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ABB ACS880-34, Hardware Manual

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ABB ACS880-34 Hardware Manual Download Page 155

Start-up   155

For drives with ATEX-certified Safe motor disconnection function using the drive Safe torque off 
function (Q971), see 

ACS880 ATEX-certified Safe disconnection function application guide

 

(3AUA0000132231 [English]).
For drives with ABB motors in explosive atmospheres, see also 

ACS880 drives with ABB motors in 

explosive atmospheres

 (3AXD50000019585 [English]).

For drive modules with an FSO-12 safety functions module (option): Test and validate the operation 
of the safety functions. See the delivery-specific circuit diagrams and 

FSO-12 safety functions 

module user’s manual 

(3AXD50000015612 [English]).

Action

Summary of Contents for ACS880-34

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 34 drive modules 132 to 400 kW 200 to 450 hp Hardware manual ...

Page 2: ...00212453 ACX AP x Assistant control panels user s manual 3AUA0000085685 Drive firmware manuals and guides ACS880 primary control program firmware manual 3AUA0000085967 Quick start up guide for ACS880 drives with primary control program 3AUA0000098062 ACS880 IGBT supply control program firmware manual 3AUA0000131562 Option manuals and guides DPMP 01 mounting platform for ACS AP control panel instal...

Page 3: ...ual ACS880 34 drive modules 132 to 400 kW 200 to 450 hp 3AXD50000035191 Rev B EN EFFECTIVE 2018 09 28 2018 ABB Oy All Rights Reserved 1 Safety instructions 6 Installation instructions Table of contents 12 Start up ...

Page 4: ......

Page 5: ...6 3 Operation principle and hardware description Contents of this chapter 29 Operation principle 29 Block diagram of the main circuit of the drive module 30 Line side converter 30 AC voltage and current waveforms 31 Charging 31 Motor side converter 31 DC connection 31 Layout 32 Standard drive module configuration 32 Converter module 33 LCL filter module 34 Power module with full power cabling pane...

Page 6: ...ion Contents of this chapter 57 Selecting the supply disconnecting device 58 European Union 58 Other regions 58 Selecting the main contactor 58 Examining the compatibility of the motor and drive 58 Protecting the motor insulation and bearings 59 Requirements table 59 Additional requirements for explosion safe EX motors 61 Additional requirements for ABB motors of types other than M2_ M3_ M4_ HX_ a...

Page 7: ...d by the FSO safety functions module options Q972 and Q973 71 Declaration of Conformity 71 Implementing the Power loss ride through function 71 Using power factor compensation capacitors with the drive 72 Implementing a safety switch between the drive and the motor 72 Using a contactor between the drive and the motor 73 Protecting the contacts of relay outputs 73 Connecting a motor temperature sen...

Page 8: ...Controlling several drives from one control panel through panel bus 97 Connecting a PC 98 7 External control unit Contents of this chapter 99 Layout 100 Removing the control panel holder from the external control unit 101 Attaching the control cable clamp plate 102 Connecting the external control unit to the drive module 103 External control unit connection cables 103 Routing the control unit cabl...

Page 9: ...s chapter 131 Limitation of liability 131 Safety 131 Required parts 132 Required tools 132 Overall flowchart of the installation process 132 Installing the drive module and LCL filter module into a cabinet 133 Connecting the power cables and installing the shrouds 134 Installing the roof and door Rittal parts 136 10 Installation example with full cabling panels option H381 Contents of this chapter...

Page 10: ...ntervals after start up 160 Cabinet 160 Cleaning the interior of the cabinet 160 Heatsink 161 Cleaning the interior of the heatsink 161 Cleaning the interior of the LCL filter 161 Fans 162 Replacing the auxiliary cooling fans of the drive module 162 Replacing the drive module main cooling fans 164 Replacing the LCL filter module cooling fan 165 Replacing the standard drive module 166 Replacing the...

Page 11: ...ns weights and free space requirements 192 Losses cooling data and noise 192 Terminal and entry data for the power cables 193 Units with optional cabling panels H381 193 Units without full size output cable connection terminals 0H371 and with a common mode filter E208 193 Terminal data for the control cables 193 Electrical power network specification 193 Motor connection data 194 DC connection dat...

Page 12: ...ivation switch 219 Cable types and lengths 219 Grounding of protective shields 219 Single drive internal power supply 220 Dual channel connection 220 Single channel connection 220 Multiple drives internal power supply 221 Multiple drives external power supply 222 Operation principle 223 Start up including acceptance test 223 Competence 223 Acceptance test reports 223 Acceptance test procedure 223 ...

Page 13: ...ions and weights 236 Ordering codes 237 Terminals and cable entry data 237 21 du dt and sine filters Contents of this chapter 239 du dt filters 239 When is a du dt filter needed 239 Selection table 239 Ordering codes 240 Description installation and technical data of the FOCH filters 240 Sine filters 240 When is a sine filter needed 240 Selection table 240 ABB ordering codes 240 Derating 240 Descr...

Page 14: ...14 ...

Page 15: ...mage to the equipment They also tell 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 Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment General warning tells about conditions other than those caused by electricity which can cau...

Page 16: ... little down 1 2 and turning it aside Whenever possible secure the module also with chains Do not tilt the drive module A It is heavy and its center of gravity is high The module overturns from a sideways tilt of 5 degrees Do not leave the module unattended on a sloping floor Do not use the module installation ramp with plinth heights which exceed the maximum height marked on the ramp The maximum ...

Page 17: ...atic restart functions of the drive control program 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 must be clearly marked as defined in IEC EN 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY The maximum number of drive power ...

Page 18: ...on is not possible Lock the disconnectors to open position and attach a warning notice to them Disconnect any external power sources from the control circuits before you do work on the control cables After you disconnect the drive always wait for 5 minutes to let the intermediate circuit capacitors discharge before you continue 3 Protect any other energized parts in the work location against conta...

Page 19: ... at a dangerous voltage when the input power is on regardless of whether the motor is running or not The DC bus terminals UDC UDC are at a dangerous voltage External wiring can supply dangerous voltages to the terminals of relay outputs XRO1 XRO2 and XRO3 of the drive control units The Safe torque off function does not remove the voltage from the main and auxiliary circuits The function is not eff...

