ABB ACS880-11 Hardware Manual Download Page 7

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Power cable types ........................................................................................

Preferred power cable types .............................................................

Alternate power cable types .............................................................

Not allowed power cable types .........................................................

Additional guidelines, North America ...........................................................

Metal conduit ....................................................................................

Power cable shield .......................................................................................

Selecting the control cables ................................................................................

Shielding ......................................................................................................

Signals in separate cables ...........................................................................

Signals that can be run in the same cable ...................................................

Relay cable ..................................................................................................

Control panel to drive cable .........................................................................

PC tool cable ................................................................................................

Routing the cables ..............................................................................................

General guidelines – IEC .............................................................................

General guidelines – North America ............................................................

Continuous motor cable shield/conduit or enclosure for equipment on the
motor cable ..................................................................................................

Separate control cable ducts .......................................................................

DC voltage boost function ...................................................................................

Protecting the drive, input power cable, motor and motor cable in short circuit
situations and against thermal overload .............................................................

Protecting the drive and the input power cable in short-circuits ...................

Circuit breakers ............................................................................................

Protecting the motor and motor cable in short-circuits .................................

Protecting the motor cables against thermal overload .................................

Protecting the motor against thermal overload ............................................

Protecting the motor against overload without thermal model or temperature
sensors .........................................................................................................

Implementing a motor temperature sensor connection ......................................

Connecting motor temperature sensor to the drive via an option module ....

Protecting the drive against ground faults ..........................................................

Residual current device compatibility ...........................................................

Implementing the emergency stop function ........................................................

Implementing the Safe torque off function ..........................................................

Implementing the power loss ride-through function ............................................

Implementing the functions provided by the FSO-xx safety functions module ....

Using power factor compensation capacitors with the drive ...............................

Using a safety switch between the drive and the motor .....................................

Implementing an ATEX-certified motor thermal protection .................................

Controlling a contactor between drive and motor ...............................................

Implementing a bypass connection ....................................................................

Protecting the contacts of relay outputs ..............................................................

Table of contents 7

Summary of Contents for ACS880-11

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 11 drives Hardware manual ...

Page 2: ......

Page 3: ... manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation IEC 7 Electrical installation North America NEC 10 Start up 3AXD50000045932 Rev F EN Original instructions EFFECTIVE 2021 07 15 ...

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Page 5: ...afety in operation 2 Introduction to the manual 21 Contents of this chapter 21 Target audience 21 Categorization by frame size and option code 21 Quick installation commissioning and operation flowchart 23 Terms and abbreviations 24 Related documents 3 Operation principle and hardware description 27 Contents of this chapter 28 Operation principle 29 DC voltage boost function 29 DC connection 30 La...

Page 6: ... DC solar PV main power supply 54 Selecting the main contactor 55 North America 55 Other regions 55 Examining the compatibility of the motor and drive 55 Protecting the motor insulation and bearings 56 Requirements table 59 Availability of du dt filter and common mode filter by drive type 59 Additional requirements for explosion safe EX motors 59 Additional requirements for ABB motors of types oth...

Page 7: ...akers 73 Protecting the motor and motor cable in short circuits 73 Protecting the motor cables against thermal overload 74 Protecting the motor against thermal overload 74 Protecting the motor against overload without thermal model or temperature sensors 75 Implementing a motor temperature sensor connection 76 Connecting motor temperature sensor to the drive via an option module 76 Protecting the ...

Page 8: ...ecting integrated EMC filter option E200 or E202 and ground to phase varistor frame R3 91 Disconnecting integrated EMC filter option E200 or E202 and ground to phase varistor frame R6 92 Disconnecting integrated EMC filter and ground to phase varistor frame R8 93 Connecting the power cables 93 Connection diagram 94 Connection procedure 100 R8 power cable connection if you detach the cable connecto...

Page 9: ... 131 Default I O diagram of the drive control unit ZCU 1x 133 Additional information on the connections 133 External power supply for the control unit XPOW 133 DI6 as a PTC sensor input 133 AI1 or AI2 as a Pt100 Pt1000 PTC or KTY84 sensor input 134 DIIL input 134 The XD2D connector 135 Safe torque off XSTO 135 FSO xx safety functions module connection X12 136 Connector data 138 ZCU 1x ground isola...

Page 10: ...O 12 option Q973 and FSO 21 option Q972 159 Functional safety components 12 Technical data 161 Contents of this chapter 161 Ratings 164 Deratings 164 Surrounding air temperature derating IP21 UL Type 1 165 Surrounding air temperature derating IP55 UL Type 12 166 Altitude derating 167 Deratings for special settings in the drive control program 170 Derating for output voltage boost 170 Fuses IEC 171...

Page 11: ...92 Protection classes for module 192 Materials 193 Applicable standards 193 Ambient conditions 195 Markings 196 Compliance with the EN 61800 3 204 A1 2012 196 Definitions 196 Category C2 197 Category C3 197 Category C4 198 UL and CSA checklist 199 Declarations of conformity 199 Design lifetime expectancy 200 Disclaimers 200 Generic disclaimer 200 Cybersecurity disclaimer 13 Dimension drawings 201 ...

Page 12: ...Validation test reports 216 Validation test procedure 218 Use 220 Maintenance 220 Competence 221 Fault tracing 222 Safety data 223 Terms and abbreviations 224 TÜV certificate 225 Declarations of conformity 15 Common mode du dt and sine filters 227 Contents of this chapter 227 Common mode filters 227 du dt filters 227 When is a du dt filter needed 228 du dt filter types 228 Description installation...

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

Page 14: ...cause it is heavy and has a high center of gravity Whenever possible secure the module with chains Do not leave an unsupported module unattended especially on a sloping floor Beware of hot surfaces Some parts such as heatsinks of power semiconductors and brake resistors remain hot for a while after disconnection of the electrical supply Vacuum clean the area around the drive before the start up to...

Page 15: ...que off or emergency stop validate them at start up See separate instructions for the safety circuits Beware of hot air exiting from the air outlets Do not cover the air inlet or outlet when the drive is running Note If you select an external source for the start command and it is on the drive will start immediately after fault reset unless you configure the drive for pulse start See the firmware ...

Page 16: ...lity voltage tester Before and after measuring the installation verify the operation of the voltage tester on a known voltage source Make sure that the voltage between the drive input power terminals L1 L2 L3 and the grounding PE busbar is zero Make sure that the voltage between the drive output terminals T1 U T2 V T3 W and the grounding PE busbar is zero Make sure that the voltage between the dri...

Page 17: ... the main and auxiliary circuits The function is not effective against deliberate sabotage or misuse Printed circuit boards WARNING Use a grounding wristband when you handle printed circuit boards Do not touch the boards unnecessarily The boards contain components sensitive to electrostatic discharge Grounding These instructions are for all personnel who are responsible for the grounding of the dr...

Page 18: ... equipment See standard IEC EN 61800 5 1 and the electrical planning instructions of the drive To comply with standard IEC EN 61800 5 1 use a protective earth conductor with a minimum cross sectional area of 10 mm2 Cu or 16 mm2 Al as an alternative when aluminum cables are permitted or use a second protective earth conductor of the same cross sectional area as the original protective earth conduct...

Page 19: ... occur These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN UL 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY Note The maximum drive power cycles is five times in ten minutes Power cycling the drive too often can damage the charging ci...

Page 20: ...ly or through any mechanical connection like felt nip rope etc Do the steps in section Electrical safety precautions page 15 Install temporary grounding to the drive output terminals T1 U T2 V T3 W Connect the output terminals together as well as to the PE During the start up Make sure that the motor cannot run overspeed for example driven by the load Motor overspeed causes overvoltage that can da...

Page 21: ...Read the manual before working on the drive You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols Categorization by frame size and option code The frame size identifies information which concerns only a certain frame size of the drive The frame size is shown on the type designation label All frame sizes are listed in the technical da...

Page 22: ...f you install the drive to another system you may need to disconnect the EMC filter and ground to phase varistor Mechanical installation page 39 Install the drive on a wall Routing the cables page 69 Route the cables Electrical installation IEC page 83 or Electrical installation North America NEC page 113 Measure the insulation of the input cable and the motor and the motor cable Electrical instal...

Page 23: ...O 01 Optional EtherCAT adapter module FECA 01 Optional Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols 2 port FENA 21 Optional Ethernet POWERLINK adapter module FEPL 02 Optional digital I O extension module FIO 01 Optional analog I O extension module FIO 11 Optional PROFIBUS DP adapter module FPBA 01 Physical size of the drive or power module Frame frame size Safety fu...

Page 24: ...3026 ACS880 11 quick installation and start up guide 3AXD50000048138 ACS880 11 quick installation guide 3AUA0000145446 ACS880 P940 and P944 drive modules supplement 3AUA0000107668 Drive modules cabinet design and construction instruc tions 3AUA0000085685 ACx AP x Assistant control panels user s manual 3AXD50000110711 ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 UK gland plate H358 installation guid...

