ABB ACS880-14 Hardware Manual Download Page 12

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198

EMC compliance (IEC/EN 61800-3:2004) .....................................................

198

Definitions .......................................................................................

198

Category C2 .....................................................................................

199

Category C3 .....................................................................................

200

Category C4 .....................................................................................

200

UL and CSA checklist .............................................................................

201

EU Declaration of Conformity (Machinery Directive) .........................................

201

Disclaimers .........................................................................................

201

Generic disclaimer .............................................................................

202

Cybersecurity disclaimer ......................................................................

18 Dimension drawings

203

Contents of this chapter ...........................................................................

204

Standard configuration ............................................................................

205

Location of power cable connection terminals with oH370, +H356 ...............

206

Drive module with o0B051+H356+0H371 ............................................

207

Configuration with H381 ................................................................

208

LCL filter module ...................................................................................

209

Bottom plate ........................................................................................

210

Air baffles ............................................................................................

210

Material of the air baffles ......................................................................

211

Air baffles for H381 in 800 mm wide Rittal VX25 enclosure .......................

212

External control unit ...............................................................................

19 Example circuit diagrams

213

Contents of this chapter ...........................................................................

213

Example circuit diagram ..........................................................................

20 The Safe torque off function

215

Contents of this chapter ...........................................................................

215

Description ..........................................................................................

216

Compliance with the European Machinery Directive ......................................

217

Wiring ................................................................................................

217

Activation switch ................................................................................

217

Cable types and lengths .......................................................................

217

Grounding of protective shields ..............................................................

218

Single drive (internal power supply) .........................................................

218

Dual-channel connection ..................................................................

219

Single-channel connection ................................................................

220

Multiple drives ...................................................................................

220

Internal power supply ......................................................................

221

External power supply ......................................................................

222

Operation principle .................................................................................

223

Start-up including validation test .................................................................

223

Competence .....................................................................................

223

Validation test reports ..........................................................................

223

Validation test procedure ......................................................................

225

Use ...................................................................................................

226

Maintenance ........................................................................................

226

Competence .....................................................................................

227

Fault tracing .........................................................................................

12 Table of contents

Summary of Contents for ACS880-14

Page 1: ...ABB INDUSTRIAL DRIVES ACS880 14 drive modules 132 400 kW 200 400 hp Hardware manual...

Page 2: ......

Page 3: ...odules 132 400 kW 200 400 hp Hardware manual Table of contents 1 Safety instructions 6 Mechanical installation 8 Electrical installation 13 Start up 3AXD50000035160 Rev D EN Original instructions EFFE...

Page 4: ......

Page 5: ...rization by frame size and option code 26 Quick installation commissioning and operating flowchart 27 Terms and abbreviations 28 Related documents 3 Operation principle and hardware description 31 Con...

Page 6: ...the mechanical installation 55 Contents of this chapter 55 Installation positions of the drive module 56 Layout example door closed 57 Layout example door open standard drive module configuration 58 L...

Page 7: ...rements table 80 Availability of du dt filter and common mode filter by drive type 80 Additional requirements for explosion safe EX motors 80 Additional requirements for ABB motors of types other than...

Page 8: ...ATEX certified motor thermal protection 95 Controlling a contactor between drive and motor 95 Implementing a bypass connection 96 Example bypass connection 96 Switching the motor power supply from dr...

Page 9: ...125 DI6 as a PTC sensor input 125 AI1 or AI2 as a Pt100 Pt1000 PTC or KTY84 sensor input 126 DIIL input 126 The XD2D connector 127 Safe torque off XSTO 127 FSO xx safety functions module connection X1...

Page 10: ...s 157 Recommended annual maintenance actions by the user 158 Recommended maintenance intervals after start up 158 Recommended functional safety actions 158 Cleaning the interior of the cabinet 159 Cle...

Page 11: ...ngs for special settings in the drive control program 184 High speed mode 185 Derating for output voltage boosting 185 400 V and 500 V drive types 185 575 V and 690 V drives 187 Fuses IEC 188 Fuses UL...

Page 12: ...fles for option H381 in 800 mm wide Rittal VX25 enclosure 212 External control unit 19 Example circuit diagrams 213 Contents of this chapter 213 Example circuit diagram 20 The Safe torque off function...

Page 13: ...es 232 Derating 232 Description installation and technical data of the sine filters 22 Step by step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide encl...

Page 14: ...14...

Page 15: ...ou 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 hazar...

Page 16: ...ng device Use the designated lifting points See the dimension drawings Incorrect lifting can cause danger or damage Obey the local laws and regulations applicable to lifting such as requirements for p...

Page 17: ...eways tilt of 5 degrees Do not leave the module unattended on a sloping floor 1 2 3 To prevent the drive module from falling attach its top lifting lugs with chains to the cabinet 1 before you push th...

Page 18: ...make sure that no dangerous situations can occur These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation m...

Page 19: ...dangerous external voltages from the control circuits After you disconnect power from the drive always wait 5 minutes to let the intermediate circuit capacitors discharge before you continue 3 Protec...

Page 20: ...ns or after peeling off and collecting dust in time cause arcing or block the cooling air flow Note The motor cable terminals of the drive are at a dangerous voltage when the input power is on regardl...

Page 21: ...ions Connect the power cable shields to protective earth PE terminals of the drive to make sure of personnel safety Make a 360 grounding of the power and control cable shields at the cable entries to...

Page 22: ...e functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN 61800 5 1 s...

Page 23: ...al safety precautions page 18 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...