Page 20: ...ivity of the grounding conductors is sufficient See section Selecting the power cables on page 63 Obey the local regulations Connect the power cable shields to protective earth PE of the drive to make sure of personnel safety Make a 360 grounding of the power and control cable shields at the cable entries to suppress electromagnetic disturbances In a multiple drive installation connect each drive ...

Page 21: ... any mechanical connection like felt nip rope etc Measure that the installation is de energized Use a multimeter with an impedance of at least 1 Mohm Make sure that the voltage between the drive output terminals T1 U2 T2 V2 T3 W2 and the grounding PE busbar is close to 0 V Make sure that the voltage between the drive input power terminals L1 U1 L2 V1 L3 W1 and the grounding PE busbar is close to 0...

Page 22: ...22 Safety instructions ...

Page 23: ...al installation of the drive cabinet connection of power and control cables to the cabinet installed drive and maintenance of the drive Read the manual before working on the drive You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Categorization by fr...

Page 24: ...acitors page 171 Check the installation site Fasten the base of the cabinet to the floor Checking the installation site page 77 Ambient conditions page 196 Guidelines for planning the cabinet installation page 43 Route the cables Routing the cables page 67 Check the insulation of the supply cable the motor and the motor cable and the resistor cable if present Checking the insulation of the assembl...

Page 25: ...B051 Install the additional components into the cabinet for example main PE busbar main disconnector main contactor main AC fuses etc Install the drive module into the cabinet Connect the power cabling between the drive module and the rest of the main circuit components in the cabinet if any Connect the input power cables and motor cables to the drive cabinet Connect the DC connection cables if an...

Page 26: ...er control interface to the drive The line side converter control unit controls the line side converter DTC Direct torque control EMC Electromagnetic compatibility EMI Electromagnetic interference FAIO 01 Optional analog I O extension module FCAN 01 Optional CANopen adapter module FCNA 01 Optional ControlNet fieldbus adapter module FDCO 0x Optional optical DDCS communication module FDIO 01 Optiona...

Page 27: ...side converter The part of the Cross reference_lc Drive that converts DC to AC for the motor The motor side converter is also capable of feeding energy from a decelerating motor into the DC link PLC Programmable logic controller QOIA Optical interface adapter board RFI Radio frequency interference SAFUR Series of optional brake resistors STO Safe torque off QOIA Optical interface adapter board TN ...

Page 28: ...28 Introduction to the manual ...

Page 29: ...his chapter This chapter describes the operating principle and construction of the drive module Operation principle The ACS880 34 is a low harmonic drive module for controlling asynchronous AC induction motors permanent magnet motors AC induction servomotors and ABB synchronous reluctance motors SynRM motors ...

Page 30: ...ide converter part The line side converter is controlled by a type ZCU control unit located inside the drive module 1 Charging circuit contactor 2 Charging circuit 3 Line contactor 4 LCL filter 5 Line side converter 6 DC link DC circuit between the line side converter and motor side converter 7 Motor side converter 8 Common mode filter option E208 1 LCL filter contactor 2 LCL filter 3 Line side co...

Page 31: ...ected to the full supply voltage The voltage must be increased gradually until the capacitors are charged and ready for normal use The drive contains a resistive charging circuit consisting of fuses contactor and charging resistors The charging circuit is in use after start up until the DC voltage has risen to a predefined level Motor side converter The motor side converter converts the DC back to...

Page 32: ...Cooling fan cassette C LCL filter module connected to the converter module 6 Support legs 1 Clear plastic shrouds attached 7 Pedestal 2 Circuit board compartment 8 Busbars for connecting the LCL filter module to the converter module 3 Upper front cover 9 Cover on busbar connections See the next page for descriptions and photos of the external control unit and converter module For LCL filter module...

Page 33: ...or top cabling 16 External control unit The control unit can also be inside the drive module option P905 4 Upper back clear plastic shroud 17 Control panel 5 Lower back clear plastic shroud 18 Control cable clamp plate 6 Front clear plastic shroud 19 Cables for connecting the control unit to the drive module ZBIB INU STO and 24VDC power 7 Input power cable connection terminals option H370 20 Busba...

Page 34: ...es for connecting the control unit to the drive module INU ZBIB QOIA 24 Cover When removed you can attach the drive module to the LCL filter module 12 PE ground terminal 25 Lifting lugs 13 Main cooling fans 26 Connector for charging circuit switch or contactor 1 Busbars for connecting the LCL filter module to the drive module electrically 4 Pedestal guide plate for the LCL filter module 2 Handle 5...

Page 35: ... panel to be attached to the drive cabinet 3 Output power cabling panel 10 Front cover 4 Top guide plate 11 Internal control unit option P905 and control panel holder mounted on the drive module option J414 5 Pedestal guide plate 12 Handle 6 Telescopic extraction and insertion ramp 13 Lifting lugs 7 Rubber grommet 14 Auxiliary cooling fan another auxiliary cooling fan is located below the circuit ...

Page 36: ...t board compartment 11 Main cooling fans 4 Output cable connection busbars T1 U2 T2 V2 T3 W2 12 Base attaching screws 5 Common mode filter option E208 13 Pedestal guide plate 6 Pedestal 14 Telescopic extraction and insertion ramp 7 Retractable support legs 15 Connector for charging circuit switch or contactor 8 Handle for pulling the drive module 16 Cover When removed you can attach the drive modu...

Page 37: ... control panel see the firmware manual or ACX AP x Assistant control panels user s manual 3AUA0000085685 English In the standard drive module configuration the control panel is located in the control panel holder of the external control unit The control panel can be mounted on the cabinet door using a DPMP 01 mounting platform option J410 or a DPMP 02 mounting platform option J413 When the control...

Page 38: ...age 39 4 Connector for the FSO xx safety functions module X12 The module can be installed on or above the control unit see page 112 or 125 5 Memory unit see page 172 6 I O terminal blocks See the layout on page 100 or 120 and default I O connection diagram on page 108 or 123 7 Control panel see page 96 8 Fiber optic link to the motor side converter Similarly the line side converter is connected to...