Page 25: ...erter modules capacitor reforming instructions 3AXD50000137671 ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 drives recycling instructions and environmental information Drive firmware manuals and guides 3AUA0000085967 ACS880 primary control program firmware manual 3AUA0000098062 Quick start up guide for ACS880 drives with primary control program Option manuals and guides Manuals and quick guides for...

Page 26: ...26 ...

Page 27: ... Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle and construction of the drive Operation principle and hardware description 27 ...

Page 28: ...ree phase AC current to direct current for the intermediate DC link of the drive The intermediate DC link further supplies the motor side converter that runs the motor Both converters consist of six insulated gate bipolar transistors IGBT with free wheeling diodes The content of AC voltage and current harmonics is low The LCL filter suppresses the harmonics further The line side converter can tran...

Page 29: ...ply voltage of the drive is below the motor nominal voltage level compensation of voltage drop due to output filter motor cable or input supply cables increased motor torque in the field weakening area ie when the drive operates the motor in the speed range above the motor nominal speed possibility to use a motor with higher nominal voltage than the actual supply voltage of the drive Example A dri...

Page 30: ... Type 1 R6 7 IP20 UL Open Type option P940 R8 UL Type 12 R6 Front cover 5 Lifting eyes 2 pcs in frame R3 6 pcs in frames R6 and R8 1 Control panel behind the control panel cover 6 Control panel 2 Hood in frames R6 and R8 7 Heatsink 3 Mounting points 4 pcs 4 30 Operation principle and hardware description ...

Page 31: ...5 Clamps for securing the FSO wiring mechanically 9 Control cable entry 4 pcs 16 Power cable connection terminals behind the shroud 10 DC cable entry 17 360 degree grounding clamps for power cable shields 11 Motor cable entry behind the 360 degree grounding clamps 18 360 degree grounding clamps for control cable shields 12 Control unit with I O cable connection ter minals 13 Operation principle an...

Page 32: ...log and digital I O extension modules feedback interface modules and fieldbus com munication modules can be inserted into slots 1 2 and 3 1 2 3 Memory unit 4 Connector for safety functions modules 5 See Default I O diagram of the drive control unit ZCU 1x page 131 and Connector data page 136 6 Control panel 7 du dt common mode or sine filter optional See Common mode du dt and sine fil ters page 22...

Page 33: ...tall the control panel put the bottom of the container in position 2a press the retaining clip at the top 2b and push the control panel in at the top edge 2c 2b 2c 2a For the use of the control panel see the firmware manual and ACx AP x assistant control panel user s manual 3AUA0000085685 English Operation principle and hardware description 33 ...

Page 34: ...unting platform for control panels installation guide 3AXD50000289561 DPMP 06 07 mounting platform for control panels installation guide Control panel mounting platform cover In deliveries without control panel option 0J400 the control panel mounting platform is covered The indication LEDs on the platform are visible through the protective cover Note The cover is not included with options 0J400 P9...

Page 35: ...16 2017 2018 YY 01 02 03 for week 1 week 2 week 3 WW Integer starting every week from 0001 XXXXX Type designation key The type designation contains information on the specifications and configuration of the drive You find the type designation on the type designation label attached to the drive The first digits from the left express the basic configuration for example ACS880 11 025A 3 The optional ...

Page 36: ...signation label as typical input voltage levels 3 400 480 500 V AC 5 Option codes Description Code IP55 UL Type 12 B056 Flange mounting C135 EMC filter for 2nd environment TN grounded system category C3 E200 EMC filter for second environment IT ungrounded system category C3 E201 EMC filter for 1st environment TN grounded system category C2 E202 Common mode filter E208 Cable conduit entry US UK H35...

Page 37: ...interface module L517 FAIO 01 analog I O extension module L525 FPTC 01 thermistor protection module L536 FPTC 02 ATEX certified thermistor protection module L537 Extended warranty 24 30 P904 Extended warranty 36 months from delivery P931 Extended warranty 60 months from delivery P932 Version for cabinet mounting Drive without front cover and cable entry box Includes panel holder cable between pane...

Page 38: ...scription Code Italian R702 Dutch R703 Danish R704 Swedish R705 Finnish R706 French R707 Spanish R708 Portuguese R709 Russian R711 Chinese R712 Turkish R714 38 Operation principle and hardware description ...

Page 39: ...nto a user defined cabinet see Drive modules cabinet design and construction instructions 3AUA0000107668 English Flange mounting option C135 See also Code English Manual name 3AXD50000349838 ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 C135 drives with flange mounting kit supplement 3AXD50000181506 ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 C135 frame R3 flange mounting kit quick installation guid...

Page 40: ...terial above and below the unit is of non flammable material The installation surface is as close to vertical as possible and strong enough to support the drive There is sufficient free space around the drive for cooling maintenance and operation See the free space specifications for the drive Make sure that there are no sources of strong magnetic fields such as high current single core conductors...

Page 41: ... not be fulfilled Note IP21 UL Type 1 construction only meets IP20 UL Type Open in horizontal orientation Free space requirements are shown in the drawings below 200 mm 7 87 in 300 mm 11 81 in 200 mm 7 87 in 30 mm 1 18 in 300 mm 11 81 in 200 mm 7 87 in 30 mm 1 18 in 200 mm 7 87 in 300 mm 11 81 in Mechanical installation 41 ...

Page 42: ...n Required tools To install the drive mechanically you need the following tools drill with suitable bits screwdriver set Torx flat and or Phillips as appropriate socket set metric tape measure if you will not be using the provided mounting template 42 Mechanical installation ...

Page 43: ...a heavy drive package Unpacking and examining delivery The figure below shows the drive package with its contents Examine that all items are present and there are no signs of damage Read the data on the type designation label of the drive to make sure that the drive is of the correct type Mechanical installation 43 ...

Page 44: ...ps 3 Cardboard sleeve 10 I O option module 4 Cardboard Box which contains control panel box 1 and option boxes 4 and 5 11 Fieldbus option module 5 Drive 12 Printed quick guides and manuals multi lingual residual voltage warning sticker manuals CD 6 To unpack Cut the straps 3 Remove the tray 9 and sleeve 10 Remove the cover protecting film Lift the drive 44 Mechanical installation ...

Page 45: ...es and manuals multi lingual residual voltage warning sticker manuals CD 1 Outer box 7 Accessories 2 Pallet 8 Mounting template 3 VCI bag 9 Package straps 4 Plastic bag 5 To unpack Cut the straps 4 Remove the outer box 7 Open the VCI bag 9 Undo the attaching screws A B Lift the drive Mechanical installation 45 ...

Page 46: ...i lingual residual voltage warning sticker manuals CD 1 Outer box 8 Accessories 2 Cardboard insert 9 Bubble wrap 3 Pallet 10 Mounting template 4 VCI bag 11 Package straps 5 UL Type 12 hood 12 Plastic bag 6 To unpack Cut the straps 5 Remove the outer box 8 Open the VCI bag 11 Undo the attaching screws A B Lift the drive 46 Mechanical installation ...

Page 47: ...anuals CD 1 Plywood support 9 VCI bag 2 Pallet 10 Mounting template 3 Screw 11 Package straps 4 Screw 12 Plastic bag 5 Drive with factory installed options 13 Packing bracket 6 Common mode filter option E208 14 Tray 7 To unpack Cut the straps 4 Remove the tray 7 and cardboard sleeve 8 Open the VCI bag 2 Undo the attaching screws a b Lift the drive Mechanical installation 47 ...

Page 48: ...cluded 10 VCI bag 2 Plywood support 11 Bubble wrap 3 Pallet 12 Mounting template 4 UL Type 12 hood 13 Package straps 5 Drive with factory installed options 14 Plastic bag 6 Screws 15 Packing bracket 7 Common mode filter option E208 16 Tray 8 To unpack Cut the straps 5 Remove the tray 8 and cardboard sleeve 9 Open the VCI bag 2 Undo the attaching screws a b Lift the drive 48 Mechanical installation...

Page 49: ...lugs into the holes and start the screws or bolts into the anchors or plugs Drive the screws or bolts long enough into the wall to make them carry the weight of the drive 4 Position the drive onto the bolts on the wall 5 For R6 and R8 with option B056 UL Type 12 Install the hood on top of the drive before you tighten the upper fastening bolts Place the vertical edge of the hood in between the wall...

Page 50: ...00 7 87 11 81 R8 R6 R3 in mm in mm in mm 37 2 945 29 6 753 18 7 474 a 10 3 263 8 4 213 6 3 160 b R8 R6 R3 lb kg lb kg lb kg 246 96 112 134 51 61 0 46 97 21 3 IP21 UL Type 1 260 19 118 138 92 63 51 38 23 3 IP55 UL Type 12 50 Mechanical installation ...

Page 51: ...tion Installing the drive vertically page 49 Installing the drive horizontally The drive can be installed either the left or right side up Follow the steps in section Installing the drive vertically page 49 For free space requirements see section Installation orientations page 40 Mechanical installation 51 ...

Page 52: ...52 ...

Page 53: ...any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Selecting the main supply disconnecting device AC main power supply You must equip the drive with a main supply disconnecting device which meets the local safety regulations You must be able to lo...

