ABB ACS880-107LC Hardware Manual Download

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Control interfaces

￭

Overview of the control connections of the BCU control unit

The diagram shows the control connections and interfaces of the BCU control unit.

FXX

FXXX

Control panel.

Analog and digital I/O extension modules and
fieldbus communication modules can be inserted
into slots 1, 2 and 3.

1
2
3

Fiber optic links to power modules (inverter,
supply, brake or converter)

Memory unit

Ethernet port. Not in use.

Slot 4 for RDCO-0x

Safety option interface. Only in use for the invert-
er units.

Terminal blocks.

￭

The ACx-AP-x control panel

The ACx-AP-x control panel is the user interface of the inverter unit, providing the essential
controls such as Start/Stop/Direction/Reset/Reference, and the parameter settings for the
control program.

Operation principle and hardware description 21

Summary of Contents for ACS880-107LC

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

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Page 3: ...ACS880 107LC inverter units Hardware manual Table of contents 3 Electrical installation 5 Start up 3AXD50000196111 Rev B EN Original instructions EFFECTIVE 2021 07 09 ...

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Page 5: ...tors 20 Cooling system 21 Control interfaces 21 Overview of the control connections of the BCU control unit 21 The ACx AP x control panel 22 Control by PC tools 23 Type designation labels 23 Inverter unit type designation label 23 Inverter module type designation label 23 Inverter unit type designation key 3 Electrical installation 27 Contents of this chapter 27 Electrical safety precautions 29 Ge...

Page 6: ...g of optional modules 4 Installation checklist 49 Contents of this chapter 49 Checklist 5 Start up 51 Contents of this chapter 51 Start up procedure 6 Maintenance 55 Contents of this chapter 55 Maintenance intervals 55 Description of symbols 55 Recommended maintenance intervals after start up 57 Retightening the power connections 58 Fans 58 Inverter module fan replacement 59 Replacing the common m...

Page 7: ...nts of this chapter 83 Description 84 Compliance with the European Machinery Directive and the UK Supply of Machinery Safety Regulations 85 Wiring 85 Activation switch 85 Cable types and lengths 85 Grounding of protective shields 86 Dual channel connection with internal power supply 86 Frame R8i and multiples 87 Single channel connection of activation switch 88 Multiple drives 88 Internal power su...

Page 8: ...ns 111 Derating 111 Surrounding air temperature derating 111 Coolant temperature derating 111 Antifreeze content derating 111 Altitude derating 111 Switching frequency derating 112 Output frequency derating 112 Inverter unit frame sizes and modules used 113 Cooling data and noise 114 DC fuses 114 Dimensions and weights 114 Free space requirements 116 Typical power cable sizes 118 Terminal and cabl...

Page 9: ...cle with one R8i module bottom cable exit 130 Inverter module cubicle with two R8i modules bottom cable exit 131 Inverter module cubicle with three R8i modules bottom cable exit 132 Units with common motor terminal cubicle H359 132 Cubicle width 300 mm bottom cable exit 133 Cubicle width 300 mm top cable exit 134 Cubicle width 400 mm bottom cable exit 135 Cubicle width 400 mm top cable exit 136 Cu...

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Page 11: ...nction 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 plan the installation install start up ...

Page 12: ...s that the unit consists of two frame size R8i modules connected in parallel The frame size is marked on the type designation labels The frame size of each unit is also shown in the rating tables in chapter Technical data The information that concerns only certain optional selections is marked with option codes such as E205 The options included in the unit can be identified from the type code visi...

Page 13: ...0000085967 ACS880 primary control program firmware manual 3AUA0000098062 ACS880 primary control program quick start up guide Manuals for application programs Crane Winder etc Brake unit and DC DC converter unit manuals 3AXD50000481491 ACS880 607LC 1 phase brake units hardware manual 3AXD50000581627 ACS880 607LC 3 phase dynamic brake units hardware manual 3AXD50000020967 ACS880 3 phase brake contro...

Page 14: ...mistor protection module FPTC 01 Optional ATEX certified thermistor protection module for potentially explosive atmo spheres 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 mot...