Page 39: ...ns are available for all types 11 Motor side converter 12 Socket for external ISU control not required for normal operation of the drive 13 Brake chopper optional see page 229 14 Brake resistors optional see page 229 1 Type designation see section Type designation key on page 39 2 Manufacturing address 3 Frame size 4 Cooling method 5 Degree of protection 6 Ratings see section 7 Short circuit withs...

Page 40: ...e drive module can be pulled from the cabinet for maintenance without disconnecting the power cables Degree of protection IP20 Not to be used with options 0B051 and 0H371 0P919 No installation ramp Control panel and control unit P905 Internal drive control unit attached to the power module 0J400 No control panel and no control panel holder Note You need at least one loose control panel to be able ...

Page 41: ...le Requires option Q971 Control program N7502 Enables setting of synchronous reluctance motor parameters in the drive control program Programmability N8010 Drive application programming CODESYS Safety Q971 ATEX certified Safe motor disconnection function using the drive Safe torque off function Q972 FSO 21 safety functions module Q973 FSO 12 safety functions module Q982 PROFIsafe with FSO xx safet...

Page 42: ...42 Operation principle and hardware description ...

Page 43: ...cal laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Installation positions of the drive module The drive module must be installed in an upright bookshelf or flat position in a cabinet Basic requirements for the cabinet Use a cabinet which has a frame sturdy enough to carry the weight of the drive componen...

Page 44: ...out to ensure easy installation and maintenance Sufficient cooling air flow obligatory clearances cables and cable support structures all require space Place the control board s away from main circuit components such as contactors switches and power cables hot parts heat sink air outlet of the drive module ...

Page 45: ...ffle is used on the cabinet roof see page 47 6 Operating handle of the disconnector 3 Air outlet for the drive module and LCL filter module and other equipment on the cabinet roof An exhaust fan if needed 7 Rubber grommets for degree of protection 4 Drive control panel with DPMP 01 mounting platform option J410 The control panel is connected to the drive module control unit inside the cabinet 8 Ro...

Page 46: ...the cabinet door see 1b on page on 44 10 Drive module control unit Note With an internal control unit option P905 the upper door air inlet is critical for proper cooling of the control board 3 Cabinet grounding busbar PE 11 External control cables 4 Input power cable including the protective 12 Grounding screws ground conductor PE of the drive 13 Alternative to grounding screws 11 5 Disconnector a...

Page 47: ...nternal control unit option P905 the upper door air inlet is critical for proper cooling of the control board 2e Optional air baffle that is needed when there is no fan on the lower part of the cabinet door see 1b on page on 44 11 External control cables 3 Cabinet grounding busbar PE 12 Grounding screws 4 Input power cable including the protective ground conductor PE of the drive 13 Alternative to...

Page 48: ...ing when you use busbars Tin plated copper is recommended but aluminum can also be used The oxide layer from aluminum busbar joints must be removed and suitable anti oxidant joint compound applied Tightening torques Apply the following torques to grade 8 8 screws with or without joint compound that tighten electric contacts Planning the fastening of the cabinet Note the following when you plan the...

Page 49: ...binet structure is 100 mm 3 94 in Pay special attention to the cooling air inlet and outlet gratings The best galvanic connection between the steel panels is achieved by welding them together as no holes are necessary If welding is not possible we recommend to leave the seams between the panels unpainted and equipped with special conductive EMC strips to provide adequate galvanic connection Usuall...

Page 50: ... and ambient temperature requirements of the drive module are met see pages 192 and 196 The internal cooling fan of the drive module rotates at a constant speed thus blowing constant air flow through the module Whether the same amount of air must be replaced all the time in the facility depends on how much heat must be removed Leave enough free space around the components to ensure sufficient cool...

Page 51: ...cooling solutions The air inlet is at the bottom of the cabinet while the outlet is on the roof on the upper part of the door Use extra exhaust fans if the air outlet is on the cabinet door see page 192 for the required cooling air flow The internal cooling fans of the power and LCL filter modules are usually sufficient to keep the component temperatures low enough in IP22 cabinets In IP54 cabinet...

Page 52: ...inlet air to the cabinet is taken Possible solutions are listed below gratings that guide air flow at the air inlet and outlet air inlet and outlet at different sides of the 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 No gaskets are usually requi...

Page 53: ...sconnector and fuses 2a Vertical air baffle that separates the cool and hot areas in the cabinet 6 Contactor 2b Horizontal air baffle 7 Drive control unit 2c Optional air baffle that is needed when there is no fan on the lower part of the cabinet door see 2 on page 44 8 Air flow out 3 Drive module 9 Cabinet grounding busbar PE 4 LCL filter module 1 8 B B 2a 2b 2a 2a 2c 3 2c 2b A A C C 2b PE T3 W2 ...

Page 54: ...is diagram shows air baffle positions inside an example 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 C 4 A A 2c B B 4 3 4 2c 2b 2d 2a ...

Page 55: ... around the drive module is required from the cabinet back panel and front door No free space for cooling is required on the left and right hand sides of the module 1 Air flow to the drive module max 40 C 104 F 4 LCL filter module 2a Vertical air baffle that separates the cool and hot areas in the cabinet 5 Disconnector and fuses 2b Vertical air baffle 6 Contactor 2c Upper horizontal air baffle 7 ...

Page 56: ...le option J414 The control panel can be mounted onto the cabinet door using a control panel mounting platform options J410 and J413 For the installation instructions refer to DPMP 01 mounting platform for ACS AP control panel 3AUA0000100140 English or DPMP 02 mounting platform for ACS AP X control panel 3AUA0000136205 English Planning the use of cubicle heaters Use a cubicle heater if there is a r...

Page 57: ...ons cable routing and way of operation for the drive system 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 breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not obeyed the drive can experience proble...

Page 58: ...nal voltage and current of the drive Examining the compatibility of the motor and drive Use an asynchronous AC induction motor permanent magnet motor AC induction servomotor or ABB synchronous reluctance motor SynRM motor with the drive Several induction motors can be connected at a time Select the motor size and drive type from the rating tables in chapter Technical data on basis of the AC line v...