Page 54: ...Code Other regions The disconnecting device must conform to the applicable local safety regulations DC solar PV main power supply When you perform maintenance or wiring activities in the drive cabinet make sure that you disconnect Solar PV supply at string combiner box level or remove the solar PV connections before installing the drive cabinet or remove DC fuse inside drive cabinet Selecting the ...

Page 55: ...e Consult the motor manufacturer before using a motor whose nominal voltage differs from the AC line voltage connected to the drive input The voltage peaks at the motor terminals are relative to the supply voltage of the drive not the drive output voltage Protecting the motor insulation and bearings The drive employs modern IGBT inverter technology Regardless of frequency the drive output comprise...

Page 56: ...when a drive du dt and common mode filters and insulated N end non drive end motor bearings are required Ignoring the requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty 56 Guidelines for planning the electrical installation ...

Page 57: ...ndard 500 V Un 600 V or N CMF N Reinforced N du dt CMF N du dt du dt Reinforced 600 V Un 690 V cable length 150 m N CMF N Reinforced 600 V Un 690 V cable length 150 m Pn 500 kW N CMF N CMF n a Standard 380 V Un 690 V Form wound HX_ and AM_ Pn 500 kW N du dt CMF N du dt with voltages over 500 V CMF Check with the motor manufac turer 380 V Un 690 V Old1 form wound HX_ and modular N CMF Enamelled wir...

Page 58: ... V Un 420 V Random wound and form wound N du dt CMF du dt N or CMF du dt Standard ÛLL 1300 V 420 V Un 500 V or N CMF N or CMF Reinforced ÛLL 1600 V 0 2 microsecond rise time N du dt CMF du dt N or CMF du dt Reinforced ÛLL 1600 V 500 V Un 600 V or N CMF N or CMF Reinforced ÛLL 1800 V N du dt CMF du dt N du dt Reinforced ÛLL 1800 V 600 V Un 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 micro second ri...

Page 59: ...addition consult the motor manufacturer for any further requirements Additional requirements for ABB motors of types other than M2_ M3_ M4_ HX_ and AM_ Use the selection criteria given for non ABB motors Additional requirements for the regenerative and low harmonics drives It is possible to increase the intermediate circuit DC voltage from the nominal standard level with a parameter in the control...

Page 60: ...ments for non ABB high output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 2001 If you plan to use a non ABB high output motor or an IP23 motor consider these additional requirements for protecting the motor insulation and bearings in drive systems If motor power is below 350 kW Equip the drive and or motor wit...

Page 61: ...e intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed Additional data for calculating the rise time and the peak line to line voltage The diagrams below show the relative peak line to line voltage and rate of change of voltage as a function of the motor ca...

Page 62: ... 1 5 2 5 3 5 4 5 100 200 300 5 5 B Drive with du dt filter A Drive without du dt filter B Motor cable length I Relative peak line to line voltage ÛLL UN Relative du dt value du dt UN Note ÛLL and du dt values are approximately 20 higher with resistor braking 62 Guidelines for planning the electrical installation ...

Page 63: ...equirements of the CE mark use one of the preferred cable types See Preferred power cable types page 64 Symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation bearing currents and wear Metal conduit reduces electromagnetic emission of the whole drive system The protective conductor must always have an adequate conductivity Un...

Page 64: ... the supply if the protective earth conductor is damaged If the protective earth conductor is separate that is it does not form part of the input power cable or the input power cable enclosure the minimum cross sectional area must be 2 5 mm2 when the conductor is mechanically protected or 4 mm2 when the conductor is not mechanically protected Typical power cable sizes See the technical data Power ...

Page 65: ... types Use as motor cabling Use as input power cabling Cable type Yes with phase conductor smaller than 10 mm2 8 AWG Cu or motors up to 30 kW 40 hp Yes with phase conductor smaller than 10 mm2 8 AWG Cu PVC Four conductor cabling in PVC conduit or jacket three phase conductors and PE Note Shielded or armored cable or cabling in metal con duit is always recommended to minimize radio frequency inter ...

Page 66: ... L3 L3 L2 L1 Preferable cable arrangement to avoid voltage or current un balance between the phases 1 Armor may act as an EMC shield as long as it provides the same performance as a concentric EMC shield of a shielded cable To be effective at high frequencies the shield conductivity must be at least 1 10 of the phase conductor conductivity The effectiveness of the shield can be evaluated based on ...

Page 67: ...or wiring in the same conduit Wireways 2 Prefer symmetrical shielded VFD cable Metallic Separate motor wiring from input power wiring and other low voltage wiring Do not run outputs of multiple drives parallel Bundle each cable wiring together and use separators where possible Free air 2 Prefer symmetrical shielded VFD cable Enclosures air handlers etc Allowed internally in enclosures when in acco...

Page 68: ...the motor cable shield of the drive is shown below It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire The better and tighter the shield the lower the emission level and bearing currents 1 3 4 5 2 Insulation jacket 1 Helix of copper tape or copper wire 2 Copper wire shield 3 Inner insulation 4 Cable core 5 Selecting the control cables Shielding Only u...

Page 69: ... ÖLFLEX by LAPPKABEL Germany has been tested and approved by ABB Control panel to drive cable Use EIA 485 with male RJ 45 connector cable type Cat 5e or better The maximum permitted length of the cable is 100 m 328 ft PC tool cable Connect the Drive composer PC tool to the drive through the USB port of the control panel Use a USB Type A PC Type Mini B control panel cable The maximum length of the ...

Page 70: ...ple drive min 300 mm 12 in min 300 mm 12 in min 500 mm 20 in min 500 mm 20 in min 200 mm 8 in 90 1 2 4 4 3 2 1 3 2 3 Motor cable 1 Input power cable 2 Control cable 3 Brake resistor or chopper cable if any 4 General guidelines North America Make sure that the installation is in accordance with national and local codes Obey these general guidelines Use separate conduits for the input power motor br...

Page 71: ...quipment are installed on the motor cable between the drive and the motor Install the equipment in a metal enclosure Use either a symmetrical shielded cable or install the cabling in a metal conduit Make sure that there is a good and continuous galvanic connection in the shield conduit between drive and motor Connect the shield conduit to the protective ground terminal of the drive and the motor G...

Page 72: ...he supply voltage of the drive is below the motor nominal voltage level compensation of voltage drop due to output filter motor cable or input supply cables increased motor torque in the field weakening area ie when the drive operates the motor in the speed range above the motor nominal speed possibility to use a motor with higher nominal voltage than the actual supply voltage of the drive Example...

Page 73: ...ction of circuit breakers independent of the manufacturer hot ionized gases can escape from the breaker enclosure in case of a short circuit To ensure safe use pay special attention to the installation and placement of the breakers Obey the manufacturer s instructions Circuit breakers See section Circuit breakers IEC page 177 or Circuit breakers UL page 177 Protecting the motor and motor cable in ...

Page 74: ...ty The user can tune the thermal model further by feeding in additional motor and load data The most common temperature sensor types are PTC or Pt100 For more information see the firmware manual Protecting the motor against overload without thermal model or temperature sensors Motor overload protection protects the motor against overload without using motor thermal model or temperature sensors Mot...

Page 75: ... basic insulation from other low voltage circuits The insulation must be rated for the same voltage level as the drive main circuit Note Extra low voltage circuits for example 24 V DC typically do not meet these requirements Make sure that the voltage does not exceed the maximum allowed voltage over the sensor As an alternative you can connect the sensor with basic insulation to the analog digital...

Page 76: ...ion x x Galvanic isolation between sensor connector and other connectors including drive control unit connector FEN xx Basic insulation Connectors of option module other than sensor connector must be left unconnected x x x Basic insulation between sensor connector and drive control unit connector No insu lation between sensor connect or and other I O connectors FAIO 01 No special requirement x Rei...

Page 77: ...it restores the drive input power after a short break The contactor must either re connect after the break automatically or remain closed over the break Depending on the contactor control circuit design this can require an additional hold circuit uninterruptible auxiliary power supply or auxiliary power supply buffering Note that if the power loss lasts so long that the drive trips on undervoltage...

Page 78: ...pensation is not needed with AC drives However if a drive is to be connected in a system with compensation capacitors installed note the following restrictions WARNING Do not connect power factor compensation capacitors or harmonic filters to the motor cables between the drive and the motor They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves If th...

Page 79: ...tion see Manual code English User s manual 3AUA0000132231 ATEX certified Safe disconnection function Ex II 2 GD for ACS880 drives Q971 application guide 3AXD50000027782 FPTC 02 ATEX certified thermistor protection module Ex II 2 GD option L537 Q971 for ACS880 drives user s manual Controlling a contactor between drive and motor The control of the output contactor depends on how you use the drive th...

Page 80: ...s defined in IEC EN UL 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY WARNING Never connect the drive output to the electrical power network The connection may damage the drive Protecting the contacts of relay outputs Inductive loads relays contactors motors cause voltage transients when switched off The relay contacts on the drive control unit are protected with varistors...

Page 81: ...230 V AC 230 V AC 24 V DC 1 2 3 4 Relay output 1 Varistor 2 RC filter 3 Diode 4 Guidelines for planning the electrical installation 81 ...

