page 97: ...e or service the drive The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English 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 rep...

Page 98: ...g spare modules and spare capacitors 4FPS10000292961 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 ratings and ambient conditions ABB recommends annual...

Page 99: ...ecautions page 57 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 Cleaning the door air inlets IP22 and IP42 Check the dustiness of the air inlet meshes If the dust cannot be removed by v...

Page 100: ...re side facing the door 6 Reinstall the grating in reverse order 3 Replacing the outlet roof filters IP54 1 Remove the front and back gratings of the fan cubicle by lifting them upwards 2 Remove the air filter mat 3 Place the new filter mat in the grating 4 Reinstall the gratings in reverse order Cleaning the heatsink The drive module heatsink fins pick up dust from the cooling air The drive runs ...

Page 101: ...ling fan s See the separate instructions 4 Blow dry clean and oil free compressed air from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust If there is a risk of dust entering adjoining equipment do the cleaning in another room 5 Reinstall the cooling fan Cooling fans The lifespan of the cooling fans of the drive depends on the running time ambient temperatu...

Page 102: ...ion Electrical safety precautions page 57 before you start the work 2 Detach the power cable clamp plate and terminal blocks 3 Release the retaining clips arrowed carefully using a screwdriver 4 Pull the fan holder out 5 Disconnect the fan cable 6 Carefully bend the clips on the fan holder to free the fan 7 Install new fan in reverse order Note The airflow direction is bottom to top Install the fa...

Page 103: ...ct the fan cable 5 Carefully bend the clips on the fan holder to free the fan 6 Install new fan in reverse order Note The airflow direction is bottom to top Install the fan so that the airflow arrow points up In the picture diretion of airflow is from right to left Replacing the R5i module main cooling fan without option C204 WARNING Obey the instructions in chapter Safety instructions If you igno...

Page 104: ...the module out any further than what is required to change the fan unless you intend to remove the module completely The rails have no stops to prevent the module from sliding all the way out 6 Lift the fan mounting plate by the front edge 7 Unplug the power supply wires 8 Lift out the fan assembly Install the new fan assembly and insert the module in reverse order to the above Make sure that the ...

Page 105: ...ules have an auxiliary fan located at the top front of the module WARNING Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English 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 57 before you start the work Note If the module is...

Page 106: ... tabs gently inwards to release the fan 4 Remove the fan Install new fan in reverse order Make sure that the fan blows upwards the arrows on the fan frame and the fan holder point in the same direction 3 3 4 106 Maintenance ...

Page 107: ...Electrical safety precautions page 57 before you start the work 2 Open the door Remove any shrouding in front of the fan unit 3 Remove the front plate 4 Remove the two screws that lock the fan unit 5 Unplug the power supply wire s of the fan s 6 To free the fan holder pull it slightly outwards about 5 mm then downwards 7 Detach the fan s from the fan holder 8 Install new fan s in reverse order to ...

Page 108: ... do installation or maintenance work WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges 1 Stop the drive and do the steps in section Electrical safety precautions page 57 before you start the work 2 Open the cubicle door 3 Remove the shroud in front of the fan if any 4 Remove the screws holding the front cover plate Lift the c...

Page 109: ...protective equipment Wear protective gloves and long sleeves Some parts have sharp edges 1 Stop the drive and do the steps in section Electrical safety precautions page 57 before you start the work 2 Open the door 3 Remove the shroud in front of the fan if any 4 Remove the screws holding the front cover plate Lift the cover plate somewhat to release it 5 Remove the bracket 6 Disconnect the wiring ...

Page 110: ...4 5 6 7 8 6 10 10 110 Maintenance ...

Page 111: ...tructions injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 57 before you start the work 2 Open the door of the module cubicle 3 Remove the two M4 12 T20 screws which lock the fan holder 4 Pull the fan holder out of the mod...