Page 59: ...rings Requirements table The following table shows how to select the motor insulation system and when optional ABB du dt filters insulated N end non drive end motor bearings and ABB common mode filters are required Failure of the motor to fulfill the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the motor warranty Motor type Nominal A...

Page 60: ...inforced ÛLL 1800 V du dt N N du dt CMF Reinforced ÛLL 2000 V 0 3 microsecond rise time N CMF N CMF If the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking check with the motor manufacturer if additional output filters are needed in the applied drive operation range Abbreviation Definition UN Nominal AC line voltage ÛLL Peak line to line voltage ...

Page 61: ...s is higher than what is stated for the particular frame size in EN 50347 2001 This table shows the requirements for ABB random wound motor series for example M3AA M3AP and M3BP Additional requirements 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 The table below shows the requiremen...

Page 62: ...er can be replaced with a sine filter The peak phase to phase voltage with the sine filter is approximately 1 5 UN Additional note for common mode filters Common mode filters are available as plus code option E208 600 V UN 690 V Reinforced ÛLL 1800 V N du dt CMF Reinforced ÛLL 2000 V 0 3 microsecond rise time N CMF If the intermediate DC circuit voltage of the drive is increased from the nominal l...

Page 63: ... A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended Compared to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation bearing currents and wear The protective conductor must always have an adequate conductivity Unless local wiring regulations ...

Page 64: ... 293A 3 3 3 95 3 3 150 2 500 MCM or 3 250 MCM 2 700 MCM or 3 350 MCM 363A 3 3 3 95 3 3 150 2 500 MCM or 3 250 MCM 2 700 MCM or 3 350 MCM 505A 3 3 3 95 3 3 150 2 500 MCM or 3 250 MCM 2 700 MCM or 3 350 MCM 585A 3 3 3 95 3 3 150 2 500 MCM or 3 250 MCM 2 700 MCM or 3 350 MCM 650A 3 3 3 120 3 3 185 2 600 MCM or 3 300 MCM 3 400 MCM or 4 250 MCM 725A 3 3 3 150 3 3 240 2 700 MCM or 3 350 MCM 3 400 MCM or...

Page 65: ...ance Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield A separate PE conductor is required if the shield does not agree with the requirements of EC 61800 5 1 see page 63 Symmetrical shielded cable with three phase conductors and symmetrically constructed PE conductor and a shield The PE conductor must agree with the requirements of EC 61800 5 1 see page...

Page 66: ...is accepted for up to 500 V AC 1000 V AC cable is required above 500 V AC below 600 V AC For drives rated over 100 amperes the power cables must be rated for 75 C 167 F Conduit Couple separate parts of a conduit together bridge the joints with a ground conductor bonded to the conduit on each side of the joint Also bond the conduits to the drive enclosure and motor frame Use separate conduits for i...

Page 67: ...ld be run as twisted pairs Relay cable type The cable type with braided metallic screen for example ÖLFLEX by LAPPKABEL Germany has been tested and approved by ABB Control panel cable length and type In remote use the cable connecting the control panel to the drive must not exceed three meters 10 ft Cable type shielded CAT 5e or better Ethernet patch cable with RJ 45 ends Routing the cables Route ...

Page 68: ...tors connection boxes or similar equipment are installed on the motor cable between the drive and the motor European Union Install the equipment in a metal enclosure with 360 degree grounding for the shields of both the incoming and outgoing cable or connect the shields of the cables otherwise together US Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding...

Page 69: ...sed with circuit breakers Protecting the motor and motor cable in short circuits The drive protects the motor cable and motor in a short circuit situation when the motor cable is dimensioned according to the nominal current of the drive No additional protection devices are needed Protecting the drive and the input power and motor cables against thermal overload The drive protects itself and the in...

Page 70: ...mpatibility The drive is suitable to be used with residual current devices of Type B Note The EMC filter of the drive includes capacitors connected between the main circuit and the frame These capacitors and long motor cables increase the ground leakage current and can cause fault current circuit breakers to function Connecting drive modules to a common DC system Do not connect the drive module to...

Page 71: ...rcuit and configuration of the FSO module are the responsibility of the machine builder The FSO module reserves the standard Safe torque off STO connection of the drive control unit STO can still be utilized by other safety circuits through the FSO For wiring instructions safety data and more information on the functions provided by the options see FSO 12 safety functions module user s manual 3AXD...

Page 72: ...a high power capacitor to the power line while the drive is connected The connection will cause voltage transients that may trip or even damage the drive 2 If capacitor load is increased decreased step by step when the AC drive is connected to the power line ensure that the connection steps are low enough not to cause voltage transients that would trip the drive 3 Check that the power factor compe...

Page 73: ...ol operates extremely fast much faster than it takes for the contactor to open its contacts When the contactor starts opening while the drive controls the motor the DTC control will try to maintain the load current by immediately increasing the drive output voltage to the maximum This will damage or even burn the contactor completely Protecting the contacts of relay outputs Inductive loads relays ...

Page 74: ...ctrical installation Install the protective component as close to the inductive load as possible Do not install protective components at the relay outputs 1 Relay outputs 2 Varistor 3 RC filter 4 diode 230 V AC 230 V AC 24 V DC 1 2 3 4 ...

Page 75: ...ouble or reinforced insulation between the motor live parts and the drive control unit See section Connection of motor temperature sensor to the drive via an option module page 75 4 You can connect the sensor to a digital input of the drive via a relay internal option or customer s external relay The sensor and the relay must form a double or reinforced insulation between the motor live parts and ...

Page 76: ...00 5 1 basic insulation can be achieved when there is basic insulation between the sensor and live parts of the motor Circuits connected to all motor protection relay inputs and outputs must be protected against direct contact Example circuit diagram See page 215 FAIO 01 Basic insulation between sensor connector and drive control unit connector No insulation between sensor connector and other I O ...

Page 77: ...re not a qualified electrical professional do not do the installation work described in this chapter Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur Checking the installation site The material below the drive must be non flammable and strong enough to carry the weight of the drive See section Ambient conditions on page 19...

Page 78: ...follows see the package drawing on page 78 Cut the straps Lift the lid Lift the sleeve Unpack the top boxes drive module package Insert lifting hooks to the drive LCL filter module lifting eyes and lift the module to the installation place Package drawings Drive module package without option E202 Transport package contents 1 Finger guard 2 Pedestal guide plate for the LCL filter module 3 Pedestal ...