Page 24: ...24...

Page 25: ...intenance work on the drive or create instructions for the end user of the drive concerning the installation and maintenance of the drive Read the manual before working on the drive You are expected t...

Page 26: ...rs page 169 Only intact units can be started up Examining the installation site page 65 Examine the installation site Attach the base of the cabinet to the floor Ambient conditions page 195 Routing th...

Page 27: ...terminals option 0H371 and IP20 shrouds option 0B051 Electrical installation page 99 Manuals for any optional equipment Install the additional components into the cabinet for example main PE busbar ma...

Page 28: ...ional thermistor 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 si...

Page 29: ...r control panels installation guide 3AXD50000015612 FSO 12 safety functions module user s manual 3AXD50000015614 FSO 21 safety functions module user s manual 3AXD50000158638 FSPS 21 PROFIsafe safety f...

Page 30: ...30...

Page 31: ...4 is a regenerative drive module for controlling asynchronous AC induction motors permanent magnet motors AC induction servomotors and ABB synchronous reluctance motors SynRM motors The drive includes...

Page 32: ...tifies three phase AC current to direct current for the intermediate DC link of the drive The line side converter can transfer energy from the electrical power system to the drive DC link and vice ver...

Page 33: ...er up the DC link capacitors smoothly Discharged capacitors cannot be connected to the full supply voltage The voltage must be increased gradually until the capacitors are charged and ready for normal...

Page 34: ...er module connected to the drive module C Pedestal 7 Clear plastic shrouds attached 1 Busbars for connecting the LCL filter module to the drive module 8 Circuit board compartment 2 Cover on busbar con...

Page 35: ...module output power cabling 2 External control unit 16 Clear plastic shroud to be attached on top of the drive module entry for top cabling 3 Control panel 17 Upper back clear plastic shroud 4 Control...

Page 36: ...le to the LCL filter module 24 Fiber optic cables for connecting the control unit to the drive module INU ZBIB QOIA 11 Lifting lugs 25 PE ground terminal 12 Connector for charging circuit switch or co...

Page 37: ...hed to the drive cabinet 8 Side guides 2 Output power cabling panel to be attached to the drive cabinet 9 Output power cabling panel 3 Front cover 10 Top guide plate 4 Handle 11 Pedestal guide plate 5...

Page 38: ...d compartment 3 Base attaching screws 12 Output cable connection busbars T1 U2 T2 V2 T3 W2 4 Pedestal guide plate 13 Common mode filter option E208 5 Telescopic extraction and insertion ramp 14 Pedest...

Page 39: ...nel bus Control of several units from one control panel page 113 For the use of the control panel see the firmware manual or ACx AP x Assistant control panels user s manual 3AUA0000085685 English For...

Page 40: ...ype designation key page 41 1 2 3 Connector for the FSO xx safety functions module X12 The module can be installed on or above the control unit see Installing the FSO xx safety functions module page 1...

Page 41: ...rs 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...

Page 42: ...bling area Not to be used with option H381 0B051 EMC filter for 1st environment TN grounded system category C2 Available for ACS880 14 xxxx 3 and 5 types only E202 Common mode filter E208 EMC filter f...

Page 43: ...000 Crane control program N5050 Winch control program N5100 Centrifuge control program N5150 PCP Progressive Cavity Pump control program N5200 Rod pump control program N5250 Cooling tower control prog...

Page 44: ...Description Code Finnish R706 French R707 Spanish R708 Portuguese R709 Russian R711 Chinese R712 Polish R713 Turkish R714 44 Operation principle and hardware description...

Page 45: ...uction Basic requirements for the cabinet construction are listed below Make sure that cabinet frame is sturdy enough to carry the weight of the components control circuitry and other equipment instal...

Page 46: ...inum can also be used Note Before joining aluminum busbars remove the oxide layer and apply suitable anti oxidant joint compound Shrouds The installation of shrouds touch protection to fulfill applica...

Page 47: ...the components to ensure sufficient cooling Observe the minimum clearances given for each component see the technical data Air inlets and outlets Equip the air inlets and outlets with gratings that a...

Page 48: ...ired for cooling and recommended filter material if used Note The heat dissipated by cables and other additional equipment must also be ventilated The internal cooling fans of the converter modules an...

Page 49: ...e cabinet cool air inlet in the lower part of the front door and an extra exhaust fan on the roof of the cabinet Prevent hot air circulation inside the cabinet with for example leak proof air baffles...

Page 50: ...ion Usually reliable strips are made of flexible silicon mass covered with a metal mesh The non tightened touch contact of the metal surfaces is not sufficient so a conductive gasket between the surfa...

Page 51: ...trol cable shields at their entries The shields can be grounded by means of conductive shielding cushions pressed against the cable shield from both directions as shown below 3 4 5 1 1 2 2 2 Tightenin...

Page 52: ...e cabinet with a sealed bottom plate and cable entries to ensure the degree of protection and to prevent the cooling air flow from the cable channel into the cabinet Cabinet side view with a bottom pl...

Page 53: ...P 02 03 mounting platform for control panels installation guide 3AXD50000308484 DPMP 04 and DPMP 05 mounting platform for control panels installation guide 3AXD50000289561 DPMP 06 07 mounting platform...

Page 54: ...54...

Page 55: ...cabinet The chapter gives cabinet layout examples and free space requirements around the module for cooling These guidelines are essential for the safe and trouble free use of the drive system Instal...