Page 112: ...the module 12 Install and tighten the two M4 12 T20 screws 10 11 12 Cabinet cooling fans Replacing R1i R5i cabinet fans 300 600 mm wide cubicles containing frame R1i R5i inverter modules have one exhaust fan in the top compartment of the cubicle 800 mm and 1000 mm wide cabinets have two fans WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage t...

Page 113: ...emove the five screws closest to the front edge of the top plate 6 Pull the front grating out You may need to bend the top plate slightly upwards out of the way 7 Remove the two screws holding the fan assembly 8 Disconnect the fan cable 9 Pull out the fan assembly Detach the fan Install the new fan in reverse order 4 3 5 6 7 9 8 2 2 Replacing the control cubicle fan Frame R8i and multiples WARNING...

Page 114: ...door You can remove the door entirely for better access 3 Remove the fuses from the DC switch disconnector of the compartment 4 Disconnect the control wiring from the inverter control unit and other equipment mounted onto the module 5 If present remove the FSO xx module together with its mounting plate 6 Remove the transverse brace in front of the base of the inverter module 7 Disconnect the outpu...

Page 115: ...given in Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English 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 57 before you start the work 2 Switch off the DC switch disconnector of the compartment and open the door You can remove the door entirely for easier acc...

Page 116: ... to the equipment can occur Note A lifting device is available from ABB See Converter module lifting device for drive cabinets hardware manual 3AXD50000210268 English 1 Stop the drive and do the steps in section Electrical safety precautions page 57 before you start the work 2 Remove the shrouds 3 Remove the air baffle at the top of the module 6 screws arrowed 4 Detach the wiring from the inverter...

Page 117: ... Pull the module outwards until the lifting eyes e at each side of the module are accessible 12 Attach a hoist to the lifting eyes and pull the module out Refit the module in reverse order Maintenance 117 ...

Page 118: ...2 3 7 9 a a c c c 6 8 b b d d 11 e e 118 Maintenance ...

Page 119: ...t the top of the module 5 Detach the DC busbars from the module Make note of the order and position of the screws and washers 6 Detach the wiring connected to the terminals on the front of the module including fiber optic cabling Move the disconnected wiring aside 7 Drives with option C121 Marine construction or C180 Seismic design a Loosen the bolts holding the transverse retaining bracket both o...

Page 120: ... pressure with one foot on the base of the module to prevent the module from falling on its back 12 Move the module into a safe location outside the immediate work area and make sure it cannot topple over Chock the wheels of the module if the floor is not completely level 13 Repeat the procedure for the other inverter modules Electrical installation 109 5 6 4 3 120 Maintenance ...

Page 121: ...7 a b d c 110 Electrical installation 7 8 8 8 9 9 Maintenance 121 ...

Page 122: ...ts and modules 3AUA0000102301 English If you ignore them injury or death or damage to the equipment can occur 1 Make sure there are no tools debris or any other foreign objects in the cubicle 2 If not already in place attach the module extraction installation ramp included to the base of the cabinet so that the tabs on the mounting bracket enter the slots on the ramp 122 Maintenance ...

Page 123: ... Reinstall the fan carriage bolts removed at previous step and tighten to 22 N m 16 lbf ft 8 Attach the DC busbars to the module Tighten to 70 N m 52 lbf ft 9 Reconnect terminal block X50 at the top of the module 10 Reconnect the wiring and fiber optic cables to the terminals on the front of the module 11 Repeat the procedure for the other inverter modules 12 Reinstall the shroud near the top of t...

Page 124: ...e baffle using M4 screws wherever possible This depends on the location of the module in the cubicle Tighten to 1 2 N m 0 7 1 5 lbf ft 3 5 6 If the inverter control unit A41 is powered from the faulty module connect the power supply wiring to another module using the extension wire set included 7 If the Safe torque off STO function is in use install the jumper wire set included in the STO wiring i...

Page 125: ...to 0 to disable the reduced run function 4 If the Safe torque off STO function is in use perform an acceptance test See the STO instructions Replacing DC fuses frame R8i and multiples WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur WARNING Read the safety instructions given in Safety instructions for ACS880 multid...