Page 15: ...verview diagram of the drive system This diagram shows an example of a multidrive The supply unit connects the drive to the AC supply network It converts the AC voltage into DC The DC voltage is distributed through the DC bus to all inverter units and optional brake units The inverter unit converts the DC 2 Operation principle and hardware description 15 ...

Page 16: ...ly 1 Main breaker or main contactor and main switch disconnector 2 Input AC fuses 3 Supply module 4 DC bus 5 Supply and inverter module DC fuses 6 DC switch disconnector optional 7 Inverter modules 8 Brake chopper fuses 9 3 phase brake chopper module optional 10 Brake resistors optional or acquired by user 11 Fuses for the brake resistors 12 Motor s acquired by user 13 16 Operation principle and h...

Page 17: ...ated at the top The motor connection is via a quick connector at the back of the module that couples when the module is inserted into the cubicle Each parallel connected module is cabled separately to the motor or connected by busbars to adjacent modules to reduce the number of cables It is also possible to build an AC bus from each module to a separate output cubicle Internal du dt filtering is m...

Page 18: ... for internal boards See section Connectors X50 X59 7 Terminal block X51 and X52 Safe torque off See section Connectors X50 X59 8 Terminal block X53 24 V DC power output See section Connectors X50 X59 9 Auxiliary voltage selector 115 or 230 V See section Connectors X50 X59 10 Unpainted fastening hole The grounding point PE between module frame and cabinet frame 11 Coolant connectors The coolant pi...

Page 19: ...iliary voltage of 230 V AC or 115 V AC selectable can optionally be fed to terminal block X50 to power the BDPS even when the DC link is not live The selection between 115 V and 230 V is made with selector plug X59 The setting can be changed by removing the two screws turning the plug 180 degrees and reinstalling the screws If the Safe torque off STO function is not used the 24V inputs on X52 must...

Page 20: ...ND FE STO signal forwarding output to next inverter module if present STO OUT X51 24V GND 24V GND FE Auxiliary voltage 230 V AC Auxiliary voltage 115 V AC Fiber optic connectors Description Name Reserved BSFC Control unit connection Must be connec ted by the installer BCU V50 BSFC V60 V10 BCU V20 Cooling system See chapter Internal cooling circuit page 99 20 Operation principle and hardware descri...

Page 21: ...o 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 ACx AP x control panel is the user interface of the inverter unit providing the essential controls such as Start Stop Direction Re...

Page 22: ...ven if the Drive composer PC tool is used For details on the control panel see ACX AP x Assistant control panels User s manual 3AUA0000085685 English 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 For more information see section Connecting a PC 22 ...

Page 23: ...drive cabinets and modules 3AUA0000102324 English 5 Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing year and week respectively The remaining digits complete the serial number so that there are no two units with the same number 6 Inverter module type designation label Each inverter module has a type designat...

Page 24: ...ble entry H350 Top power cable entry H351 Motor cabling direction up H353 Common motor terminal cubicle H359 Common output terminals for inverter modules mounted in the same cubicle H366 ACS AP W control panel with Bluetooth J400 LED monitoring display J401 Control panel mounting platform J410 Panel bus control of several units from one control panel K450 FDNA 01 DeviceNet adapter module K451 FLON...

Page 25: ...module L526 FPTC 01 thermistor protection module L536 FPTC 02 ATEX certified thermistor protection module L537 Starter for auxiliary motor fan trip limit 2 5 4 A M602 Starter for auxiliary motor fan trip limit 4 6 3 A M603 Starter for auxiliary motor fan trip limit 6 3 10 A M604 Starter for auxiliary motor fan trip limit 10 16 A M605 Starter for auxiliary motor fan trip limit 16 20 A M606 Starter ...

Page 26: ...66 ATEX certified safe disconnection function Q971 FSO 21 safety functions module Q972 FSO 12 safety functions module Q973 PROFIsafe with FSO xx safety functions module and FPNO 21 Ethernet adapter module Q982 26 Operation principle and hardware description ...