Page 56: ...filter module and other equipment on the cabinet roof An exhaust fan if needed 3 Fan required for IP20 IP42 or IP54 air outlet kit has to be ordered separately See Cooling fans page 177 9 Drive contro...

Page 57: ...the recirculation of hot air page 60 2a Drive module control unit 10 2b External control cables 11 Optional air baffle that is needed when there is no fan on the lower part of the cabinet door See se...

Page 58: ...ate the cool and hot areas leak proof lead throughs See section Preventing the recir culation of hot air page 60 2 External control cables 11 Optional air baffle that is needed when there is no fan on...

Page 59: ...elow shows typical cabinet cooling solutions The air inlet is at the bottom of the cabinet while the outlet is on the roof or on the upper part of the door Use extra exhaust fans if the air outlet is...

Page 60: ...2a 7 3 2c L1 U1 L2 V1 L3 W1 2b C C 3 4 B B A A 3 4 Disconnector and fuses 5 Air flow to the drive modules max 40 C 104 F 1 Contactor 6 Vertical air baffle that separates the cool and hot areas in the...

Page 61: ...e cabinet For the descriptions see the next page 1 8 C C 2a 2c B B A A 2c 3 2a 2a 2d x 2e 2d 3 2b 2b y 2e D D x y 2b 2b 2c 2d 2b 2b PE T3 W2 T2 V2 T1 U2 5 6 3 9 2a 7 3 2d 2e L1 U1 L2 V1 L3 W1 2b D D C...

Page 62: ...needed when there is no fan on the lower part of the cabinet door 2e Drive module 3 Bookshelf mounting option H381 See Installation example with full cabling panels option H381 page 139 Required free...

Page 63: ...free space for cooling is required on the left and right hand sides of the module The module can be installed in a cabinet with the following dimensions width 800 mm 31 50 in depth 600 mm 23 62 in hei...

Page 64: ...64...

Page 65: ...ient conditions page 195 for the allowed ambient conditions and section Losses cooling data and noise page 190 for the required cooling air Moving and unpacking WARNING Obey the safety instructions of...

Page 66: ...pages Center of gravity symbol 5 Package for LCL filter fan 6 Package for LCL filter pedestal 7 Telescopic extraction installation ramp 8 Package for option H370 Full size input power cable connectio...

Page 67: ...rol unit 21 Package with option E202 A B A 5 6 3AXD50000174287_091117 4 13 14 2 10 7 12 10 17 15 22 11 18 21 1 20 19 16 3 6 8 5 Transport package contents With standard drive module configuration Clea...

Page 68: ...stic bag control panel and cable or control panel with door mounting kit option J410 delivery documents printed multilingual installation and start up quick guides Other printed manuals with option R7...

Page 69: ...the drive module 6 Cardboard box bottom 7 Cardboard box cover 8 Rubber grommet 9 Strap 10 Support bracket 11 Output connection terminals box with standard drive module configuration 3AXD5000009515 2...

Page 70: ...Input cable connection terminal L3 W1 3 Input cable connection terminal L2 V1 4 Input cable connection terminal L1 U1 5 Cardboard box 6 Screws and insulators in a plastic bag 7 Ramp box 3AXD500004761...

Page 71: ...for IGBT LCL connection 3 pcs 3 Cardboard box 4 Installation bracket 2 pcs 5 Feed through 2 pcs 6 LCL filter module package 3AXD50000113651 1 2 5 4 3 7 8 6 VCI bag 1 Plywood support 2 Lid for cardboar...

Page 72: ...e Lifting Lift the drive module only by the lifting lugs Attaching the drive module and LCL filter module to a mounting plate or wall Attach the LCL filter module and the drive module to wall or a mou...

Page 73: ...00 mm wide enclosure page 233 Grounding the drive module and the LCL filter module Ground the drive module and the LCL filter module from the fastening points Installing the drive in Rittal VX25 enclo...

Page 74: ...ittal VX25 800 mm wide enclosure page 233 Drive module without full size output cable connection terminals option 0H371 and IP20 shrouds option 0B051 The power cables can be connected directly to the...

Page 75: ...disconnecting device You must equip the drive with a main supply disconnecting device which meets the local safety regulations You must be able to lock the disconnecting device to the open position fo...

Page 76: ...Code Other regions The disconnecting device must conform to the applicable local safety regulations Examining the compatibility of the motor and drive Use asynchronous AC induction motors permanent m...

Page 77: ...ly erode the bearing races and rolling elements du dt filters protect motor insulation system and reduce bearing currents Common mode filters mainly reduce bearing currents Insulated N end non drive e...

Page 78: ...dard 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...

Page 79: ...00 V 500 V Un 600 V or N CMF N or CMF Reinforced LL 1800 V N du dt CMF du dt N du dt Reinforced LL 1800 V 600 V Un 690 V N CMF N CMF Reinforced LL 2000 V 0 3 micro second rise time1 1 If the intermedi...

Page 80: ...s higher than what is stated for the particular frame size in EN 50347 2001 This table shows the requirements for protecting the motor insulation and bearings in drive systems for ABB random wound mot...

Page 81: ...ermediate 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 Additio...

Page 82: ...tallation select a cable rated for at least 70 C 158 F maximum permissible temperature of conductor in continuous use For North America select a cable rated for at least 75 C 167 F Note For drives wit...

Page 83: ...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 conducto...

Page 84: ...10 mm2 8 AWG Cu or motors up to 30 kW 40 hp Yes with phase conductor smaller than 10 mm2 8 AWG Cu PVC Note Shielded or armored cable or cabling in metal conduit is always recommended to minimize radi...