Page 126: ... DC switch c c 5 Slide out the fuse block 6 Move the screws nuts and washers from the blown fuse to the new fuse Make sure to keep the washers in the original order Note See the technical data for a table of recommended fuses 7 Insert the new fuse block into its slot Tighten both nuts of the fuse only until there is no play between the fuse and the busbars 126 Maintenance ...

Page 127: ... 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 see Capacito...

Page 128: ... Stop the drive and do the steps in section Electrical safety precautions page 57 before you start the work 2 Remove the M4 8 T20 screws at the ends of the control unit 3 To see the battery remove the XD2D terminal block 4 Carefully lift the edge of the control unit cover on the side with the I O terminal blocks 5 Carefully pull the battery out of the battery holder 6 Carefully put a new CR2032 ba...

Page 129: ...pose of the old battery according to local disposal rules or applicable laws 5 Set the real time clock 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 pane...

Page 130: ...130 ...

Page 131: ...kW A kW A kVA kW A A A UN 400 V 1 5 4 0 1 5 4 5 3 3 1 5 4 8 7 0 5 8 R1i 004A8 3 1 5 5 0 2 2 5 5 4 2 2 2 6 0 8 8 7 2 R1i 006A0 3 2 2 6 0 3 0 7 6 5 5 3 0 8 0 10 5 9 6 R1i 008A0 3 3 0 9 0 4 0 9 7 7 3 4 0 10 5 13 5 12 6 R2i 0011A 3 4 0 11 0 5 5 13 0 9 7 5 5 14 0 16 5 16 8 R2i 0014A 3 5 5 14 0 7 5 16 8 12 5 7 5 18 0 21 21 6 R2i 0018A 3 7 5 19 0 11 0 23 17 3 11 0 25 33 30 R3i 0025A 3 11 0 29 15 0 32 24 ...

Page 132: ...0 1653 1200 2122 1531 1200 2210 2880 2486 3 R8i 2210A 3 1000 1952 1400 2506 1808 1400 2610 3140 2936 3 R8i 2610A 3 1400 2581 1800 3312 2390 1800 3450 4140 3881 4 R8i 3450A 3 1800 3209 2000 4118 2972 2400 4290 5150 4826 5 R8i 4290A 3 2000 3837 2400 4925 3554 2800 5130 6160 5771 6 R8i 5130A 3 UN 500 V 1 5 3 0 1 5 3 4 3 1 1 5 3 6 5 3 4 3 R1i 003A6 5 1 5 4 0 2 2 4 5 4 2 2 2 4 8 7 0 5 8 R1i 004A8 5 2 2...

Page 133: ...00 2887 2400 3706 3343 2400 3860 5020 4343 5 R8i 3860A 5 2400 3448 2800 4426 3992 3200 4610 6000 5186 6 R8i 4610A 5 UN 690 V 4 0 5 5 5 5 7 0 8 7 5 5 7 3 9 5 8 2 R5i 007A3 7 5 5 7 3 7 5 9 4 11 7 7 5 9 8 12 7 11 0 R5i 009A8 7 7 5 10 6 11 0 13 6 17 0 11 0 14 2 18 5 16 0 R5i 014A2 7 11 0 13 5 15 0 17 3 21 5 15 0 18 0 23 20 R5i 0018A 7 15 0 16 5 18 5 21 26 3 18 5 22 29 25 R5i 0022A 7 18 5 20 22 26 32 2...

Page 134: ...A 7 Definitions Nominal AC supply voltage of drive system UN Nominal rms input current I1 Nominal output current available continuously with no over loading I2 Typical motor power in no overload use PN The horsepower ratings are typical NEMA motor sizes at 460 V ACS880 107 xxxxA 5 and 575 V ACS880 107 xxxxA 7 respectively Apparent power in no overload use SN Continuous rms output current allowing ...