Page 79: ...H370 also Input cable connection terminals box See below for the box contents 13 Lid for sleeve 14 Cardboard sleeve 15 17 Cardboard support 18 Pallet 19 Strap 20 VCI film or bag 21 Drive module with factory installed options and multilingual residual voltage warning sticker fastening screws in a plastic bag internal control unit with control cable clamp plate and factory installed optional modules...

Page 80: ...l unit 7 Package EMC filter ARFI 10 option E202 8 Package for LCL filter fan 9 Package for LCL filter pedestal 10 Telescopic extraction and insertion ramp 11 Package for option H370 Full size input power cable connection terminals and PE busbar 12 Plywood support 13 With standard drive module configuration Clear plastic shrouds box and output cable connection terminals box With option H370 also In...

Page 81: ... guides and manuals CD Other printed manuals with option R700 3AXD50000009484 3 4 8 7 1 12 10 6 2 5 9 11 14 13 15 Shroud box with standard drive module configuration 1 Paper fill 2 Clear plastic shroud for output cabling 3 Cardboard box cover 4 Cardboard box bottom 5 Support 6 Bands 7 Back clear plastic shroud lower 8 Back clear plastic shroud upper 9 Front clear plastic shroud 10 Clear plastic sh...

Page 82: ...put power cabling panel and the drive module 7 Cardboard box bottom 8 Cardboard box cover 9 Rubber grommet 10 Strap 11 Support bracket 12 Top guide 3AXD5000009515 2 6 7 5 4 3 1 Output connection terminals box with standard drive module configuration 1 Paper fill 2 Output cable connection terminal T3 W2 3 Output cable connection terminal T2 V2 4 Output cable connection terminal T1 U2 5 Grounding te...

Page 83: ... shroud with ground bar 2 Paper fill 3 Input cable connection terminal L3 W1 4 Input cable connection terminal L2 V1 5 Input cable connection terminal L1 U1 6 Cardboard box 7 Screws and insulators in a plastic bag 3AXD50000166787 1 2 3 Ramp box 1 Screw package 2 Telescopic extraction and insertion ramp 3 Cardboard box ...

Page 84: ...rdboard support 6 Pallet 7 Strap 8 LCL filter 1 3AXD50000229734 3 4 2 Accessories box 1 Screw package includes also spacers for FSO module installation 2 Rubber grommets for control unit cable entry holes in the middle front cover of the drive module 3 Bracket for attaching the drive module from top 4 Cardboard box 3AXD50000113651 8 ...

Page 85: ...d Ground the motor cable shield 360 degrees at the entry of the motor terminal box Checking the insulation of the assembly Drive Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive Every drive has been tested for insulation between the main circuit and the chassis at the factory Also there are voltage limiting circuits inside th...

Page 86: ...f other motors consult the manufacturer s instructions Note Moisture inside the motor casing will reduce the insulation resistance If you suspect moisture dry the motor and repeat the measurement Brake resistor and resistor cable Check the insulation of the brake resistor assembly if present as follows 1 Stop the drive and do the steps in section Precautions before electrical work on page 18 befor...

Page 87: ...ilter E202 connected to a system that the filter is not suitable for This can cause danger or damage the drive Note When the EMC filter is disconnected the drive EMC compatibility is considerably reduced Ground to phase varistor A drive with the ground to phase varistor connected can be installed to a symmetrically grounded TN S system If you install the drive to another system you may need to dis...

Page 88: ... varistor capacitor leakage current will cause the residual current device to trip Frame size Symmetrically grounded TN systems TN S systems 1 Corner grounded and midpoint grounded delta systems 2 IT systems ungrounded or high resistance grounded 30 ohms 3 R11 Do not disconnect EMC AC or VAR screws Do not disconnect ARFI 10 Do not install the drive on a corner grounded or mid point grounded system...

Page 89: ...ct power to the drive 1 input voltage line to line UL L 2 input voltage 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 line to ground voltages in relation to the line to line voltage of the electrical power system types are shown below 3AXD10000681917 UL L UL1 G UL2 G UL3 G Electrical power system type X 0 58 X 0 58 X 0 58 X Symmetrically g...

Page 90: ...C filter and ground to phase varistor EMC AC and varistor VAR grounding wires are located at the top of the circuit board compartment Disconnect them 1 and attach them with the nearby plastic clamp 2 Remove the ARFI 10 filter from the cabinet 1 2 ...

Page 91: ... by step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet on page 243 Attaching the drive module to the LCL filter module See chapter Step by step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet on page 243 Attaching the drive module and the LCL filter module to the cabinet base See chapt...

Page 92: ...tal TS cabinet For an installation example on how to install the drive module with clear plastic shrouds into a Rittal TS 8 cabinet see chapter Installation example of the standard drive module configuration on page 131 and Step by step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet on page 243 ...

Page 93: ...uds option 0B051 The power cables can be connected directly to the drive module input and output terminals with cable lugs or by busbars The drive module can also be installed self standing on the floor in an electrical equipment room when the power cable terminals and electrical parts are protected against contact and the drive module is grounded properly Installing the EMC filter option E202 See...

Page 94: ...a or a cable with a grounding conductor 2b 3 We recommend 360 degree grounding at the cabinet entry if a shielded cable is used Ground the other end of the input cable shield or PE conductor at the distribution board 4 We recommend 360 degree grounding at the cabinet entry see page 49 5 Use a separate grounding cable if the conductivity of the cable shield is 50 of the conductivity of the phase co...

Page 95: ... 6 Twist the cable shields of the input cables into bundles and connect them and any separate ground conductors or cables to the drive module ground terminal or to the cabinet PE busbar 7 Connect the phase conductors of the input cables to terminals L1 U1 L2 V1 and L3 W1 of the drive module For the tightening torques see page 193 8 Brake chopper option Run the power cables from the brake chopper t...

Page 96: ...l control unit and control panel holder mounted on the drive module option J414 put the control panel on the control panel holder With door mounting kit option J410 connect the control panel to the control unit as follows 1 Connect an Ethernet cable to the RJ 45 connector of the control panel 2 Connect the other end of the cable to the X13 connector of the control unit ...