Page 85: ...hield can be evaluated based on the shield inductance which must be low and only slightly dependent on frequency The requirements are easily met with a copper or aluminum shield armor Cross section of...

Page 86: ...ese installations inherently have an increased chance for nuisance problems due to the potential for water moisture in the conduit Water moisture in the conduit increases the likelihood of VFD faults...

Page 87: ...air cable is also acceptable a b Signals in separate cables Run analog and digital signals in separate shielded cables Do not mix 24 V DC and 115 230 V AC signals in the same cable Signals that can be...

Page 88: ...o not run extra cables through the drive Make sure that the cable trays have good electrical bonding to each other and to the grounding electrodes Aluminum tray systems can be used to improve local eq...

Page 89: ...t 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...

Page 90: ...The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary Depending on a drive parameter value the function either monitors a calculat...

Page 91: ...pay special attention to the installation and placement of the breakers Obey the manufacturer s instructions Protecting the drive against thermal overload The drive has overload protection as standard...

Page 92: ...he drive digital and analog inputs 3 You can connect the sensor to the drive via an option module The sensor and the module must form a double or reinforced insulation between the motor live parts and...

Page 93: ...round fault protective function to protect the unit against ground faults in the motor and motor cable This function is not a personnel safety or a fire protection feature See the firmware manual for...

Page 94: ...steps are low enough not to cause voltage transients that would trip the drive 3 Make sure that the power factor compensation unit is suitable for use in systems with AC drives ie harmonic generating...

Page 95: ...never open the output contactor while the drive controls the motor The DTC motor control operates extremely fast much faster than it takes for the contactor to open its contacts When the contactor st...

Page 96: ...when motor is connected direct on line S42 Switching the motor power supply from drive to direct on line 1 Stop the drive and the motor with the drive control panel stop key drive in the local control...

Page 97: ...n switched off The relay contacts on the drive control unit are protected with varistors 250 V against overvoltage peaks In spite of this it is highly recommended that inductive loads are equipped wit...

Page 98: ...98...

Page 99: ...sional do not do installation or maintenance work Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Grounding the motor cable shield at...

Page 100: ...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...

Page 101: ...t the varistor is not suitable for If you do the varistor circuit can be damaged WARNING Do not install the drive on a corner grounded or midpoint grounded delta system Disconnecting the EMC filter an...

Page 102: ...t in the same cubicle with the drive module 1 If a shielded cable is used not required but recommended and the conductivity of the shield is 50 of the conductivity of the phase conductor use a separat...

Page 103: ...rame must be connected to the cabinet frame See Grounding of mounting structures page 46 and section Grounding the drive module and the LCL filter module page 73 9 Note If there is a symmetrically con...

Page 104: ...pare the ends of the cables PE PE WARNING Apply grease to stripped aluminum conductors before attaching them to non coated aluminum cable lugs Obey the grease manufacturer s instructions Aluminum alum...

Page 105: ...n coated aluminum cable lugs Obey the grease manufacturer s instructions Aluminum aluminum contact can cause oxidation in the contact surfaces 1 Run the motor cables from the motor to the cabinet Grou...

Page 106: ...ontrol panel holder from the external control unit 1 Disconnect the control panel cable from connector X13 on the control unit 2 Loosen the mounting screws of the control panel holder and take the hol...

Page 107: ...delivered with the drive module for connecting the drive module and control panel to the external control unit are shown below 1 2 ZBIB INU STO STO1 X7 BPOW 1100 mm 43 31 in 1250 mm 49 21 in BGDR STO...

Page 108: ...es to the drive module 1 Connect power supply cable to terminal X2 2 Connect the STO cable to the INU STO connector 3 Connect the fiber optic cables to the QOIA V8 V13 V2 and V7 connectors ZBIB QOIA V...

Page 109: ...ISU ZBIB V20 V21 2 1 X7 STO1 INU STO X8 STO2 X3 X2 V2 V2 V1 V7 V21 V8 V22 V13 Attaching the external control unit The drive control unit can be attached on a mounting plate or onto a DIN rail Electri...

Page 110: ...the control unit onto the screws and tighten the screws 3AUA0000130997 1 2 Attaching the external control unit vertically on a DIN rail 1 Attach the latch A to the back of the control unit with three...

Page 111: ...l control unit horizontally on a DIN rail 1 Attach the latches A to the back of the control unit with three screws 2 Click the control unit to the rail as shown below B A A B B 3AUA0000130997 Electric...

Page 112: ...also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points Tighten the screws to secure the connection 3 Connect the conductors...

Page 113: ...to give a descriptive name to the drive Use parameter 49 01 to assign the drive with a unique node ID number Set other parameters in group 49 if necessary Use parameter 49 06 to validate any changes T...

Page 114: ...With twin connectors in the control panel holder 1 2 3 1 114 Electrical installation...

Page 115: ...With FDPI 02 modules OPEN TERMIN ATED 1 1 2 2 OPEN TERMINATED 3 Electrical installation 115 11...

Page 116: ...iagnostics and panel interface installed onto the motor side converter control unit X1 1 X2 Daisy chain bus terminal 1 RJ 45 shielded female connector for connecting a control panel X2 X204 X3 Daisy c...

Page 117: ...control unit X1 1 X2 Daisy chain bus terminal 1 RJ 45 shielded female connector for connecting a control panel X2 X204 X3 Daisy chain bus terminal 2 RJ 45 shielded female connector for connecting to...

Page 118: ...her by inserting the control panel into the 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...