Page 82: ...82 ...

Page 83: ...s of the drive If you ignore them injury or death or damage to the equipment can occur Required tools To do the electrical installation you need these tools wire stripper screwdriver set Torx flat and or Phillips as appropriate torque wrench Grounding the motor cable shield at the motor end For minimum radio frequency interference ground the cable shield 360 degrees at the cable entry of the motor...

Page 84: ...ty instructions of the drive If 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 1 Do the steps in section Electrical safety precautions page 15 before you start the work 2 Make sure that the motor cable is disconnected from the drive output terminals 3 Measure the insulation resistanc...

Page 85: ...RNING Do not install the drive with the EMC filter options E200 and E202 connected to a system that the filter is not suitable for This can cause danger or damage the drive Note When EMC filter E200 or E202 is disconnected the drive EMC compatibility is considerably reduced Ground to phase varistors A standard drive with the ground to phase varistor connected can be installed to a symmetrically gr...

Page 86: ...oint grounded delta systems and TT systems Requirements for disconnecting EMC filter and varistor and additional requirements for different electrical power systems are given below Symmetrically grounded TN systems TN S systems ie center grounded wye Do not disconnect EMC or VAR screws PE L2 L3 L1 N Corner grounded delta systems 600 V R3 Do not disconnect EMC or VAR screws PE L3 L2 L1 R6 Disconnec...

Page 87: ...e supply system Note Because the EMC filter screws have been disconnec ted ABB does not guarantee the EMC category ABB does not guarantee the functioning of the ground leakage detector built inside the drive In large systems the residual current device can trip without a real reason Note 1 Frames R3 and R6 are evaluated for use on corner grounded systems and midpoint grounded delta systems by UL s...

Page 88: ...Ground to phase varistor screws EMC filter options E200 and E202 screws Frame size VAR1 EMC DC R8 1 VAR screw functions also as EMC AC screws in frame R8 88 Electrical installation IEC ...

Page 89: ...ge line 1 to ground UL1 G 3 input voltage line 2 to ground UL2 G 4 input voltage line 3 to ground UL3 G The table below shows the line to ground voltages in relation to the line to line voltage for each grounding system Electrical power system type UL3 G UL2 G UL1 G UL L Symmetrically grounded TN system TN S system 0 58 X 0 58 X 0 58 X X Corner grounded delta system nonsymmet rical 0 1 0 X 1 0 X X...

Page 90: ...nd ground to phase varistor frame R3 1 Stop the drive and do the steps in section Electrical safety precautions page 15 before you start the work 2 Remove the front cover 3 Remove the EMC screw 4 Remove the VAR screw EMC VAR 3 4 90 Electrical installation IEC ...

Page 91: ...hase varistor frame R6 1 Stop the drive and do the steps in section Electrical safety precautions page 15 before you start the work 2 Remove the front cover 3 Remove the VAR screw 4 Remove the EMC AC and or EMC DC screw 3 4 EMC AC EMC DC VAR 4 Electrical installation IEC 91 ...

Page 92: ... frame R8 1 Stop the drive and do the steps in section Electrical safety precautions page 15 before you start the work 2 Remove the front cover if it is not already removed 3 Remove the VAR screw 4 Remove the EMC DC screw 3 VAR 4 EMC DC 92 Electrical installation IEC ...

Page 93: ...le is used Ground the other end of the input cable shield or PE conductor at the distribution board 3 ABB requires 360 degree grounding 4 Use a separate grounding cable if the shield does not meet the requirements of IEC 61800 5 1 and there is no symmetrically constructed grounding conductor in the cable See section Selecting the AC power cables page 63 5 Note If there is a symmetrically construct...

Page 94: ... the front cover lift the cover from the bottom outwards 1a and then up 1b R3 IP55 R3 IP21 2 1b 1a 2 1b 1a For frame R6 and R8 IP21 Remove the cover as follows Release the retaining clip with a screwdriver Remove the middle front cover Remove the lower front cover For frame R6 and R8 IP55 Remove the covers as follows Loosen the screws that attach the front cover to the frame Remove the cover For f...

Page 95: ...R6 R8 IP21 R6 R8 IP55 Electrical installation IEC 95 ...

Page 96: ... voltage warning sticker in the local language 3 For frames R6 and R8 Remove the shroud on the power cable terminals R8 R6 4 For frame R8 For easier installation you can remove the side plates 96 Electrical installation IEC ...

Page 97: ...uate hole into the rubber grommet Slide the grommet onto the cable 7 Prepare the ends of the cables as shown in the figure Two different motor cable types are shown If you use aluminum cables put grease to the peeled aluminum cable before you connect it to the drive Note The bare shield will be grounded 360 degrees PE PE Electrical installation IEC 97 ...

Page 98: ...ditional PE conductors if any Connect the phase conductors of the motor cable to the T1 U T2 V and T3 W terminals and the phase conductors of the input cable to the L1 L2 and L3 terminals For frame R8 Install the common mode filter For instructions see Common mode filter kit for ACS880 01 frame R7 and for ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 frame R8 option E208 installation instructions 3A...

Page 99: ...R6 L1 L2 L3 T1 U T2 V T3 W 5 6 N m 2 9 N m 2 N m R8 L1 L2 L3 30 N m T1 U T2 V T3 W 30 N m 9 8 N m 2 N m Electrical installation IEC 99 ...

Page 100: ... R8 power cable connection if you detach the cable connectors The power cable connectors of frame R8 are detachable If you detach them you can connect the cables with cable lugs as follows Remove the nut that attaches the connector to the terminal post and remove the connector Alternative 1 Put the conductor to the connector Tighten to a torque of 30 N m Put the connector back onto the post Tighte...

Page 101: ...e 131 for the default I O connections of the drive Connection procedure WARNING Obey the safety instructions of the drive If 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 Electrical installation IEC 101 ...

Page 102: ...elds and grounding wires under the grounding clamp screw at the cable entry Frame R6 and R8 Ground the pair cable shields and grounding wire under the clamp screw below the control unit 8 Connect the conductors to the appropriate terminals of the control unit and tighten to 0 5 0 6 N m See Default I O diagram of the drive control unit ZCU 1x page 131 Note Leave the other ends of the control cable ...

Page 103: ...R6 1 5 N m 0 5 N m Electrical installation IEC 103 ...

Page 104: ...R8 1 5 N m 0 5 0 6 N m 104 Electrical installation IEC ...

Page 105: ...ons of the drive If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Electrical safety precautions page 15 before you start the work 2 Remove the front cover s if not already removed 3 For frame R3 Pull the control panel holder up 4 Insert the module carefully into its position on the control unit 5 Tighten the mounting screw torque ...

Page 106: ...ure into Slot 2 WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Electrical safety precautions page 15 before you start the work 2 Remove the front cover 3 For frame R3 Pull the control panel stand up 4 Insert the module carefully into its position on the control unit 5 Attach the ...

Page 107: ...er s manual 3AXD50000015612 English or in FSO 21 safety functions module user s manual 3AXD50000015614 English 3 5 5 5 5 6 X12 Installation next to the control unit on frames R6 and R8 WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Electrical safety precautions page 15 2 Remove t...

Page 108: ...d to connector X12 on the drive control unit 7 Connect the Safe torque off STO cable to connector X111 on the module and to connector XSTO on the drive module control unit as shown in Wiring page 211 8 Connect the external 24 V power supply cable to connector X112 9 Connect the other wires as shown in FSO 12 safety functions module user s manual 3AXD50000015612 English or in FSO 21 safety function...

Page 109: ...55 UL Type 12 frame R8 connect the second auxiliary cooling fan power supply wire see section Replacing the second auxiliary cooling fan IP55 UL Type 12 frame R8 page 153 R3 5 5 P I 1 2 P I 2 1 2 1 2 N m 2 N m R6 R8 IP21 2 N m IP55 2 N m Electrical installation IEC 109 ...

Page 110: ...c 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 can be used to control several drives or inverter units supply units etc by constructing a panel bus This is done by daisy chaining the panel connections of the drives Some drives have the necessary twin panel connectors in the control panel holder those that do not ...

Page 111: ... mounted on the front cover move the terminating switch into the outer position With an FDPI 02 module move termination switch S2 into the TERMINATED position Make sure that bus termination is off on all other drives 4 On the control panel switch on the panel bus functionality Options Select drive Panel bus The drive to be controlled can now be selected from the list under Options Select drive If ...

Page 112: ...With FDPI 02 modules OPEN TERMIN ATED 1 1 2 2 OPEN TERMINATED 3 112 Electrical installation IEC ...

Page 113: ...maintenance work Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Required tools To do the electrical installation you need these tools wire stripper screwdriver set Torx flat and or Phillips as appropriate torque wrench Required tools wire stripper screwdriver and or wrench with a set of suitable bits Electrical installation North A...

Page 114: ...C Drive 1 Insulated ground conductor in a conduit Ground to drive s PE terminal and to the distribution panel ground bus For a VFD cable installation See d a Conduit ground Bond the conduit to the drive s conduit box and to the distribution panel enclosure For a VFD cable installation see c and d b Shield of a VFD shielded cable Ground the shield 360 under drive s grounding clamp c Symmetrically c...