Page 97: ...s in group 49 if necessary Use parameter 49 06 to validate any changes Repeat the above for each drive 2 With the panel connected to one drive link the drives together using Ethernet cables Each panel platform has two connectors 3 In the last drive switch bus termination on by moving the terminating switch into the outer position Termination should be off on all other drives 4 On the control panel...

Page 98: ...To connect a PC to the control panel with a USB data cable USB Type A USB Type Mini B 1 Lift the USB connector cover on the control panel from bottom upwards 2 Insert the USB cable Mini B plug in the control panel USB connector 3 Insert the USB cable A plug in the USB connector of the PC a The panel displays USB connected b Note 1 When a PC is connected to the control panel the control panel keypa...

Page 99: ...xternal control unit instructions on how connect the external control unit to the drive module instructions on how connect the control cables to the terminals of the control unit default I O connection diagram with descriptions of the terminals Instruction on how to install option modules technical data for the external control unit ...

Page 100: ...ock connection DIIL and 24 V output XDIO Digital input outputs XDI Digital inputs XSTO Safe torque off connection X12 Connector for optional safety functions modules X13 Control panel connection Slot 1 Option module Slot 2 Option module Slot 3 Option module X205 Memory unit J1 J2 Voltage Current selection jumpers J1 J2 for analog inputs J3 Drive to drive link termination jumper J6 Common digital i...

Page 101: ...ng the control 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 holder off 1 X13 X13 2 2 2 2 ...

Page 102: ... the top or base of the control unit with four screws as shown below Note If you install the FSO xx safety functions module above the control unit fasten the control cable clamp plate on the base of the control unit See section Installing the FSO safety functions module option Q973 on page 112 0 7 N m 6 2 lbf in ...

Page 103: ...le itself Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt Routing the control unit cables into the drive module Route the control unit connection cables to the drive module through the slot in the middle front cover at the front or left side First remove the plate which covers the slot Then install the rubber grommet from the accessories box item 2 i...

Page 104: ...r 3 Connect the fiber optic cables to the QOIA V8 V13 V2 and V7 connectors In the control unit 1 Pull the fiber optic power supply and STO cables through the hollow back frame of the control unit 2 Connect the cables to the ZBIB terminals QOIA ZBIB X7 STO1 X7 STO1 X8 STO2 X8 STO2 X2 X3 V2 V2 V7 V1 V8 V21 V13 V22 INU ZBIB V1 V2 ISU ZBIB V20 V21 2 1 V8 V13 ISU panel QOIA V2 V7 INU STO X2 ISU ext 24V...

Page 105: ... control unit can be fastened on a mounting plate through the fastening holes in its back or by using a DIN rail Mounting the external control unit to wall 1 Fasten the fastening screws in the wall 2 Lift the unit onto the screws and tighten the screws 3aua0000130997 1 2 ...

Page 106: ...k of the control unit with three screws 2 Click the control unit to the rail as shown below B Mounting the control unit horizontally on a DIN rail 1 Fasten 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 3aua0000130997 A A B B A A B B 3aua0000130997 ...

Page 107: ... fastened with a screw at the clamp plate Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacitor eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points Tighten the screws to secure the connection 3 Connect the conductors to the appr...

Page 108: ...D Drive to drive link termination 6 ON OFF Drive to drive link Shield 4 BGND 3 A 2 B 1 Safe torque off XSTO Safe torque off Both circuits must be closed for the drive to start IN2 4 IN1 3 SGND 2 OUT 1 Digital inputs XDI By default not in use DI6 6 Constant speed 1 select 1 on 5 DI5 5 Acceleration deceleration select 4 DI4 4 Reset DI3 3 Forward 0 Reverse 1 DI2 2 Stop 0 Start 1 DI1 1 Digital input o...

Page 109: ...ned by parameter 22 26 6 Must be set to ON when the drive is the last unit on the drive to drive XD2D link 7 Determines whether DICOM is separated from DIOGND ie common reference for digital inputs floats See also Ground isolation diagram on page 117 DICOM connected to DIOGND DICOM and DIOGND separate 8 See section DIIL input XD24 1 on page 111 External power supply for the control unit External 2...

Page 110: ...EC 60664 the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfill the requirement the I O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I O terminals 1 Set the input type to voltage with switch J...

Page 111: ...ication implemented by application programming See the firmware manual of the drive for the related parameter settings Set termination activation jumper J3 next to this terminal block to the ON position on the drives at the ends of the drive to drive link On intermediate drives set the jumper to the OFF position Use shielded twisted pair cable with a twisted pair for data and a wire or another pai...

Page 112: ...order to removing it see section Removing the control panel holder from the external control unit on page 101 Installing optional modules Installing the FSO safety functions module option Q973 Install the FSO safety functions module in Slot 2 of the control unit as described below WARNING Obey the safety instructions in chapter Safety instructions If you ignore them injury or death or damage to th...

Page 113: ... Connect the FSO xx data cable to FSO xx connector X110 7 Connect the Safe torque off four wire cable to connector X111 on the module and to connector XSTO on the drive module control unit 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 FSO 21 safety functions module user ...

Page 114: ...occur 1 Stop the drive and do the steps in section Precautions before electrical work on page 18 before you start work 2 Insert the module carefully into its position on the control unit 3 Tighten the grounding screw to torque of 0 8 N m Note The screw tightens the connections and grounds the module It is essential for fulfilling the EMC requirements and for proper operation of the module Wiring t...

Page 115: ... PNP Hardware filtering 0 04 ms digital filtering up to 8 ms Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 Input output mode selection by parameters DIO1 can be configured as a frequency input 0 16 kHz with hardware filtering of 4 microseconds for 24 V level square wave signal sinusoidal or other wave form cannot be used DIO2 can be configured as a 24 V level square wave frequency output ...

Page 116: ...d twisted pair cable with twisted pair for data and a wire or pair for signal ground nominal impedance 100 165 ohm for example Belden 9842 Transmission rate 9 6 115 2 kbit s Termination by switch Safe torque off connection XSTO Connector pitch 5 mm 0 2 in wire size 2 5 mm2 14 AWG Input voltage range 3 30 V DC Logic levels 0 5 V 1 19 V For the drive to start both connections must be closed OUT1 to ...