Page 119: ...or fulfilling the EMC requirements and for proper operation of the module 6 Connect the FSO xx data cable to FSO xx connector X110 7 Connect the Safe torque off four wire cable to connector X111 on th...

Page 120: ...work 2 Insert the module carefully into its position on the control unit 3 Tighten the grounding screw torque of 0 8 N m Note The screw tightens the connections and grounds the module It is essential...

Page 121: ...l unit 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 9 External co...

Page 122: ...unit When the ZCU is controlling a supply unit de energizing the inputs will stop the unit but will not constitute a true safety function XSTO Connection for FSO xx safety functions module inverter un...

Page 123: ...t 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...

Page 124: ...rrent 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 126 4 See section DIIL...

Page 125: ...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 requi...

Page 126: ...the connection of safety circuits The input is parametrized to stop the unit when the input signal is lost Note This input is NOT SIL or PL certified The XD2D connector The XD2D connector provides an...

Page 127: ...que off function page 215 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...

Page 128: ...2 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 curren...

Page 129: ...ire 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 includi...

Page 130: ...IL 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 d...

Page 131: ...l the drive module in a 800 mm wide Rittal TS 8 enclosure see revision B of this manual Limitation of liability The installation must always be designed and made according to applicable local laws and...

Page 132: ...3AUA0000125203 IP20 3AUA0000114968 IP42 Customer made parts not ABB or Rittal products See section Air baffles page 210 4 Air baffles See section Bottom plate page 209 1 Bottom plate Required tools S...

Page 133: ...ing the drive module and LCL filter module into a Rittal VX25 enclosure page 235 Tasks Step Mechanical accessories Attach the plinth to the floor 1 Attach the enclosure frame to the plinth 2 Make the...

Page 134: ...ing on its back 19 Unfasten the extraction installation ramp and attach the drive module to the bottom plate 20 LCL filter module and drive module attachments and intermediate electrical connections A...

Page 135: ...g the shrouds See Connecting the input power cables and installing the shrouds page 243 Tasks input cables Step Ground the input cable shields if present 360 degrees at the enclosure entry 1 Connect t...

Page 136: ...shroud and the upper front cover of the drive module 12 Install the entry clear plastic shroud and motor cable shroud 13 Install the top clear plastic shroud to the drive module 14 Installing the air...

Page 137: ...al parts This drawing shows a layout tested by ABB Door 1 Install these gratings as close to each other as possible Remove the filter mats 2 Installation example of the standard drive module configura...

Page 138: ...he cooling air cannot flow freely through the module and the drive will run to overtemperature WARNING Remove the protective covering from the top of the LCL filter module after the installation If th...

Page 139: ...Limitation of liability The installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which br...

Page 140: ...age 176 1 SZ DK 7967 000 one set four pieces additional spacers Punched section without mounting flange for 800 mm horizontal 1 VX 8617 140 one set four pieces Air filter 323 mm 323 mm Remove the filt...

Page 141: ...the plinth to the floor 2 Attach the enclosure frame to the plinth 3 Make the bottom plate with 360 degree grounding entries for power cables Attach the bottom plate to the enclosure frame 4 Attach t...

Page 142: ...4 5 6 3 3 1 1 1 1 2 142 Installation example with full cabling panels option H381...

Page 143: ...ple of this chapter the disconnecting device is not in the same cubicle with the drive module 1 If a shielded cable is used not required but recommended and the conductivity of the shield is 50 of the...

Page 144: ...extra wear Power cable connection procedure WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Run the motor cables from the m...

Page 145: ...of the input power cabling panel B 360 degree grounding at the entry plate for the output power cables C Grounding busbar of the output power cabling panel D Allowed space for power cables E Note The...

Page 146: ...e floor and during installation and maintenance work Open the support legs by pressing each leg a little down and turning it aside 1 2 When ever possible secure the module also with chains from top Do...

Page 147: ...ers of the drive module M4 8 combi screws 2 N m 1 48 lbf ft 4 Connect the busbars of the drive module to the busbars of the cabling panels M12 combi screw 70 N m 52 lbf ft 5 Attach the enclosure roof...

Page 148: ...onnecting the drive module to the cabling panels 3AXD50000248919 1 2 Combi screw M12 25 hex delta or equal 9 pcs 1 Extraction insertion ramp 3AXD50000476374 2 148 Installation example with full cablin...

Page 149: ...egree of protection for the drive module install the input power cables through the rubber grommet Install the grommet as follows 1 Cut adequate holes into the grommet for the input power cables 2 Put...

Page 150: ...150 Installation example with full cabling panels option H381...

Page 151: ...RNING Stop the drive and do the steps in section Electrical safety precautions page 18 before you start the work Make sure that The ambient operating conditions meet the drive ambient conditions speci...

Page 152: ...ected to the correct terminals the phase order is correct and the terminals are tightened to the correct torque There is an adequately sized protective earth ground conductor between the motor and the...

Page 153: ...nd motor See Quick start up guide for ACS880 drives with primary control program 3AUA0000098062 English or ACS880 primary control program firmware manual 3AUA0000085967 English If you need more inform...

Page 154: ...ocedure page 223 7 For drive modules with an FSO xx safety functions module options Q972 and Q973 Test and validate the operation of the safety functions See the delivery specific circuit diagrams and...

Page 155: ...dule with option J410 When the LED is lit Color LED Where Control unit is powered and 15 V is supplied to the control panel Green POWER Control panel mounting platform Drive in fault state Red FAULT W...