Page 135: ...0 0 90 40 C 104 F 50 C 122 F k 0 80 Altitude derating At altitudes 1000 2000 m 3281 6562 ft above sea level the output current derating is 1 percentage point for every added 100 m 328 ft For example the derating factor for 1500 m 4921 ft is 0 95 For altitudes above 2000 m 6562 ft contact ABB If surrounding air temperature is below 40 C the derating can be reduced by 1 5 percentage points for every...

Page 136: ...04A8 3 280 Cooper Bussmann FWP 10A14F 2 ACS880 104 006A0 3 1 ACS880 107 006A0 3 280 Cooper Bussmann FWP 15A14F 2 ACS880 104 008A0 3 1 ACS880 107 008A0 3 435 Cooper Bussmann FWP 20A14F 2 ACS880 104 0011A 3 1 ACS880 107 0011A 3 865 Cooper Bussmann FWP 25A14F 2 ACS880 104 0014A 3 1 ACS880 107 0014A 3 865 Cooper Bussmann FWP 32A14F 2 ACS880 104 0018A 3 1 ACS880 107 0018A 3 785 Mersen 6 921 CP URQ 27x6...

Page 137: ...3 ACS880 107 2610A 3 72000 Cooper Bussmann 170M6419 8 ACS880 104 0900A 3 4 ACS880 107 3450A 3 90000 Cooper Bussmann 170M6419 10 ACS880 104 0900A 3 5 ACS880 107 4290A 3 108000 Cooper Bussmann 170M6419 12 ACS880 104 0900A 3 6 ACS880 107 5130A 3 UN 500 V 280 Cooper Bussmann FWP 10A14F 2 ACS880 104 003A6 5 1 ACS880 107 003A6 5 280 Cooper Bussmann FWP 10A14F 2 ACS880 104 004A8 5 1 ACS880 107 004A8 5 28...

Page 138: ...FR27UB10C32T 2 ACS880 104 014A2 7 1 ACS880 107 014A2 7 343 Mersen FR27UB10C40T 2 ACS880 104 0018A 7 1 ACS880 107 0018A 7 687 Mersen FR27UB10C40T 2 ACS880 104 0022A 7 1 ACS880 107 0022A 7 687 Mersen FR27UB10C50T 2 ACS880 104 0027A 7 1 ACS880 107 0027A 7 687 Mersen FR27UB10C63T 2 ACS880 104 0035A 7 1 ACS880 107 0035A 7 687 Mersen FR27UB10C80T 2 ACS880 104 0042A 7 1 ACS880 107 0042A 7 687 Mersen FR27...

Page 139: ... used for the protection of individual modules The cubicle also contains larger main DC fuses that are common to all modules The size of the main DC fuses depends on the number and size of the inverter modules Blown fuses must be replaced using equivalent fuses Noise and cooling characteristics Air flow Heat dissipation Noise level Inverter unit type ACS880 107 Total Sine filter option E206 Invert...

Page 140: ...200 6590 6000 3530 5200 3060 61 21 40 76 3450A 3 14500 8535 8000 4710 6500 3825 78 28 50 77 4290A 3 17800 10480 10000 5890 7800 4590 95 35 60 78 5130A 3 UN 500 V 24 14 0 06 47 003A6 5 24 14 0 07 47 004A8 5 24 14 0 08 47 006A0 5 24 14 0 09 47 008A0 5 48 28 0 13 39 0011A 5 48 28 0 15 39 0014A 5 48 28 0 18 39 0018A 5 142 84 0 23 63 0025A 5 142 84 0 28 63 0030A 5 142 84 0 32 63 0035A 5 200 118 0 48 71...

Page 141: ...165 0 58 62 0022A 7 280 165 0 66 62 0027A 7 280 165 0 86 62 0035A 7 280 165 1 00 62 0042A 7 280 165 1 12 62 0052A 7 650 383 0 80 71 0062A 7 650 383 1 1 71 0082A 7 650 383 1 3 71 0100A 7 650 383 1 5 71 0130A 7 650 383 1 8 71 0140A 7 650 383 2 5 71 0190A 7 940 553 2 8 72 0220A 7 940 553 3 3 72 0270A 7 2000 1180 700 410 1300 765 8 2 3 0 5 2 72 0340A 7 2000 1180 700 410 1300 765 9 1 3 0 6 1 72 0410A 7...