Page 27: ...this chapter This chapter gives instructions on the wiring of the drive Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive motor cable or motor 3 Electrical installation 27 11 ...

Page 28: ...nit optional or a DC feeder unit optional Open the DC switch disconnector Q11 option F286 or F290 of the unit Open the disconnecting device of the energy storage connected to the unit outside the drive cabinet Open the auxiliary voltage switch disconnector if present and all other possible disconnecting devices that isolate the drive from dangerous voltage sources In the liquid cooling unit if pre...

Page 29: ... and UDC and the grounding PE terminal is zero In cabinet built drives measure between the drive DC busbars and and the grounding PE busbar WARNING The busbars inside the cabinet of liquid cooled drives are partially coated Measurements made through the coating are potentially unreliable so only measure at uncoated portions Note that the coating does not constitute a safe or touch proof insulation...

Page 30: ...tions page 27 before you start the work 2 Make sure that the motor cable is disconnected from the drive output terminals 3 Measure the insulation resistance between each phase conductor and the protective earth conductor Use a measuring voltage of 1000 V DC The insulation resistance of an ABB motor must be more than 100 Mohm reference value at 25 C 77 F For the insulation resistance of other motor...

Page 31: ...on Connecting control cabling 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 EMI conductive cushions and pull the cushions apart 2 Cut adequate holes to the rubber gromme...

Page 32: ... of cables When each cable has its own rubber grommet sufficient IP and EMC protection can be achieved However if there is more than one cable per grommet plan the installation beforehand as follows 1 Make a list of the cables coming to the cabinet 2 Sort the cables going to the left into one group and the cables going to the right into another group to avoid unnecessary crossing of cables inside ...

Page 33: ... ground the outer shield of the cable here since it is grounded at the lead through Keep any signal wire pairs twisted as close to the terminals as possible Twisting wire with its return wire reduces disturbances caused by inductive coupling 6 If more than one cable go through a grommet seal the grommet by applying Loctite 5221 or equivalent adhesive sealant inside the grommet Routing the control ...

Page 34: ...its return wire reduces disturbances caused by inductive coupling At the other end of the cable leave the shields unconnected or 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 34 Electrical installation ...

Page 35: ...s equipped with a common motor terminal cubicle option H359 or a sine output filter option E206 follow the instructions in section Connecting the motor cables units with common motor terminal cubicle or sine output filter page 40 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 thr...

Page 36: ...the middle Note The H366 option only interconnects the outputs of inverter modules within the same cubicle not modules installed in different cubicles Therefore when the drive has more than three inverter modules make sure that the load is distributed evenly between the modules In case of two inverter cubicles of two modules connect the same number of cables to each cubicle In case of one inverter...

Page 37: ... 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 Seal the gap between the cable and mineral wool sheet if used with sealing compound eg CSD F ABB brand name DXXT 11 code 35080082 15 Connect the twisted shields of the cables to the PE busbar of the cabine...

Page 38: ...4 a 8 b 16 18 PE PE 10 38 Electrical installation ...

Page 39: ...13 12 21 Electrical installation 39 11 ...

Page 40: ...nual Connection diagram U2 V2 W2 PE M 3 U1 W1 V1 PE Inverter unit cubicle Common motor terminal or sine filter cubicle The recommended cable types are given in chapter Technical data Procedure WARNING Obey the safety instructions given in ACS880 liquid cooled multidrive cabinets and modules safety instructions 3AXD50000048633 English If you ignore the safety instructions injury or death or damage ...

Page 41: ...nal box or ground the cable by twisting the shield wider than 1 5 of its length 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 separate ground conductors cables to the PE busbar in the cubicle 7 Connect the phase conductors to the output terminals Use the torque...

Page 42: ...panel holder or platform or by using an Ethernet eg Cat 5e networking cable 2 Remove the USB connector cover on the front of the control panel 3 Connect an 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 instruc...

Page 43: ...D number Set other parameters in group 49 if necessary Use parameter 49 06 to validate any changes The parameter group is 149 with supply line side brake or DC 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 tha...