Page 156: ...156...

Page 157: ...and ambient conditions ABB recommends annual drive inspections to ensure the highest reliability and optimum performance Note Long term operation near the specified maximum ratings or ambient conditi...

Page 158: ...10 and R11 LONG LIFE Aging R R R ZCU control unit battery real time clock R R Control panel battery real time clock 4FPS10000239703 Recommended functional safety actions Functional safety actions I Sa...

Page 159: ...a vacuum cleaner with antistatic hose and nozzle and wear a grounding wristband Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Stop the drive and do the ste...

Page 160: ...om ABB Do not use other than ABB specified spare parts Replacing the auxiliary cooling fans of the drive module WARNING Obey the safety instructions of the drive If you ignore them injury or death or...

Page 161: ...e new fan in reverse order Make sure that the arrow in the fan points up 7 Reset the counter if used in group 5 in the primary control program 2 3 5 4 6 Replacing the drive module main cooling fans WA...

Page 162: ...to both FAN1 PWR1 and FAN2 PWR2 7 Reset the counter if used in group 5 in the primary control program 2 3 4 5 Replacing the LCL filter module cooling fan WARNING Obey the safety instructions of the dr...

Page 163: ...mage to the equipment can occur Handle the drive module carefully Use safety shoes with a metal toe cap to prevent foot injury Lift the drive module only by the lifting lugs Make sure that the module...

Page 164: ...control unit to the drive module page 107 5 Disconnect the cooling fan power supply cable from the LCL filter module Pull the cable inside the drive module 6 Remove the screws that attach the drive m...

Page 165: ...10 Adjust the extraction installation ramp to the correct height and attach it to the cabinet base with the two mounting screws Maintenance 165...

Page 166: ...e LCL filter module in the same way as the drive module Replacing the drive module with option H381 WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to th...

Page 167: ...e input cabling panel Combi screw M12 70 N m 52 lbf ft 4 Disconnect the drive module busbars from the output cabling panel Combi screw M12 70 N m 52 lbf ft 5 Remove the front air baffle 6 See Step by...

Page 168: ...the drive module 2 Undo the screws that attach the LCL filter module to the enclosure frame 3 Attach the extraction ramp to the enclosure base with two screws 4 To prevent the LCL filter module from f...

Page 169: ...ibrary https library abb com en Control panel For detailed information on the control panel see ACx AP x assistant control panels user s manual 3AUA0000085685 English Cleaning the control panel Use a...

Page 170: ...ical safety precautions page 18 before you start the work 2 Remove the M4 8 T20 screws at the ends of the control unit 3 To see the battery remove the XD2D terminal block 4 Carefully lift the edge of...

Page 171: ...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 control unit is powered WARNING Obey the saf...

Page 172: ...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...

Page 173: ...s available from ABB All other parts must be sourced from a third party by the system integrator ACS AP W and ACS AP I control panel Illustration Ordering code Description Type 3AXD50000025965 Control...

Page 174: ...Cotrol panel mounting platform DPMP 04 Output du dt filters See section du dt filters page 231 Sine filters See section Sine filters page 232 EMC filter ARFI 10 Ordering code 68241561 Cabinet ventilat...

Page 175: ...ng code Kit code Enclosure width Degree of protection 3AUA0000117009 A 8 X 026 800 mm IP42 Instruction code 3AUA0000116875 3AXD50000009186 A 8 X 029 800 mm IP54 Instruction code 3AXD50000010001 Orderi...

Page 176: ...800 mm IP20 Instruction code 3AXD50000001982 Note Fan to be ordered separately 3AUA0000114967 A 4 X 060 2 800 mm IP42 Instruction code 3AUA0000115290 Note Fan to be ordered separately 3AXD50000009187...

Page 177: ...rdering code Qty Component Enclosure width Degree of protection Data Name 3AXD50000000514 2 R2E225 RA92 17 230 V Fan 800 mm IP20 IP42 3AXD50000000882 2 MSB MKP 3 5 603 E1679 Capacitor 3AXD50000000723...

Page 178: ...e cable connection terminals for input power cables 3AXD50000019544 1 Full size cable connection terminals for output power cables 3AXD50000019538 2 For frame R11 IP20 shrouds for covering the input a...

Page 179: ...e ACS880 14 Heavy duty use Light duty use Nominal use PHd IHd PLd ILd Sn Pn I2 Imax I1 kW A kW A kVA kW A A A Un 400 V 110 206 132 234 170 132 246 350 212 R11 246A 3 132 246 160 278 203 160 293 418 25...

Page 180: ...355 370 400 420 514 400 430 520 375 R11 430A 7 3AXD00000588487 UL NEC RATINGS Output ratings Max current Input current Frame size ACS880 14 Heavy duty use Light duty use App power PHd IHd PLd ILd Sn I...

Page 181: ...ent The power ratings apply to most IEC 34 motors at the nominal voltage of the drive ABB recommends to select the drive motor and gear combination for the required motion profile with the DriveSize d...

Page 182: ...0 85 0 90 0 80 Derating factor 1 00 Derating factor 0 95 Derating factor 0 90 Derating factor 0 85 Derating factor 0 80 Deratings for special settings in the drive control program Enabling special se...

Page 183: ...199 132 212 162 205 132 216 171 217 132 228 240A 5 210 216 160 229 216 222 160 234 228 235 160 247 260A 5 227 300 200 318 234 309 200 325 247 326 200 343 361A 5 315 343 250 365 325 354 250 373 343 37...