Page 115: ...ottom outwards 1a and then up 1b R3 UL Type 12 R3 UL Type 1 2 1b 1a 2 1b 1a For frame R6 and R8 UL Type 1 Remove the cover as follows Release the retaining clip with a screwdriver Remove the middle front cover Remove the lower front cover For frame R6 and R8 UL Type 12 Remove the covers as follows Loosen the screws that attach the front cover to the frame Remove the cover For frame R8 disconnect t...

Page 116: ...R6 R8 UL Type 1 R6 R8 UL Type 12 116 Electrical installation North America NEC ...

Page 117: ... warning sticker in the local language 3 For frames R6 and R8 Remove the shroud on the power cable terminals R8 R6 4 For frame R8 For easier installation you can remove the side plates Electrical installation North America NEC 117 ...

Page 118: ...hroughout the conduit Slide the cables through the conduit 7 Cut the cables to suitable length note the extra length of the grounding conductors If you use a symmetrically shielded VFD cable twist the grounding wires together with the cable shield and connect them to the grounding terminals Ground the shield 360 degrees at the clamp If you use discrete conductors connect the insulated ground condu...

Page 119: ...mmon mode filter For instructions see Common mode filter kit for ACS880 01 frame R7 and for ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 frame R8 option E208 installation instructions 3AXD50000015179 English If DC cables are present use only two phase conductors and the ground conductor Connect the phase conductors to the UDC and UDC terminals EMT Tighten the screws to the torque given in the insta...

Page 120: ...R3 7 7 8 8 L1 L2 L3 T1 U T2 V T3 W PE Ground 1 7 N m 1 2 lbf ft 120 Electrical installation North America NEC ...

Page 121: ...R6 7 7 8 8 PE Ground 2 9 N m 2 1 lbf ft L1 L2 L3 T1 U T2 V T3 W 5 6 N m 4 1 lbf ft Electrical installation North America NEC 121 ...

Page 122: ...side plates if removed Note For frame R8 The power cable connectors can be detached For the instructions see section R8 power cable connection if you detach the connectors page 123 9 For frame R6 types bigger than 040A x Cut tabs in the shroud for the installed cables 122 Electrical installation North America NEC ...

Page 123: ...ols page 185 in the technical data Cable lug installation for T1 U T2 V T3 W UDC and UDC Remove the nut that attaches the connector to its terminal post and remove the connector Alternative 1 Put the conductor to the connector Tighten to a torque of 30 N m 22 lbf ft Put the connector back onto the post Tighten the connector to 30 N m 22 lbf ft Alternative 2 Attach a cable lug to the conductor Put ...

Page 124: ...e Default I O diagram of the drive control unit ZCU 1x page 131 Connection procedure WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 124 Electrical installation North America NEC ...

Page 125: ... conductivity is consistent throughout the conduit Slide the control cables through the conduit Cut to suitable length note the extra length of the grounding conductors and strip the conductors 5 Ground the outer shields of all control cables 360 degrees at a grounding clamp 6 Route the cables as shown below 7 Secure the cables inside the drive mechanically 8 Frame R3 Ground the pair cable shields...

Page 126: ...nder the clamp below the control unit R8 R6 9 Connect the conductors to the appropriate terminals of the control unit and tighten to 0 5 0 6 N m 0 4 lbf ft See Default I O diagram of the drive control unit ZCU 1x page 131 126 Electrical installation North America NEC ...

Page 127: ... no significant voltage drop between the end points Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by inductive coupling Installing option modules See section Installing option modules page 105 Reinstalling cover s After installation reinstall the covers UL Type 12 UL Type 1 2 1 2 N m 1 5 lbf ft R3 R3 2 1 ...

Page 128: ...fan IP55 UL Type 12 frame R8 page 153 UL Type 12 UL Type 1 2 N m 1 5 lbf ft R6 R8 R6 R8 1 2 2 N m 1 5 lbf ft Connecting a PC See section Connecting a PC page 110 Controlling several drives through the panel bus See section Panel bus Control of several units from one control panel page 110 128 Electrical installation North America NEC ...

Page 129: ...the drive Contents of this chapter This chapter describes the connections of the control unit s used in the drive contains the specifications of the inputs and outputs of the control unit s Control units of the drive 129 ...

Page 130: ...safety func tions module X12 Control panel connection X13 Option slot 1 X202 Option slot 2 X203 Option slot 3 X204 Memory unit connection memory unit inserted in the picture X205 Cooling fan 1 connection X208 Cooling fan 2 connection X210 Voltage Current selection jumpers J1 J2 for analog inputs J1 J2 Drive to drive link termination switch J3 J3 Common digital input ground selec tion switch J6 J6 ...

Page 131: ...ult not in use 0 4 20 mA Rin 100 ohm2 AI2 AI2 AI1 AI2 current voltage selection AI1 I AI1 U XAO Analog outputs Motor speed rpm AO1 AO1 AGND AO2 AGND 1 2 3 4 0 20 mA RL 500 ohm AGND Motor current 0 20 mA RL 500 ohm AO2 AGND XD2D Drive to drive link Master follower drive to drive or embedded fieldbus connection 3 B 1 2 3 B A BGND A BGND Drive to drive link termination 3 J3 XRO1 XRO2 XRO3 Relay outpu...

Page 132: ...ent 0 4 20 mA Rin 100 ohm or voltage 0 2 10 V Rin 200 kohm input selected by switch AI2 Change of setting requires reboot of control unit 3 See section The XD2D connector page 134 4 See section DIIL input page 134 Total load capacity of these outputs is 4 8 W 200 mA at 24 V minus the power taken by DIO1 and DIO2 6 Determines whether DICOM is separated from DIOGND ie common reference for digital in...

Page 133: ...h no significant voltage drop between the end points See the firmware manual of the inverter unit for parameter settings 1 24V DI6 t t t t t t One to six PTC thermistors connected in series 1 WARNING As the inputs pictured above are not insulated according to IEC 60664 the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If...

Page 134: ...y does not fulfill the requirement protect the I O board terminals against contact and do not connected them to other equipment or isolate the temperature sensor from the I O terminals Make sure that the current does not exceed the maximum allowed current through the Pt100 Pt1000 sensor DIIL input The DIIL input is used for the connection of safety circuits The input is parametrized to stop the un...

Page 135: ...g diagram shows the wiring between control units ZCU 12 XD2D XD2D XD2D J3 J3 J3 1 2 3 B A BGND 1 2 3 B A BGND 1 2 3 B A BGND Safe torque off XSTO See chapter The Safe torque off function page 209 Note The XSTO input only acts as a true Safe torque off input on the inverter control unit De energizing the IN1 and or IN2 terminals of other units supply DC DC converter or brake unit will stop the unit...

Page 136: ...e 2 5 mm2 Start interlock input DIIL XD24 1 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Input type NPN PNP Hardware filtering 0 04 ms digital filtering up to 8 ms Connector pitch 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 Filtering 1 ms Input output mode selection by parameters As outputs Total output current ...

Page 137: ... twisted pair for data and a wire or another pair for signal ground nom inal impedance 100 165 ohm for example Belden 9842 Maximum length of link 50 m 164 ft Termination by jumper Connector pitch 5 mm wire size 2 5 mm2 Safe torque off connection XSTO Input voltage range 3 30 V DC Logic levels 0 5 V 1 17 V Note For the unit to start both connections must be 1 This applies to all control units inclu...

Page 138: ...L 1 24VD 2 DICOM 3 24VD 4 DIOGND 5 XDIO DIO1 1 DIO2 2 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 XSTO OUT1 1 GND 2 IN1 3 IN2 4 Common mode voltage between channels 30 V Ground selector J6 settings All digital inputs share a common ground DICOM connected to DIOGND This is the default setting Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO signal ground DIOGND Isolation voltage 50 ...

Page 139: ... 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 Stop the drive and do the steps in section Electrical safety precautions page 15 before you start the work Make sure that The ambient operating conditions meet the drive ambient conditions specification and enclosure rating IP code ...

Page 140: ...tive earth ground conductor between the motor and the drive and the conductor is connected to the correct terminal and the terminal is tightened to the correct torque Proper grounding has also been measured according to the regulations The motor cable 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 awa...

Page 141: ...s See Sine filter hardware manual 3AXD50000016814 English For drives with ABB motors in explosive atmospheres See ACS880 drives with ABB motors in explosive atmospheres supplement 3AXD50000019585 English 2 Validate the Safe torque off function according to the instructions given in chapter The Safe torque off function page 209 3 Validate the safety functions options Q923 Q973 and Q982 as described...

Page 142: ...142 ...

Page 143: ...consult your local 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 Recommended annual actions by the user Description Action Quality of supply v...

Page 144: ...Functional safety I See the maintenance inform ation of the safety function Safety function test 20 years Safety component expiry Mission time TM 4FPS10000309652 Note 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 drive inspections to ensure the highest reliability ...

Page 145: ...water from entering the drive Never use excessive amount of water a hose steam etc Cleaning the heatsink The drive module heatsink fins pick up dust from the cooling air The drive runs into overtemperature warnings and faults if the heatsink is not clean When necessary clean the heatsink as follows WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some ...