Page 44: ...With FDPI 02 modules OPEN TERMINATED 1 1 2 2 OPEN TERMINATED 3 44 Electrical installation ...

Page 45: ...the mounting screw Note The screw secures and grounds the 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 Read the safety instructions given in Safety instructions for ACS880 liquid cooled multidrive cabinets and modules 3AXD50000048633 English If you ignore them injury or death or ...

Page 46: ...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 47: ... Wiring of optional modules See the appropriate optional module manual for specific installation and wiring instructions Electrical installation 47 11 ...

Page 48: ...48 ...

Page 49: ...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 power cable motor cable and motor is measured according to local regulations and the manuals of the drive The drive ca...

Page 50: ...der 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 If an external brake resistor is connected to the drive There is an adequately sized protective earth ground conductor between the brake resistor and the drive and the conductor is connected to the correct ter...

Page 51: ...r 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 safety option...

Page 52: ...m and trip levels of the Pt100 relay as low as possible based on the operating temperature and test results of the machine The 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 i...

Page 53: ...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 operation of the Safe torque off ...

Page 54: ...54 ...

Page 55: ...ocal ABB Service representative www abb com searchchannels Description of symbols Description Action Inspection visual inspection and maintenance action if needed I Performance of on off site work commissioning tests measurements or other P work Replacement R Recommended maintenance intervals after start up 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 ...

Page 56: ...mbient conditions dustiness corrosion temperature I I I I I I I I I I I I I Checking coolant pipe connections Functional safety I See the maintenance information of the safety function Safety function test 20 years Safety component expiry Mission time TM 3AXD10000578918 rev L 1 To replace CIO module or to reset fan counters see CIO 01 I O module for distributed I O bus control user s manual 3AXD50...

Page 57: ...quipment 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 27 before you start the work 2 Examine the tightness of the cable connections Use the tightening torques given in the technical data Maintenance 57 ...

Page 58: ...f you ignore them 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 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 27 2 Remove any shrouding in front of...

Page 59: ...edges 1 Stop the drive and do the steps in section Electrical safety precautions page 27 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 Maintenance 59 ...

Page 60: ...own 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 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 thread visible 2 3 mm 0 08 0 12 WARNING Use the required personal protective equipment Wear protective glo...

Page 61: ... 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 cubicle This will drain all modules in the cubicle a b c 7 After the module has drained disconnect the piping from the module Maintenance 61 ...

Page 62: ...module carefully out onto a table or other platform Keep the module secured to a hoist or equivalent to prevent the module from falling For information on using the lifting device see Converter module lifting device for drive cabinets hardware manual 3AXD50000210268 English 62 Maintenance ...

Page 63: ...ted current even if one or more module is out of service for example because of maintenance work In principle reduced run is possible with only one module but the physical requirements of operating the motor still apply for example the modules remaining in use must be able to provide the motor with enough magnetizing current Note The wiring accessories and the air baffle needed during the procedur...

Page 64: ... is powered from the faulty module connect the power supply wiring to another module using the extension wire set included 8 If the Safe torque off STO function is in use install the jumper wire set included in the STO wiring in place of the missing module This is not needed if the module was the last on the STO wire chain X51 X52 X51 X52 X51 X52 R8i R8i R8i BCU Jumper wire set Removed module 8 9 ...

Page 65: ...een the number of detected modules parameter 95 14 and the value set in 95 13 will generate a fault Returning the module 1 Install the module in reverse order Use the following tightening torques DC busbar assembly to upper insulators 2 M8 9 N m 6 6 lbf ft DC busbar assembly to lower insulators 2 M10 18 N m 13 3 lbf ft Fuses to DC busbars 50 N m 37 lbf ft Bussmann 46 N m 34 lbf ft Mersen Ferraz Sh...

Page 66: ... 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 Capacitor reforming ...

Page 67: ... drive and do the steps in section Electrical safety precautions page 27 before you start the work 2 Open the door of the cubicle in which the fuses are 3 Remove the shrouding from in front of the fuses 4 Slacken the nuts of the headless screws of the fuses so that you can slide out the fuse blocks Make note of the order of the washers on the screws 5 Remove the screws nuts and washers from the ol...