Page 117: ... XD24 DIIL 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 Ground Common mode voltage between channels 30 V Ground selector J6 settings ZCU 14 All digital inputs share a common ground DICOM connected to DIOGND This is the default setting ZCU 14 Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO signal groun...

Page 118: ...118 External control unit ...

Page 119: ...ns on how to install the external control unit instructions on how connect the external control unit to the drive module instructions on how connect the control cables to the terminals of the control unit default I O connection diagram with descriptions of the terminals Instruction on how to install option modules technical data for the external control unit ...

Page 120: ... output XDIO Digital input outputs XDI Digital inputs XSTO Safe torque off connection X12 Connector for optional safety functions modules X13 Control panel connection X202 Option slot 1 X203 Option slot 2 X204 Option slot 3 X205 Memory unit connection X208 Auxiliary cooling fan connection J1 J2 Voltage Current selection jumpers J1 J2 for analog inputs J3 J6 Drive to drive link termination jumper J...

Page 121: ...the control cables through the grommet Note If you route the control cables from top or bottom instead of front or side you need tho make holes for the entries to the clear plastic shrouds 6 Ground the control cables at the clamp plate as described in Step 2 in section Connecting the control cables to the terminals of the control unit on page 107 7 Connect the conductors to the appropriate detacha...

Page 122: ...view of a drive module with full cabling panels option H381 is shown below 6 Ground the outer control cable shields 360 degrees at the cabinet entry plate recommendation 7 Ground the control cables at the clamp plate as described in Step 2 in section Connecting the control cables to the terminals of the control unit on page 107 8 Connect the conductors to the appropriate detachable terminals of th...

Page 123: ...250 V AC 30 V DC 2 A 22 COM 23 NO 31 NC Faulted 1 250 V AC 30 V DC 2 A 32 COM 33 NO XD24 Digital interlock 1 DIIL Run enable 2 24VD 24 V DC 200 mA 3 3 DICOM Digital input ground 4 24VD 24 V DC 200 mA 3 5 DIOGN Digital input output ground J6 Ground selection switch XDIO Digital input outputs 1 DIO1 Output Ready 2 DIO2 Output Running XDI Digital inputs 1 DI1 Stop 0 Start 1 2 DI2 Forward 0 Reverse 1 ...

Page 124: ... page 112 for Safety functions module connection X12 Technical data of the connectors Drive to drive link XD2D The drive to drive link is a daisy chained RS 485 transmission line that can be used for basic master follower communication with one master drive and multiple followers fieldbus control through the embedded fieldbus interface EFB and drive to drive D2D communication implemented by applic...

Page 125: ...ot 2 of the control unit as described below WARNING Obey the safety instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Precautions before electrical work on page 18 before you start work 2 If the bottom plate of the FSO xx module looks different from that in the drawing below remove the bo...

Page 126: ...t 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 FSO 21 safety functions module user s manual 3AXD50000015614 English 3 4 5 4 4 4 ...

Page 127: ... 1 Stop the drive and do the steps in section Precautions before electrical work on page 18 before you start work 2 Insert the module carefully into its position on the control unit 3 Tighten the grounding screw to torque of 0 8 N m Note The screw tightens the connections and grounds the module It is essential for fulfilling the EMC requirements and for proper operation of the module Wiring the op...

Page 128: ...pe NPN PNP Hardware filtering 0 04 ms digital filtering up to 8 ms Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 Input output mode selection by parameters DIO1 can be configured as a frequency input 0 16 kHz with hardware filtering of 4 microseconds for 24 V level square wave signal sinusoidal or other wave form cannot be used DIO2 can be configured as a 24 V level square wave frequency o...

Page 129: ...hielded twisted pair cable with twisted pair for data and a wire or pair for signal ground nominal impedance 100 165 ohm for example Belden 9842 Transmission rate 9 6 115 2 kbit s Termination by switch Safe torque off connection XSTO Connector pitch 5 mm 0 2 in wire size 2 5 mm2 14 AWG Input voltage range 3 30 V DC Logic levels 0 5 V 1 17 V For the drive to start both connections must be closed OU...

Page 130: ...OM 32 NO 33 XD24 DIIL 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 Ground Common mode voltage between channels 30 V Ground selector J6 settings ZCU 12 All digital inputs share a common ground DICOM connected to DIOGND This is the default setting ZCU 12 Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO s...

Page 131: ...front facing the cabinet door Available alternative ABB parts are also given Limitation of liability Always obey the general rules given in this chapter and local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches local laws and or other regulations Safety WARNING If you are not a qualified electrical professional do not do the installation work d...

Page 132: ... TS 8612 580 1 Punched section with mounting flange outer mounting level for 800 mm horizontal Contact ABB for the suitable filter 4 Air filter Remove the filter mats Alternative ABB parts for Rittal parts ABB air inlet kit 800 mm 3AUA0000117005 IP20 3AUA0000117009 IP42 2 See section Air inlet kits on page 176 ABB air outlet kit 800 mm 3AUA0000125203 IP20 3AUA0000114968 IP42 2 See section Air outl...

Page 133: ...nsertion ramp to the pedestal guide plate To prevent the LCL filter module from falling attach its lifting lugs with chains to the cabinet frame Push the LCL filter module carefully into the cabinet along the telescopic insertion ramp Work preferably with help from another person as shown below Keep a 3 Attach the drive module and LCL filter module to the cabinet Step by step drawings for an insta...

Page 134: ...tant pressure with one foot on the base of the module to prevent the module from falling on its back Unfasten the insertion ramp and attach the drive module to the bottom plate Attach the LCL filter module and drive module to the punched section Attach LCL filter module to the side of drive module from top and bottom Reinstall the cover Connect the LCL filter busbars to the drive module busbars wi...

Page 135: ...cables to the connected Align the holes in the vertical direction according to the alignment holes in the shroud Smooth the hole edges Remove the plastic sheeting from both sides of the shroud Attach the cables firmly to the cabinet frame to prevent chafing against the hole edges 4 Put the conductors of the input cables through the drilled holes in the clear plastic shroud 5 For drive modules with...