Page 146: ...ases the life span of the fan In a speed controlled fan the speed of the fan matches the cooling needs This increases the life span of the fan Main fans are speed controlled When the drive is stopped the main fan is kept running at low speed to cool the control board IP21 UL Type 1 frames R6 R8 and all IP55 UL Type 12 frames have auxiliary fans that are not speed controlled and run all the time wh...

Page 147: ...op the drive and do the steps in section Electrical safety precautions page 15 before you start the work 2 To release the locking turn clockwise with a screwdriver 3 Turn the fan assembly off 4 Install the new fan in reverse order Maintenance 147 ...

Page 148: ...precautions page 15 before you start the work 2 Lever the fan assembly off the drive frame with for example a screwdriver 2a and pull out the fan assembly 2b 3 Pull the fan assembly down 4 Unplug the fan power supply and grounding wires from the drive 5 Install the new fan in reverse order 148 Maintenance ...

Page 149: ...l safety precautions page 15 before you start the work 2 Undo the mounting screws of the fan assembly 3 Unplug the fan power supply and grounding wires from the drive 4 Pull the fan assembly down 5 Undo the mounting screws of the fan 6 Install the new fan in reverse order 2 2 3 5 Maintenance 149 ...

Page 150: ...y precautions page 15 before you start the work 2 Remove the front cover See section Connection procedure page 94 3 Release the retaining clips 4 Lift the fan off 5 Unplug fan power supply wires 6 Install the new fan in reverse order Note Make sure that the arrow on the fan points down Blowing direction down 150 Maintenance ...

Page 151: ...emove the upper front covers See section Connection procedure page 94 3 Release the retaining clips 4 Lift the fan off 5 Unplug fan power supply wires 6 Remove the grille from the fan 7 Install the new fan in reverse order Note Make sure that the arrow on the fan points up 8 Reinstall the front covers See section Reinstalling cover s page 109 Maintenance 151 ...

Page 152: ...fore you start the work 2 Remove the upper front covers See section Connection procedure on page 90 3 Release the retaining clips 4 Lift the fan off 5 Unplug fan power supply wires 6 Remove the grille 7 Install the new fan in reverse order Note Make sure that the arrow on the fan points up 8 Replace the front covers 152 Maintenance ...

Page 153: ...autions page 15 before you start the work 2 Remove the IP55 front cover Unplug the auxiliary cooling fan power supply wire 3 Remove the lower front cover from the IP55 cover 4 Pull the fan supply wire through the grommet 5 Remove the fan 6 Install the new fan in reverse order Make sure that the arrow on the fan points up Maintenance 153 ...

Page 154: ... Fan arrow must point up 154 Maintenance ...

Page 155: ...d 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 instructions 3BFE64059629 English in the ABB Library https library abb com en Control panel See ACx AP x Assistant control panels user s manual 3AUA0000085685 English Drive LEDs There is a green POWER and a red FAULT LED visibl...

Page 156: ...el or switch off the drive power Red FAULT Control unit Replacing the memory unit of ZCU 12 After replacing a control unit you can retain the existing parameter settings by transferring the memory unit from the defective control unit to the new control unit After power up the drive will scan the memory unit This can take several minutes WARNING Do not remove or insert the memory unit when the cont...

Page 157: ... The ejector is included on the battery slot The battery is of type CR2032 1 Stop the drive and do the steps in section Electrical safety precautions page 15 before you start the work 2 Move the battery ejector into the battery slot on the battery 3 Carefully pull the battery out of the battery holder 4 Carefully put a new CR2032 battery into the battery holder Maintenance 157 ...

Page 158: ...functions modules FSO 12 option Q973 and FSO 21 option Q972 Do not repair safety functions modules Replace a faulty module with a new one as described in section Installation of safety functions modules page 106 158 Maintenance ...

Page 159: ...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 Note that some of the components may already have been r...

Page 160: ...160 ...

Page 161: ...ratings Input cur rent Frame size ACS880 11 Heavy duty use Light duty use Nominal use PHd IHd PLd ILd Pn I2 Sn Imax I1 kW A kW A kW A kVA A A Un 400 V 3 0 8 0 4 0 9 5 4 0 10 0 6 9 13 6 8 R3 09A4 3 4 0 10 0 5 5 12 0 5 5 12 9 8 9 17 0 10 R3 12A6 3 5 4 12 9 7 5 16 7 5 17 0 12 21 9 14 R3 017A 3 7 5 17 11 24 11 25 17 28 8 20 R3 025A 3 11 25 15 30 15 32 22 42 5 27 R6 032A 3 15 0 32 18 5 36 18 5 38 26 54...

Page 162: ...18 5 34 29 45 9 26 2 R6 034A 5 18 5 34 22 0 38 22 0 40 35 57 8 31 2 R6 040A 5 22 0 40 30 0 49 30 0 52 45 68 0 40 1 R6 052A 5 30 0 52 37 0 62 37 0 65 56 88 4 49 5 R6 065A 5 1 37 0 65 45 0 73 45 0 77 67 110 5 60 2 R6 077A 5 1 37 0 77 45 91 45 0 101 87 148 71 R8 101A 5 45 0 96 55 118 55 0 124 107 178 96 R8 124A 5 55 0 124 75 148 75 0 156 137 247 115 R8 156A 5 75 0 156 90 171 90 0 180 156 287 141 R8 1...

Page 163: ...40 C 104 F I1 Maximum output current Available for 10 seconds at start otherwise as long as allowed by drive temperature 140 200 of IHd depending on power rating Imax Continuous rms output current No overload capability at 40 C 104 F This is indicated in the type designation label as output current I2 I2 Typical motor power in no overload use Pn Apparent power no overload Sn Continuous rms output ...

Page 164: ...No derating up to 40 C up to 104 F Derate 1 for every 1 C 1 8 F Calculate the output by multiplying the current given in the rating table by the derating factor k in the diagram below 40 55 C 104 131 F T 1 00 0 90 40 C 104 F 50 C 122 F k 55 C 131 F 0 80 15 C 5 F 0 85 0 95 164 Technical data ...

Page 165: ...ng up to 40 C up to 104 F Derate 1 for every 1 C 1 8 F up to 45 C 113 F Derate 2 for every 1 C 1 8 F up to 55 C 131 F Calculate the output by multiplying the current given in the rating table by the derating factor k in the diagram below 40 55 C 104 131 F T 1 00 0 90 40 C 104 F 50 C 122 F k 55 C 131 F 0 80 45 C 113 F 0 75 0 85 0 95 15 C 5 F ACS880 11 206A 3 B056 and 180A 5 B056 No derating up to 4...

Page 166: ...775 Note For surrounding air temperatures above 40 C 104 F the power cables must be rated for 90 C 194 F minimum Altitude derating At altitudes from 1000 to 4000 m 3300 to 13123 ft above sea level the derating is 1 for every 100 m 328 ft If ambient temperature is below 40 C 104 F the derating can be reduced by 1 5 for every 1 C reduction in temperature For a more accurate derating use the DriveSiz...

Page 167: ... 80 Deratings for special settings in the drive control program Ex motor sine filter low noise Deratings are needed in these cases drive is used with an ABB motor for explosive atmospheres Ex and EX motor in parameter 95 15 Special HW settings is enabled sine filter given in the selection table in chapter Filters is used and ABB Sine filter in parameter 95 15 Special HW settings is enabled Low noi...

Page 168: ...y duty use Light duty use Nominal use IHd ILd IN A A A Un 400 V 6 5 8 1 8 5 09A4 3 8 5 10 7 11 3 12A6 3 11 3 14 3 15 017A 3 15 0 20 9 22 025A 3 22 29 30 032A 3 30 33 35 038A 3 35 39 41 045A 3 41 53 56 061A 3 47 53 56 072A 3 56 64 67 087A 3 87 100 105 105A 3 105 138 145 145A 3 145 161 169 169A 3 169 196 206 206A 3 Un 500 V 4 4 6 2 6 5 07A6 5 6 5 8 9 9 4 11A0 5 9 4 11 4 12 0 014A 5 12 0 17 1 18 0 02...

Page 169: ...put frequencies smaller than this recommended maximum output frequency the current derating is less than the values given in the table Contact ABB for operation above the recommended maximum output frequency or for the output current derating with output frequencies above 120 Hz and below the maximum output frequency At the output frequency 120 Hz no derating Output ratings with selection High spe...

Page 170: ...0 C 104 F In Continuous rms output current allowing 10 overload for 1 minute every 5 minutes ILd Continuous rms output current allowing 50 overload for 1 minute every 5 minutes IHd Derating for output voltage boost See ACS880 11 ACS880 31 ACS880 14 ACS880 34 ACS880 17 ACS880 37 drives product note on DC voltage boost 3AXD50000691838 English Fuses IEC Fuses protect the input cable in short circuit ...