Page 68: ... nuts to torque as follows Cooper Bussmann fuses 50 N m 37 lbf ft Mersen Ferraz Shawmut 46 N m 34 lbf ft Other Refer to the fuse manufacturer s instructions 8 Reinstall the shroud and close the door 4 68 Maintenance ...

Page 69: ...f the control panel 1 Turn the lid on the back of the control panel counter clockwise until the lid opens 2 Remove the battery gently 3 Replace the battery with a new CR2032 battery The battery holder has grip nails First slide the battery and then press on the other side The battery will snap in 4 Make sure that the battery polarity shows positive on the upside 5 Put the lid back and tighten it b...

Page 70: ...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 27 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 71: ...xpiry of mission time terminates the certification and SIL PL classification of the safety function The following options exist Renewal of the whole drive and all optional functional safety module s and components Renewal of the components in the safety function circuit In practice this is economical only with larger drives that have replaceable circuit boards and other components such as relays N...

Page 72: ...72 ...

Page 73: ... 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 the control unit types BCU 02 BCU 12 and BCU 22 These have a different number of power module connections 2 7 and 12 respectivel...

Page 74: ...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 75: ...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 76: ...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 77: ... 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 for example because of continuous fiel...

Page 78: ... be grounded directly at both ends if they 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 ...

Page 79: ...uch as motor cables The following diagram shows 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 83 Note The XSTO input only acts as a true Safe torque off input on the inverter control unit De energi...

Page 80: ... 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 81: ...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 83 Connector pi...

Page 82: ...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 83: ... a prevention of unexpected start up function that enables short time maintenance operations like cleaning or work on non electrical parts of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage for the power semiconductors of the drive output stage A see the diagrams below thus preventing the drive from generati...

Page 84: ...lectronic program mable electronic safety related systems IEC 61508 2 2010 Functional safety Safety instrumented systems for the process industry sector IEC 61511 1 2017 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 electron...

Page 85: ...d 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 86: ...24VDC CH1 GND 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 86 The Safe torque off function ...

Page 87: ...the activation switch Otherwise no SIL PL classification is given Pay special attention to avoiding any potential failure modes for the wiring For example use shielded cable For measures for fault exclusion of wiring see eg EN ISO 13849 2 2012 table D 4 Drive 1 Control unit 2 Activation switch K The Safe torque off function 87 ...

Page 88: ... 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 88 The Safe torque off function ...

Page 89: ... 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 89 ...

Page 90: ... 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 91: ...ook of the machine The report shall include documentation of start up activities and test results references to failure reports and resolution of failures Any new validation tests performed due to changes or maintenance shall be logged into the logbook Validation test procedure After wiring the Safe torque off function validate its operation as follows Note If the drive is equipped with safety opt...

Page 92: ...ribed above in testing the operation when the motor is stopped Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Test the operation of the failure detection of the drive The motor can be stopped or running Open the 1st channel of the STO circuit If the motor was running it should coast to a stop The drive generates a FA81 Safe Torque Off 1 loss ...

Page 93: ...nly achieved through the XSTO connector of the inverter control unit A41 True Safe torque off functionality is not achieved through the XSTO connectors of other control units such as the supply 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 The d...

Page 94: ... activating the Safe torque off function The Safe torque off function overrides all other functions of the drive The Safe torque off function is ineffective against deliberate sabotage or misuse The Safe torque off function has been designed to reduce the recognized hazardous conditions In spite of this it is not always possible to eliminate all potential hazards The assembler of the machine must ...

Page 95: ...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 96: ... 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 ...

Page 97: ...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 98: ... 61508 PFH Performance level Levels a e correspond to SIL EN ISO 13849 1 PL Periodic test performed to detect failures in a safety related system so that if necessary a repair can restore the system to an as new condition or as close as practical to this condition IEC 61508 IEC 62061 Proof test Systematic capability IEC 61508 SC Safe failure fraction IEC 61508 SFF Safety integrity level 1 3 IEC 61...