Page 142: ...es used The standard filters listed require no current derating For availability of sine output filters for other inverter unit types contact your local ABB representative Cooling data Dimensions Nominal current Sine filter s used Inverter unit type ACS880 107 Air flow Heat dissipation weight Width Type Qty m3 h ft3 min kW kg lbs mm A UN 400 V See Noise and cooling charac teristics page 139 840 18...

Page 143: ... 5 3840 8470 4000 4468 NSIN 1380 6 4 3860A 5 4800 10580 5000 5525 NSIN 1380 6 5 4610A 5 UN 690 V See Noise and cooling charac teristics page 139 340 750 400 447 NSIN 0485 6 1 0340A 7 340 750 400 447 NSIN 0485 6 1 0410A 7 840 1850 1000 783 NSIN 0900 6 1 0530A 7 840 1850 1000 783 NSIN 0900 6 1 0600A 7 840 1850 1000 783 NSIN 0900 6 1 0800A 7 960 2120 1000 1201 NSIN 1380 6 1 1030A 7 960 2120 1000 1201...

Page 144: ...90 V are typical drive input voltage levels shown on the type designation label of the supply unit corresponding to 525 690 V AC 0 500 Hz except Frequency f2 0 120 Hz with sine output filters option E206 0 120 Hz for frames R1i R5i with du dt filters option E205 0 200 Hz for frames R6i and R7i with du dt filters option E205 For higher operational output frequencies please contact your local ABB re...

Page 145: ... 8 10 6 stranded R1i R2i 10 solid 15 16 1 7 1 8 6 16 R3i R5i Screw terminal block 53 71 6 8 1 0 50 copper cable R4i 133 15 2 0 70 aluminum cable option H371 Output terminals Frames R1i to R5i Output terminals Frames R6i and R7i Side view Screw size M12 or Tightening torque 70 N m 52 lbf ft Busbar material Tin plated copper Technical data 145 ...

Page 146: ...Output terminals Frame R8i Side view Screw size M12 or Tightening torque 70 N m 52 lbf ft Busbar material Tin plated copper 146 Technical data ...

Page 147: ...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 148: ...6 510 602 696 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 1020 1204 1391 4 44 4 50 4 55 4 58 ...

Page 149: ...long term tensile load 1 N 3 6 ozf Flexing Max 1000 cycles 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 ...

Page 150: ... must support this otherwise 1S2 Chemical gases Class 3C2 Solid particles Class 3S2 3S1 with IP20 No con ductive dust allowed 2 Pollution degree IEC EN 60721 3 2 1997 IEC EN 60721 3 1 1997 IEC EN 60721 3 3 2002 Vibration 2 9 Hz max 3 5 mm amplitude 10 57 Hz max 0 075 mm amplitude 10 57 Hz max 0 075 mm amplitude IEC EN 61800 5 1 IEC 60068 2 6 2007 EN 60068 2 6 2008 Envir onmental testing Part 2 Tes...

Page 151: ...t film PE thickness 0 10 mm VCI stretch film PE thickness 0 04 mm VCI emitter bags PP tape PET strap sheet metal steel Seaworthy package For sea transport with or without containerization For long storage periods in environments where roofed and humidity controlled storage cannot be arranged Disposal The main parts of the drive can be recycled to preserve natural resources and energy Product parts...

Page 152: ...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 153: ... 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 154: ...154 ...

Page 155: ...Circuit diagrams Refer to the circuit diagrams delivered with the unit 9 Circuit diagrams 155 ...

Page 156: ...156 ...