Page 184: ...Light duty use Nominal use Fre quency IHd ILd Pn In fmax IHd ILd Pn In f A A kW A Hz A A kW A Hz Un 400 V 170 193 110 201 500 206 234 132 246 120 246A 3 203 229 132 240 500 246 278 160 293 120 293A 3...

Page 185: ...500 V drive types This drawing shows the required derating for 3 and 5 400 V and 500 V drive types 0 80 0 85 0 90 0 95 1 00 1 10 1 05 1 00 0 95 0 90 0 85 0 80 0 75 0 70 P Pn U Un 0 875 0 975 0 70 0 7...

Page 186: ...ply voltage 690 V increase the DC voltage to 690 V 2 1 03 1005 V Input voltage of the drive U Nominal supply voltage of the drive For 3 types Un 400 V for 5 types Un 500 V For 7 types Un 690 V but 575...

Page 187: ...00 800 455 503A 5 Un 690 V 1 170M4409 690 21000 250 123 142A 7 1 170M4410 690 42000 315 149 174A 7 2 170M5408 690 74000 400 186 210A 7 2 170M5410 690 145000 500 232 271A 7 3 170M6410 690 210000 630 29...

Page 188: ...0 170M4010 690 315 149 174A 7 2 170M5308 170M5608 170M5008 690 400 186 210A 7 2 170M5310 170M5610 170M5010 690 500 232 271A 7 3 170M6310 170M6610 170M6010 690 630 293 330A 7 3 170M6311 170M6611 170M60...

Page 189: ...mm in mm 355 161 19 9 506 12 0 305 57 6 1462 R11 Optional selection H381 full power cabling panels Weight Depth Width Height Frame size lb kg in mm in mm in mm 432 196 20 3 516 12 9 329 62 62 1590 R1...

Page 190: ...279 2100 R11 585A 3 75 14200 1279 2100 R11 650A 3 Un 500 V 75 5280 1279 2100 R11 240A 5 75 6400 1279 2100 R11 260A 5 75 8000 1279 2100 R11 302A 5 75 8000 1279 2100 R11 361A 5 75 10000 1279 2100 R11 41...

Page 191: ...CM or 2 2 0 300 MCM or 2 1 0 3 3 50 2 3 70 271A 7 600 MCM or 2 4 0 or 3 1 0 400 MCM or 2 2 0 2 3 120 2 3 50 330A 7 700 MCM or 2 4 0 or 3 2 0 500 MCM or 2 3 0 2 3 150 3 3 70 370A 7 2 300 MCM or 3 3 0 7...

Page 192: ...4 xxxx 3 drive modules 380 415 VAC 3 phase 10 15 This is indicated in the type designation label as typical input voltage level 3 400 V AC Voltage U1 ACS880 14 xxxx 5 drive modules 380 500 V AC 3 phas...

Page 193: ...100 THDi Indicates the total magnitude of the voltage distortion This value is defined as the ratio in of the harmonic voltage to the fundamental non har monic voltage THDv 40 2 n 2 U U1 100 THDv Shor...

Page 194: ...se depends on the motor cable length and characteristics Contact ABB for more information Note that a sine filter optional at the drive output also causes a voltage decrease DC connection data Capacit...

Page 195: ...181 40 70 C 40 158 F 40 70 C 40 158 F 15 55 C 5 131 F No frost allowed See When is derating neces sary page 181 Surrounding air temperature Max 95 Max 95 5 95 Relative humidity No condensation allowed...

Page 196: ...e 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 c...

Page 197: ...ings These markings are attached to the drive CE mark Product complies with the applicable European Union legislation For fulfilling the EMC requirements see the additional information concerning the...

Page 198: ...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 cate...

Page 199: ...filter capacitors which may cause danger or damage to the unit Category C3 The drive complies with the standard with the following provisions 1 The drive is equipped with EMC filter E210 2 The motor...

Page 200: ...d configuration for a power drive system 3AFE61348280 English 3 The motor and control cables are selected and routed according to the electrical planning guidelines of the drive The EMC recommendation...

Page 201: ...it breakers These protective devices provide branch circuit protection in accordance with the national regulations National Electrical Code NEC or Canadian Electrical Code Obey also any other applicab...

Page 202: ...measures such as but not limited to the installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network i...

Page 203: ...Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules with optional parts for Rittal VX25 enclosure 18 Dimension drawings 203...

Page 204: ...Standard configuration 204 Dimension drawings...

Page 205: ...Location of power cable connection terminals with options H370 H356 3AXD50000038012 Dimension drawings 205...

Page 206: ...Drive module with options 0B051 H356 0H371 206 Dimension drawings...

Page 207: ...Configuration with option H381 3AXD50000323210 Dimension drawings 207...

Page 208: ...LCL filter module 208 Dimension drawings...

Page 209: ...Bottom plate This drawing shows the dimensions of the bottom plate for 800 mm Rittal VX25 enclosure It is not an ABB product Dimension drawings 209...

Page 210: ...00 mm Rittal VX25 enclosure These are not ABB products 3AXD50000453931 REAR FRONT LEFT RIGHT Material of the air baffles 0 75 mm polycabonate PC film LEXAN FR60 GE with UL94 V 0 listing UV stability L...

Page 211: ...ide Rittal VX25 enclosure This drawing shows the dimensions of the air baffles for the full cabling panels option H381 in 800 mm Rittal VX25 enclosure These are not ABB products 3AXD50000453931 REAR F...

Page 212: ...External control unit 3AXD50000011687 212 Dimension drawings...