Page 99: ...ed 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 in the cubicle from the main cooling circuit In cabinet line ups built by ABB valves are c...

Page 100: ...n IGBT supply 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 104 100 Internal c...

Page 101: ...he limits specified in Technical data page 104 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 106 Coolant temperature control The temperature of the coolant in t...

Page 102: ...point of the cooling circuit The most practical location 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...

Page 103: ... valve at the cooling unit 14 After one to two minutes 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 103 ...

Page 104: ...circuit with air fill the cooling circuit with coolant specified under Coolant specification page 104 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 t...

Page 105: ...ired 40 45 C 104 113 F drive output current must be derated by 2 percentage points per 1 C 1 8 F temperature 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 ar...

Page 106: ...d 300 kPa maximum Base pressure denotes the pressure of the 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...

Page 107: ...r brass or bronze must not be used under any circumstances 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 u...

Page 108: ...108 ...

Page 109: ...s chapter This chapter contains the technical specifications of the drive for example the ratings fuse data sizes and technical requirements provisions for fulfilling the requirements for CE and other markings 10 Technical data 109 ...

Page 110: ... 1984 1750 1600 1660 2490 1868 1660A 7 1500 1400 1451 2000 1800 1862 2319 2000 1800 1940 2910 2183 1940A 7 1750 1400 1631 2000 2093 2605 2000 2180 3270 2453 2180A 7 2000 1800 1848 2300 2371 2952 2300 2470 3710 2779 2470A 7 2000 2154 2700 2765 3442 2700 2880 4320 3240 2880A 7 2300 2438 3000 3130 3896 3000 3260 4890 3668 3260A 7 2600 2678 3200 3437 4279 3400 3580 5370 4028 3580A 7 2800 3029 3800 388...

Page 111: ...000601909 XLS Nominal ratings UN Nominal input voltage For U1 see Electrical power network specification on page 139 For U2 see DC connection data on page 139 I1 Continuous rms input AC current No overload capability at the coolant temperature of 40 C 104 F and air temperature of 45 C 113 F I2 Continuous rms output DC current No overload capability at the coolant temperature of 40 C 104 F and air ...

Page 112: ... 104LC 0600A 7 E205 1 R8i 0600A 7 ACS880 104LC 0670A 7 E205 1 R8i 0670A 7 ACS880 104LC 0750A 7 E205 1 R8i 0750A 7 ACS880 104LC 0850A 7 E205 1 R8i 0850A 7 ACS880 104LC 0530A 7 E205 2 2 R8i 1030A 7 ACS880 104LC 0600A 7 E205 2 2 R8i 1170A 7 ACS880 104LC 0670A 7 E205 2 2 R8i 1310A 7 ACS880 104LC 0750A 7 E205 2 2 R8i 1470A 7 ACS880 104LC 0850A 7 E205 2 2 R8i 1660A 7 ACS880 104LC 0670A 7 E205 3 3 R8i 19...

Page 113: ...1 1 4 0 0 8 3 2 1030A 7 66 0 4 15 6 8 5 32 1 1 4 0 0 8 3 2 1170A 7 66 0 5 17 9 8 5 32 1 1 4 0 0 8 3 2 1310A 7 66 0 5 20 6 8 5 32 1 1 4 0 0 8 3 2 1470A 7 66 0 6 24 2 8 5 32 1 1 4 0 0 8 3 2 1660A 7 68 0 7 26 5 12 7 48 1 5 5 7 1 3 4 8 1940A 7 68 0 8 30 6 12 7 48 1 5 5 7 1 3 4 8 2180A 7 68 0 9 36 0 12 7 48 1 5 5 7 1 3 4 8 2470A 7 69 1 0 40 4 16 9 64 2 1 8 0 1 7 6 4 2880A 7 69 1 2 47 5 16 9 64 2 1 8 0 ...

Page 114: ...0 1000 2 0530A 7 170M6549 Bussmann 1000 1100 2 0600A 7 170M6500 Bussmann 1100 1250 2 0670A 7 170M6501 Bussmann 1100 1400 2 0750A 7 0850A 7 170M6548 Bussmann 1100 1000 4 1030A 7 170M6549 Bussmann 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 6 2470A 7 8 2880A 7 8 326...