Page 157: ...es The following drawing displays a 400 mm wide cubicle but the main dimensions apart from width are also applicable to wider cubicles For details refer to the dimension drawings delivered with the unit Option C128 cooling air intake through floor of cabinet extends the cabinet depth by 130 mm Weights The table shows the estimated maximum weights of R1i R5i cubicles Estimated max weight Cubicle wi...

Page 158: ...R7i inverter unit is housed in a 400 mm wide cubicle such as the one pictured below The approximate weight of the cubicle is 250 kg 550 lbs For details refer to the dimension drawings delivered with the unit Options H353 motor cabling through roof of cabinet and C128 cooling air intake through floor of cabinet extend the cabinet depth by 130 mm 158 Dimensions and weights ...

Page 159: ... Dimension drawing 400 mm wide cubicle R1i R4i 400 mm R6i R7i Dimensions and weights 159 ...

Page 160: ...ively Larger inverter units are combinations of these cubicles As standard the control equipment is located in a separate 300 mm wide cubicle DCU a 400 mm wide cubicle is optionally available Option C128 cooling air intake through floor of cabinet extends the cabinet depth by 130 mm Option H353 motor cabling through roof of cabinet extends the cabinet depth by 200 mm 160 Dimensions and weights ...

Page 161: ... Dimension drawing R8i without C128 or H353 bottom cable exit Dimensions and weights 161 ...

Page 162: ... Dimension drawing R8i without C128 or H353 top cable exit 162 Dimensions and weights ...

Page 163: ... Dimension drawing 2 R8i without C128 or H353 bottom cable exit Dimensions and weights 163 ...

Page 164: ... Dimension drawing 2 R8i without C128 or H353 top cable exit 164 Dimensions and weights ...

Page 165: ... Dimension drawing 3 R8i without C128 or H353 bottom cable exit Dimensions and weights 165 ...

Page 166: ... Dimension drawing 3 R8i without C128 or H353 top cable exit 166 Dimensions and weights ...

Page 167: ... Dimension drawing drive control unit DCU 300 mm Dimensions and weights 167 ...

Page 168: ... Location and size of output terminals Units without common motor terminal cubicle Inverter module cubicle with one R8i module bottom cable exit 168 Dimensions and weights ...

Page 169: ...Inverter module cubicle with one R8i module top cable exit Dimensions and weights 169 ...

Page 170: ...bottom cable exit Location and size of output terminals units without common motor terminal cubicle Frame 1 R8i 1 R8i without sine output filter See page 218 Inverter module cubicle with two R8i modules bottom cable exit 170 Dimensions and weights ...

Page 171: ...ule cubicle with two R8i modules top cable exit Dimensions 223 Inverter module cubicle with two R8i modules top cable exit Inverter module cubicle with three R8i modules bottom cable exit Dimensions and weights 171 ...

Page 172: ...Inverter module cubicle with three R8i modules bottom cable exit Inverter module cubicle with three R8i modules bottom cable exit 172 Dimensions and weights ...

Page 173: ...r module cubicle with three R8i modules top cable exit 224 Dimensions Inverter module cubicle with three R8i modules top cable exit Sine filter E206 cubicle 400 mm bottom cable exit Dimensions and weights 173 ...

Page 174: ...Sine filter cubicle 1000 mm bottom cable exit Sine filter E206 cubicle 1000 mm bottom cable exit 174 Dimensions and weights ...

Page 175: ...Sine filter cubicle 1000 mm top cable exit 226 Dimensions Sine filter E206 cubicle 1000 mm top cable exit Dimensions and weights 175 ...

Page 176: ...imensions 245 Location and size of output terminals units with common motor terminal cubicle Note See the dimension tables starting on page 203 as to which common motor terminal cubicle width is used with which drive type Cubicle width 300 mm bottom cable exit 176 Dimensions and weights ...

Page 177: ...Cubicle width 300 mm top cable exit 246 Dimensions Cubicle width 300 mm top cable exit Dimensions and weights 177 ...

Page 178: ...Cubicle width 400 mm bottom cable exit Dimensions 247 Cubicle width 400 mm bottom cable exit Cubicle width 400 mm top cable exit 178 Dimensions and weights ...