Page 171: ...316 690 2550 80 51 300 061A 3 000 170M1317 690 4650 100 63 400 072A 3 000 170M1318 690 8500 125 76 400 087A 3 000 170M1319 690 16000 160 88 700 105A 3 000 170M1320 690 28000 200 120 970 145A 3 00 170M2618 690 42000 250 144 1100 169A 3 00 170M2619 690 68500 315 176 1600 206A 3 3 phase Un 500 V 000 170M1308 690 25 5 10 5 8 32 07A6 5 000 170M1309 690 48 16 7 8 42 11A0 5 000 170M1311 690 130 25 10 6 6...

Page 172: ... 16000 160 76 700 087A 3 1 170M3817 690 46500 315 88 1200 105A 3 1 170M3817 690 46500 315 120 1200 145A 3 2 170M5809 690 105000 450 144 1900 169A 3 2 170M5810 690 145000 500 176 2200 206A 3 3 phase Un 500 V 000 170M1561 690 130 25 5 8 65 07A6 5 000 170M1561 690 130 25 7 8 65 11A0 5 000 170M1563 690 460 40 10 6 120 014A 5 000 170M1563 690 460 40 15 6 120 021A 5 000 170M1565 690 1450 63 21 3 170 027...

Page 173: ...100 500 63600 100 76 0 1000 087A 3 3 phase Un 500 V 000 OFAF000H16 500 700 16 5 8 120 07A6 5 000 OFAF000H16 500 700 16 7 8 120 11A0 5 000 OFAF000H25 500 2500 25 10 6 200 014A 5 000 OFAF000H32 500 4500 32 15 6 250 021A 5 000 OFAF000H40 500 7700 40 21 3 350 027A 5 000 OFAF000H50 500 15400 50 26 2 400 034A 5 000 OFAF000H63 500 21300 63 31 2 500 040A 5 000 OFAF000H80 500 37000 80 40 1 800 052A 5 000 O...

Page 174: ... 35 087A 3 Un 500 V 5 0 4 1 3 9 8 9 7 5 7 2 3 1 5 07A6 5 5 0 4 1 3 9 8 9 7 5 7 2 3 1 5 11A0 5 7 6 7 3 7 2 12 12 12 3 6 014A 5 7 6 7 3 7 2 16 15 15 3 6 021A 5 11 10 10 22 21 21 3 10 027A 5 11 10 10 25 24 24 3 10 034A 5 18 17 17 31 30 30 3 35 3 16 040A 5 19 18 18 51 49 48 3 35 3 25 052A 5 30 29 29 63 61 60 3 50 3 35 065A 5 46 43 42 63 61 60 3 70 3 35 077A 5 Calculating the short circuit current of t...

Page 175: ...r drive supply Un 430 V transformer impedance zk 7 2 Supply cable length 170 m resistance length 0 398 ohm km reactance length 0 082 ohm km 430 V 2 600 kVA 22 19 mohm Zk zk UN 2 SN 0 072 m 0 398 ohm km 67 66 mohm Rc 170 m 0 082 ohm km 13 94 mohm Xc 170 410 V 2 67 66 mohm 2 22 19 mohm 13 94 mohm 2 Ik2 ph 2 7 kA The calculated short circuit current 2 7 kA is higher than the minimum short circuit cur...

Page 176: ...0 25 10 6 014A 5 T JJS 35 600 35 15 6 021A 5 T JJS 40 600 40 21 3 027A 5 T JJS 50 600 50 26 2 034A 5 T JJS 60 600 60 31 2 040A 5 T JJS 80 600 80 40 1 052A 5 T JJS 90 600 90 49 5 065A 5 T JJS 110 600 110 60 2 077A 5 T JJS 150 600 150 74 101A 5 T JJS 200 600 200 100 124A 5 T JJS 225 600 225 120 156A 5 T JJS 300 600 300 147 180A 5 1 Fuses are required as part of the installation are not included in t...

Page 177: ...in the same enclosure as the drive For more information see the manual supplement 3AXD50000645015 English 1 For UL Type Open Type 1 or UL Type 12 drives no Enclosure Minimum Volume is required but the drive must be mounted inside an enclosure 2 If combining a drive with no Enclosure Minimum Volume and others with an Enclosure Minimum Volume specified start with the largest specified Enclosure Mini...

Page 178: ...ng if Ipeak and I2t are the same or less than the ABB specified circuit breaker 9 Only current limiting inverse time circuit breakers can be used 10 The drives listed below have no Enclosure Minimum Volume unlike 480 V and 600 V ACS880 01 drives Max Ipeak Max I2t ABB circuit breaker Drive volume CB Voltage CB Maxim um cur rent Input cur rent Frame ACS880 11 kA A2s in3 V A A Un 480 V 23 2 0 512 106...

Page 179: ...or types 105A 3 145A 3 101A 5 124A 5 109 kg 3 for types 105A 3 145A 3 101A 5 124A 5 100 kg Weight Depth Width Height Frame size lb in in in UL Type 1 50 72 14 02 8 07 19 49 R3 161 85 15 03 9 92 30 35 R6 UL Type 12 50 72 14 17 7 99 19 29 R3 161 85 17 54 9 92 30 35 R6 UL Open Type option P940 40 34 13 74 7 99 19 29 R3 130 07 14 09 9 92 30 35 R6 253 531 1 94 11 81 37 95 R8 1 for types 105A 3 145A 3 1...

Page 180: ...h flange kit option C135 Frame size UL Type 12 UL Type 1 lb lb 60 52 56 11 R3 151 85 147 27 R6 290 79 277 56 R8 Hood not included Free space requirements See section Installation orientations page 40 180 Technical data ...

Page 181: ... Package dimensions R6 R3 R8 Technical data 181 ...

Page 182: ...R3 57 212 361 329 12A6 3 R3 57 212 361 395 017A 3 R3 57 212 361 579 025A 3 R6 71 324 550 625 032A 3 R6 71 324 550 751 038A 3 R6 71 324 550 912 045A 3 R6 71 324 550 1088 061A 3 R6 71 324 550 1502 072A 3 R6 71 324 550 1904 087A 3 R8 68 537 913 1877 105A 3 R8 68 537 913 2963 145A 3 R8 68 537 913 3168 169A 3 R8 68 537 913 3990 206A 3 Un 500 V R3 57 212 361 219 07A6 5 R3 57 212 361 278 11A0 5 R3 57 212...

Page 183: ...A 5 R8 68 537 913 2800 124A 5 R8 68 537 913 3168 156A 5 R8 68 537 913 3872 180A 5 These losses are not calculated according to IEC 61800 9 2 Cooling air flow and heat dissipation for flange mounting option C135 Frame size Cooling air flow Heat dissipation ACS880 11 Front Heatsink Front Heatsink m3 h m3 h W W Un 400 V R3 361 40 186 09A4 3 R3 361 41 288 12A6 3 R3 361 42 353 017A 3 R3 361 46 533 025A...

Page 184: ...wer cables Input motor and DC cable entries maximum wire sizes per phase and terminal screw sizes and tightening torques are given below Ø Maximum cable diameter accepted For the bottom plate hole diameters see chapter Dimension drawings page 201 The minimum specified wire size does not necessarily have sufficient current carrying capacity at maximum load The terminals do not accept a conductor th...

Page 185: ...erminals Cable entries Frame Tightening torque Max wire size solid stran ded Min wire size solid stran ded Ø pcs lbf ft AWG AWG in 1 3 6 20 0 91 3 R3 4 1 2 0 10 1 77 3 R6 22 5 300 4 1 77 3 R8 For tightening torques of grounding terminals see section Connection procedure page 115 UL listed cable lugs and tools Crimping tool Compression lug Wire size kcmil AWG No of crimps Type Manufacturer Type Man...

Page 186: ...CL 1 0 38 Ilsco 3 TBM 8 Thomas Betts 54110 Thomas Betts 2 0 2 MY29 3 Burndy YAL26T38 Burndy 1 IDT 12 Ilsco CRA 2 0 Ilsco 1 MT 25 Ilsco CCL 2 0 38 Ilsco Terminal and entry data for the control cables IEC Control cable entries wire sizes and tightening torques T are given below Control cable entries and terminal sizes Cable entries Frame size DI AI O AGND RO STO terminals 24V DCOM DGND EXT 24V termi...

Page 187: ...erminal and entry data for power cables see Terminal and entry data for the power cables page 184 UL NEC 3 IEC1 Frame size Drive type ACS880 11 Cu cable type Al cable type 2 Cu cable type AWG kcmil mm2 mm2 Un 400 V 3 1 5 R3 09A4 3 3 1 5 R3 12A6 3 3 6 R3 017A 3 3 6 R3 025A 3 3 16 3 10 R6 032A 3 3 16 3 10 R6 038A 3 3 35 3 16 R6 045A 3 3 35 3 25 R6 061A 3 3 50 3 35 R6 072A 3 3 70 3 50 R6 087A 3 3 70 ...

Page 188: ...t carrying conductors in raceway or cable or earth directly buried For other conditions size the cables according to local safety regulations appropriate input voltage and the load current of the drive 4 In the USA aluminum cables must not be used Temperature For IEC select a cable rated for at least 70 C maximum permissible temperature of conductor in continuous use For North America power cables...