Page 115: ...Above Sides Front in mm in mm in mm 9 85 250 0 0 59 1500 Technical data 115 ...

Page 116: ...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 117: ...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 118: ...rs ABB synchronous re luctance SynRM motors Motor types 0 to AC supply voltage of drive 3 phase symmetrical Umax at field weakening point Voltage U2 0 500 Hz Frequency f2 For higher operational output frequencies please contact your local ABB representative Operation outside the range of 12 150 Hz requires derating See section Derating page 111 See section Ratings Current 3 kHz typical Switching f...

Page 119: ... F Maximum short term tensile force 50 N 11 2 lbf Minimum short term bend radius 25 mm 1 0 in Minimum long term bend radius 35 mm 1 4 in Maximum 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 actu...

Page 120: ...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 121: ...without containerization for long storage periods in environments where roofed and humidity controlled storage cannot be arranged Cabinets 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 ...

Page 122: ... 42 N m 31 lbf ft M10 8 8 70 N m 52 lbf ft M12 8 8 120 N m 90 lbf ft M16 Mechanical connections Strength class Max torque Size 8 8 6 N m 53 lbf in M5 8 8 10 N m 7 4 lbf ft M6 8 8 24 N m 17 7 lbf ft M8 Insulation supports Strength class Max torque Size 8 8 5 N m 44 lbf in M6 8 8 9 N m 6 6 lbf ft M8 8 8 18 N m 13 3 lbf ft M10 8 8 31 N m 23 lbf ft M12 Cable lugs Strength class Max torque Size 8 8 15 ...

Page 123: ... responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls prevention of physical access application of authentication measures encryption of data installation of anti virus programs etc ...

Page 124: ...124 ...

Page 125: ... standard depth of the cabinet line up is 644 mm 25 35 excluding protruding equipment such as handles UL Listed C129 units are top cable entry exit by default Top cable exit increases the height and free top space requirement of the cabinet line up by 50 mm 2 Depending on the configuration top cable exit will also increase either the width or depth of the cabinet line up The control electronics of...

Page 126: ... 7 0480A 7 0530A 7 0600A 7 0670A 7 0750A 7 0850A 7 950 430 500 500 1030A 7 1170A 7 1310A 7 1470A 7 1660A 7 1320 600 700 700 1940A 7 2180A 7 2470A 7 1900 860 1000 500 500 2880A 7 3260A 7 2270 1030 1200 700 500 3580A 7 4050A 7 2650 1200 1400 700 700 4840A 7 3220 1460 1700 700 500 500 5650A 7 3790 1720 1900 700 700 500 6460A 7 126 Dimensions ...

Page 127: ... Dimension drawing examples Cabinet height and depth Side view marine construction option C121 bottom cable exit Side view bottom cable exit Dimensions 127 ...

Page 128: ...Side view top cable exit without common motor terminal cubicle Side view top cable exit with common motor terminal cubicle 128 Dimensions ...

Page 129: ...Location and size of output terminals Units without common motor terminal cubicle Inverter module cubicle with one R8i module bottom cable exit Dimensions 129 ...

Page 130: ...Inverter module cubicle with two R8i modules bottom cable exit 130 Dimensions ...

Page 131: ...Inverter module cubicle with three R8i modules bottom cable exit Dimensions 131 ...

Page 132: ... Units with common motor terminal cubicle H359 Cubicle width 300 mm bottom cable exit 132 Dimensions ...

Page 133: ...Cubicle width 300 mm top cable exit Dimensions 133 ...

Page 134: ...Cubicle width 400 mm bottom cable exit 134 Dimensions ...

Page 135: ...Cubicle width 400 mm top cable exit Dimensions 135 ...

Page 136: ...Cubicle width 600 mm bottom cable exit 136 Dimensions ...

Page 137: ...Cubicle width 600 mm top cable exit Dimensions 137 ...

Page 138: ...138 ...

Page 139: ... 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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