Page 213: ...cabinet installed drive module Example circuit diagram This diagram is an example for the main wiring of a drive cabinet Note that the diagram includes components which are not included in a basic de...

Page 214: ...1 ACS AP W control panel 2 ZCU control unit 3 Main contactor 4 Motor temperature supervision 5 Switch fuse disconnector 6 Common mode filter 7 du dt filter or sine filter 8 Drive module 9 Input and o...

Page 215: ...s of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage of the power semiconductors of the drive output stage A...

Page 216: ...d 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...

Page 217: ...ed 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 fi...

Page 218: ...ingle drive internal power supply Dual channel connection 24 V OUT 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 218 The Safe torque off functi...

Page 219: ...n 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 wir...

Page 220: ...ower 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 220 Th...

Page 221: ...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 t...

Page 222: ...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 remova...

Page 223: ...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 option Q972 Q973 or Q982 also do the proced...

Page 224: ...cuit If the motor was running it should coast to a stop The drive generates a FA81 Safe Torque Off 1 loss fault indication see the firmware manual Give a start command to verify that the STO function...

Page 225: ...hen 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 synchronous re...

Page 226: ...egrity requirement for the safety function is SIL 2 HFT 1 or PL d cat 3 the proof test for the function must be performed at least every 12 months The STO function of the drive does not contain any el...

Page 227: ...unction 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...

Page 228: ...n requested A fault exclusion on the failure mode short circuit on printed circuit board has been made EN 13849 2 table D 5 The analysis is based on an assumption that one failure occurs at one time N...

Page 229: ...bility IEC 61508 SC Safe failure fraction IEC 61508 SFF Safety integrity level 1 3 IEC 61508 SIL Maximum SIL level 1 3 that can be claimed for a safety function or subsystem IEC EN 62061 SILCL Safe to...

Page 230: ...Declaration of conformity 230 The Safe torque off function...

Page 231: ...S880 14 Un 690 V Un 500 V Un 400 V FOCH0260 7x 142A 7 FOCH0260 7x 240A 5 FOCH0260 7x 246A 3 FOCH0260 7x 174A 7 FOCH0260 7x 260A 5 FOCH0260 7x 293A 3 FOCH0260 7x 210A 7 FOCH0320 5x 302A 5 FOCH0320 5x 3...

Page 232: ...B84143V0207S230 174A 7 B84143V0230S229 260A 5 B84143V0390S229 293A 3 B84143V0207S230 210A 7 B84143V0390S229 302A 5 B84143V0390S229 363A 3 B84143V0207S230 271A 7 B84143V0390S229 361A 5 B84143V0390S229...

Page 233: ...module power cable connection diagram page 233 Installing the drive module and LCL filter module into a Rittal VX25 enclosure page 235 Connecting the motor cables and installing the shrouds page 240...

Page 234: ...G The UDC and UDC terminals of the drive module must not be used for any other than optional external brake chopper connection INPUT OUTPUT ACS880 14 U1 V1 W1 3 M E P E P E P 3 4 5 6 7 9 L1 L2 L3 L1 L...

Page 235: ...e See instructions in section Installing the drive module and LCL filter module into an enclosure page 133 Rittal 8806 000 Rittal 8617 140 1705 5 67 15 Tapping screw M6 12 Torx T30 8 N m 71 lbf in 360...

Page 236: ...Combi screw M8 30 Hex 20 N m 14 75 lbf ft Tapping screw M6 12 Torx T30 Hex 8 N m 71 lbf in 8 10 9 11 12 236...

Page 237: ...Combi screw M4 8 Torx T20 2 N m 18 lbf in Combi screw M4 8 Torx T20 2 N m 18 lbf in Combi screw M4 8 Torx T20 2 N m 18 lbf in 15 16 18 17 17 14 19 237...

Page 238: ...Combi screw M8 24 N m 17 70 lbf ft Combi screw M8 24 N m 17 70 lbf ft M6 Serpress 8 N m 71 lbf in Screw M10x30 and washer M6 Serpress 8 N m 71 lbf in 21 21 22 23 23 238...

Page 239: ...Combi screw M4 8 Torx T20 2 N m 18 lbf in Combi screw M4 8 Torx T20 2 N m 18 lbf in Combi screw M12 25 70 N m 52 lbf ft M10 30 FAN3 LCL 25 24 26 239...

Page 240: ...Connecting the motor cables and installing the shrouds See instructions in section Connecting the motor cables and installing the shrouds page 134 240...

Page 241: ...241...

Page 242: ...Combi screw M6 20 Torx T25 2 N m 18 lbf in Combi screw M6 20 Torx T25 2 N m 18 lbf in Combi screw M4 10 Torx T20 2 N m 18 lbf in 15 16 13 14 10 11 12 242...

Page 243: ...ds See instructions in section Connecting the input cables and installing the shrouds page 135 Hex screw M12 35 full thread 70 N m 52 lbf ft Hex nut M12 70 N m 52 lbf ft L3 W1 L2 V1 L1 U1 UDC L3 W1 L2...

Page 244: ...Combi screw M4 10 Torx T20 2 N m 18 lbf in Combi screw M4 10 Torx T20 2 N m 18 lbf in Combi screw M6 20 Torx T25 2 N m 18 lbf in L3 W1 L2 V1 L1 U1 UDC UDC 12 13 14 244...

Page 245: ...Installing the air baffles and removing the cardboard covers See instructions in section Installing the air baffles page 136 245...

Page 246: ...246...

Page 247: ...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 man...

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