Page 189: ...rrent IEC 61439 1 The drive is suitable for use on a circuit capable of delivering not more than 100 000 rms symmetrical amperes at 480 V maximum when pro tected by the fuses given in the fuse table Short circuit current protection UL 61800 5 1 47 63 Hz This is indicated in the type designation label as typical input frequency f1 50 60 Hz Frequency f1 Max 3 of nominal phase to phase input voltage ...

Page 190: ...dered installa tion PCC Indicates the total harmonic current distortion of the wave form This value is defined as the ratio in of the harmonic current to the fundamental non harmonic current measured at a load point at the particular moment when the measurement is taken THDi 40 2 n 2 I I1 100 THDi Indicates the total magnitude of the voltage distortion This value is defined as the ratio in of the ...

Page 191: ... With motor cables longer than 150 m 492 ft or switching fre quencies higher than default the EMC Directive requirements may not be fulfilled Note 2 Longer motor cables cause a motor voltage decrease which limits the available motor power The decrease depends on the motor cable length and characteristics Contact ABB for more information Note that a sine filter optional at the drive output also cau...

Page 192: ...od cardboard and molded pulp Foam cushions PE PP E bands PP Package The main parts of the drive can be recycled to preserve natural resources and energy Product parts and materials should be dismantled and separated Disposal Generally all metals such as steel aluminum copper and its alloys and precious metals can be recycled as material Plastics rubber cardboard and other packaging material can be...

Page 193: ... Adjustable speed electrical power drive systems Part 3 EMC require ments and specific test methods IEC EN 61800 3 2004 A1 2012 Adjustable speed electrical power drive systems Part 5 1 Safety require ments electrical thermal and energy IEC EN 61800 5 1 2007 Adjustable speed electrical power drive systems Part 9 2 Ecodesign for power drive systems motor starters power electronics and their driven a...

Page 194: ... 1S3 packing must support this oth erwise 1S2 Class 3S2 No conduct ive dust allowed Solid particles Pollution degree 2 Pollution degree IEC EN 61800 5 1 60 to 106 kPa 70 to 106 kPa 70 to 106 kPa Atmospheric pressure 0 6 to 1 05 atmo spheres 0 7 to 1 05 atmo spheres 0 7 to 1 05 atmo spheres 10 150 Hz Vibration Amplitude 0 075 mm 10 57 56 Hz IEC 60068 2 6 Constant peak acceler ation 10 m s 1 gn 57 5...

Page 195: ...ain England Wales and Scotland UL Listed mark for USA and Canada Product has been tested and evaluated against the relevant North American standards by the Underwriters Laboratories Valid with rated voltages up to 600 V RCM mark Product complies with Australian and New Zealand requirements specific to EMC telecommunications and electrical safety For fulfilling the EMC requirements see the addition...

Page 196: ...ment includes establishments connected to a network not supplying domestic premises Drive of category C1 drive of rated voltage less than 1000 V and intended for use in the first environment Drive of category C2 drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment Note A professional is a person or organizatio...

Page 197: ...and control cables are selected as specified in this manual 3 The drive is installed according to the instructions given in this manual 4 For the maximum motor cable length with 4 kHz switching frequency see section Motor connection data page 191 WARNING A drive of category C3 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference i...

Page 198: ...according to the electrical planning guidelines of the drive The EMC recommendations are obeyed 4 The drive is installed according to its installation instructions The EMC recommendations are obeyed WARNING A drive of category C4 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a networ...

Page 199: ...it breakers UL page 177 WARNING The opening of the branch circuit protective device may be an indication that a fault current has been interrupted To reduce the risk of fire or electric shock current carrying parts and other components of the device should be examined and replaced if damaged The drive provides motor overload protection This feature is not enabled when the drive leaves the ABB fact...

Page 200: ... 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 201: ...13 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the drive The dimensions are given in millimeters and inches Dimension drawings 201 ...

Page 202: ...R3 IP21 UL Type 1 3AXD50000045323 202 Dimension drawings ...

Page 203: ...R3 Option B056 IP55 UL Type 12 3AXD50000045322 Dimension drawings 203 ...

Page 204: ...R6 IP21 UL Type 1 3AXD50000045353 204 Dimension drawings ...

Page 205: ...R6 Option B056 IP55 UL Type 12 3AXD50000045352 Dimension drawings 205 ...

Page 206: ...R8 IP21 UL Type 1 3AXD50000047667 206 Dimension drawings ...

Page 207: ...R8 Option B056 IP55 UL Type 12 3AXD50000047667 Dimension drawings 207 ...

Page 208: ...208 ...

Page 209: ...ction 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 generating the torque required to rotate the mot...

Page 210: ...r electrical elec tronic programmable 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 requirements Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related electric al electronic and programm...

Page 211: ...ted pair cable is recommended Maximum cable lengths 300 m 1000 ft between activation switch K and drive control unit 60 m 200 ft between multiple drives 60 m 200 ft between external power supply and first control unit Note A short circuit in the wiring between the switch and an STO terminal causes a dangerous fault Therefore it is recommended to use a safety relay including wiring diagnostics or a...

Page 212: ... Single drive internal power supply 24 V OUT1 SGND IN2 UDC UDC A K IN1 1 2 3 4 Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K 212 The Safe torque off function ...

Page 213: ... Multiple drives Internal power supply 24 V OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 K XSTO XSTO XSTO 1 1 1 2 2 2 Drive 1 Control unit 2 Activation switch K The Safe torque off function 213 ...

Page 214: ...External power supply OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 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 214 The Safe torque off function ...

Page 215: ... 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 216: ...ion test reports Signed validation test reports must be stored in the logbook 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 valid...

Page 217: ...bed 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 fa...

Page 218: ...ge sources WARNING The drive cannot detect or memorize any changes in the STO circuitry when the drive control unit is not powered If both STO circuits are closed and a level type start signal is active when the power is restored it is possible that the drive starts without a fresh start command Take this into account in the risk assessment of the system WARNING With permanent magnet or synchronou...

Page 219: ...ainst 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 inform the final user about the residual risks The Safe torque off function 219 ...

Page 220: ...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 221: ...function is performed and the drive trips on an STO hardware failure fault An attempt to use the STO in a non redundant manner for example activating only one channel will trigger the same reaction See the firmware manual of the drive control program for the indications generated by the drive and for details on directing fault and warning indications to an output on the control unit for external d...

Page 222: ... 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 A safety component as defined in IEC 61508 2 Relevant failure modes The STO trips spuriously safe failure The STO does not activate when requested A fault exclusion on the...

Page 223: ...ndetected failures during a partic ular measurement interval under stated conditions EN ISO 13849 1 MTTFD Average probability of dangerous 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...

Page 224: ...alid The same interval must be followed to keep the PL capability EN ISO 13849 valid IEC 61508 6 T1 See also section Maintenance Mission time the period of time covering the intended use of the safety function device After the mission time elapses the safety device must be replaced Note that any TM values given cannot be regarded as a guarantee or warranty EN ISO 13849 1 TM TÜV certificate The TÜV...

Page 225: ... Declarations of conformity The Safe torque off function 225 ...

Page 226: ... 04F M04 14 34 Safe Torque Off Safe stop 1 Safe stop emergency Safely limited speed Safe maximum speed Safe brake control Prevention of unexpected start up with FSO 12 option module Q973 encoderless Safe stop 1 Safe stop emergency Safely limited speed Safe maximum speed Safe brake control Safe speed monitor Safe direction Prevention of unexpected start up with FSO 21 and FSE 31 option modules Q972...

Page 227: ...me R8 is available from ABB also with order number 3AXD50000017270 For installation instructions see Common mode filter kit for ACS880 01 ACS880 11 and ACS880 31 drives installation instructions frame R6 option E208 3AXD50000015178 English Common mode filter kit for ACS880 01 frame R7 and for ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 frame R8 option E208 installation instructions 3AXD50000015179...

Page 228: ...3 FOCH0260 7X 180A 5 FOCH0260 70 206A 3 3AXD00000588487 Description installation and technical data of the filters See AOCH and NOCH du dt filters hardware manual 3AFE58933368 English or FOCHxxx xx du dt filters hardware manual 3AFE68577519 English Sine filters See section Examining the compatibility of the motor and drive page 55 Selecting a sine filter for the drive The table below lists the pre...

Page 229: ... B84143V0025R229 021A 5 75 785 160 625 11 0 25 B84143V0033R229 027A 5 78 931 220 711 15 32 B84143V0050R229 034A 5 78 1027 220 807 18 5 35 B84143V0050R229 040A 5 78 1210 250 960 22 44 B84143V0066R229 052A 5 78 1473 250 1223 30 52 B84143V0066R229 065A 5 78 1870 310 1560 37 61 B84143V0075R229 077A 5 80 2625 630 1995 45 0 80 B84143V0130S230 101A 5 80 3430 630 2800 55 0 104 B84143V0130S230 124A 5 80 37...

Page 230: ... Description installation and technical data For the filter data sheets go to http en tdk eu See also Sine filters hardware manual 3AXD50000016814 English 230 Common mode du dt and sine filters ...

Page 231: ... 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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