Page 179: ...Cubicle width 400 mm top cable exit Cubicle width 400 mm top cable exit Dimensions and weights 179 ...

Page 180: ...Cubicle width 600 mm bottom cable exit 248 Dimensions Cubicle width 600 mm bottom cable exit Cubicle width 600 mm top cable exit 180 Dimensions and weights ...

Page 181: ...Cubicle width 600 mm top cable exit Cubicle width 600 mm top cable exit Dimensions and weights 181 ...

Page 182: ...182 ...

Page 183: ...tenance operations like cleaning or work on non electrical parts of the machinery without switching off the power supply to the inverter When activated the Safe torque off function disables the control voltage of the power semiconductors of the inverter output stage A see the diagrams below thus preventing the inverter from generating the torque required to rotate the motor If the motor is running...

Page 184: ...lectrical 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 programmab...

Page 185: ...control unit 60 m 200 ft between multiple drives or inverter units 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 met...

Page 186: ...ction with internal power supply Frames R1i R7i 24 V OUT SGND IN2 UDC UDC A K IN1 1 2 3 4 Inverter unit 1 Control unit 2 Control logic 3 To motor 4 Activation switch K OUT1 with frame R5i 186 The Safe torque off function ...

Page 187: ... 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 Inverter control unit 1 Inverter module s 2 To remaining inverter modules 3 Activation switch K The Safe torque off function 187 ...

Page 188: ...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 Inverter unit 1 Control unit 2 Activation switch K OUT1 with frame R5i 188 The Safe torque off function ...

Page 189: ...4 V OUT SGND IN1 IN2 OUT SGND IN1 IN2 OUT SGND IN1 IN2 K XSTO XSTO XSTO 1 1 1 2 2 2 Drive Inverter unit 1 Control unit 2 Activation switch K Terminal designation may vary depending on drive inverter unit type The Safe torque off function 189 ...

Page 190: ...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 Inverter unit 1 Control unit 2 Activation switch K Terminal designation may vary depending on drive inverter unit type 190 The Safe torque off function ...

Page 191: ... 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 inverter 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 mal...

Page 192: ...ation 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 inverter unit 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 to the equi...

Page 193: ...o IN1 If the motor was running it should coast to a stop The inverter 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 inverter s operation The motor should not start Close the STO circuit Reset any active faults Restart the inverter and check that the motor runs normally Open the 2nd channel of the STO...

Page 194: ...upply 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 inverter can produce an alignment torque which maximally rotates the...

Page 195: ...egrity 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 Safe...

Page 196: ...ction is performed and the inverter 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 inverter control program for the indications generated by the inverter and for details on directing fault and warning indications to an output on the control unit for exte...

Page 197: ...0 6310 2 6E 06 1 1E 06 1 2E 10 99 e 3 7 R8i 20 80 1 3 3 90 5620 2 8E 06 1 2E 06 1 3E 10 99 e 3 8 R8i 20 80 1 3 3 90 5060 3 1E 06 1 3E 06 1 4E 10 99 e 3 9 R8i 20 80 1 3 3 90 4610 3 3E 06 1 4E 06 1 5E 10 99 e 3 10 R8i 3AXD10000041323 F 3AXD10000078136 F The following temperature profile is used in safety value calculations 670 on off cycles per year with ΔT 71 66 C 1340 on off cycles per year with Δ...

Page 198: ...rous failure on demand that is mean unavailability of a safety related system to perform the specified safety function when a demand occurs IEC 61508 PFDavg Average frequency of dangerous failures per hour that is average frequency of a dangerous failure of a safety related system to perform the specified safety function over a given period of time IEC 61508 PFH Performance level Levels a e corres...

Page 199: ... TÜV certificate The TÜV certificate is available on the Internet at www abb com drives documents The Safe torque off function 199 ...

Page 200: ...200 ...

Page 201: ... 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...

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ABB ACS880-107, Hardware Manual

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