Page 136: ... module configuration Installing the roof and door Rittal parts This drawing shows a layout tested by ABB 1 Door 2 Install these gratings as close to each other as possible Remove the filter mats Rittal 7967 000 3AXD50000310210 2 1 Rittal 3243 200 ...

Page 137: ... additional components can be made by connecting two or more TS8 cabinets together Available alternative ABB parts are also given Limitation of liability Always obey the general rules given in this chapter and local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches local laws and or other regulations Safety WARNING If you are not a qualified elec...

Page 138: ...nels for the cabinet SZ DK 7967 000 one set four pieces additional spacers 1 Spacers for roof plate Alternative ABB roof 3AUA0000125203 IP20 AUA0000114968 IP42 see section Air outlet kits on page 178 TS 8612 560 one set four pieces 1 Punched section with mounting flange outer mounting level for 600 mm horizontal TS 8612 580 one set four pieces 1 Punched section with mounting flange outer mounting ...

Page 139: ...Attach the output cabling panel to the punched sections 4 Install the side guides to the output cabling panel 2 screws for each guide 5 Attach the grounding busbar to the input cabling panel 6 Install the side guides to the input cabling panel 2 screws for each side guide 7 Attach the input cabling panel to the punched sections 8 Install the telescopic extraction and insertion ramp as shown in the...

Page 140: ...140 Installation example with full cabling panels option H381 M8 16 Hex 2 5 4 3 1 1 1 1 2 6 7 ...

Page 141: ...ding conductor 2b 3 We recommend 360 degree grounding at the cabinet entry if a shielded cable is used Ground the other end of the input cable shield or PE conductor at the distribution board 4 Input and output power cabling panels option H381 5 We recommend 360 degree grounding at the cabinet entry see page 49 6 Use a separate grounding cable if the conductivity of the cable shield is 50 of the c...

Page 142: ...lds 360 at the entry plate 6 Twist the cable shields of the input cables into bundles and connect them and any separate ground conductors or cables to grounding busbar of the input cabling panel 7 Connect the phase conductors of the input cables to terminals L1 U1 L2 V1 and L3 W1 of the input cabling panel For the tightening torques see page 193 8 Brake chopper option Connect the conductors to the...

Page 143: ...r of the input power cabling panel C 360 degree grounding at the entry plate for the output power cables D Grounding busbar of the output power cabling panel E Allowed space for power cables Note The input and output power cables must fit inside the area marked with diagonal lines to prevent chafing of the cables when the drive module is inserted into the cabinet C A A B C D 102 mm 4 in L1 U1 L2 V...

Page 144: ... carefully Make sure that the module does not fall down when moving it on the 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 not tilt the drive module A It is heavy and its center of gravity is high The module will overturn from a sideways tilt of ...

Page 145: ...anel to the drive module 3 Remove the upper and lower left hand side front covers of the drive module M4 8 combi screws 2 N m 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 cabinet roof on the spacers 6 Attach the side panels 7 Remove the filter mats from the air filters according to Rittal s instructions Install the fil...

Page 146: ...146 Installation example with full cabling panels option H381 Assembly drawing of connecting the drive module to the cabling panels 3AXD50000248919 ...

Page 147: ...ree 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 the cables through the grommet 3 Attach the grommet to the input cabling panel with five M4x8 Torx T20 screws as shown below ...

Page 148: ...example is shown below Rittal code Qty pcs Description TS 8406 500 1 Enclosure without mounting plate Includes frame door side and back panels TS 8606 5xx 1 Enclosure without mounting plate Includes frame door side and back panels 8800 410 One set 6 Baying clamp for connecting the cabinet frames 8800 430 One set 4 Angular baying bracket for connecting the cabinet frames 8800 860 One set 1 Baying c...

Page 149: ... equipment can occur Check that Cabinet construction The drive module is fastened properly to the cabinet See chapters Guidelines for planning the cabinet installation Installation example of the standard drive module configuration Mechanical joints are tightened and not broken Parts are clean and painted surfaces not scratched The cabinet frame and parts which are in metal to metal contact with t...

Page 150: ...ng an insufficient clearance or loss of shielding against contact The control unit is wired properly to the drive module The control panel cable is connected properly Cables are not lying against sharp edges or bare live parts Bending radius of fiber optic cables is at least 3 5 cm 1 38 in The type markings insulation plates and cross connections of terminal blocks are correct Grounding and protec...

Page 151: ...ge matches the nominal input voltage of the drive Check the type designation label The input power cable has been connected to the appropriate terminals the phase order is right and the terminals have been tightened Pull the conductors to check Appropriate AC fuses and a main disconnector have been installed The motor cable has been connected to the appropriate terminals the phase order is right a...

Page 152: ...152 Installation checklist ...

Page 153: ... the drive module Action Safety WARNING Obey the safety instructions during the start up procedure See chapter Safety instructions on page 15 Only qualified electrical professionals are allowed to start up the drive Checks Settings with no voltage connected Ensure that the disconnector of the supply transformer is locked to the off 0 position ie no voltage is and cannot be connected to the drive i...

Page 154: ...panels user s manual 3AUA0000085685 English For drives with ABB du dt filter check that bit 13 of parameter 95 20 HW options word 1 is switched on For drives with ABB sine filter check that parameter 95 15 Special HW settings is set to ABB sine filter For other sine filters see Sine filter hardware manual 3AXD50000016814 English For drives with a fieldbus adapter module optional Set the fieldbus p...

Page 155: ...3AUA0000132231 English For drives with ABB motors in explosive atmospheres see also ACS880 drives with ABB motors in explosive atmospheres 3AXD50000019585 English For drive modules with an FSO 12 safety functions module option Test and validate the operation of the safety functions See the delivery specific circuit diagrams and FSO 12 safety functions module user s manual 3AXD50000015612 English A...

Page 156: ...156 Start up ...

Page 157: ...ith options J410 Warning and fault messages See the firmware manual for the descriptions causes and remedies of the control program warning and fault messages Where LED Color When the LED is lit Control panel mounting platform POWER Green Control unit is powered and 15 V is supplied to the control panel FAULT Red Drive in fault state ...

Page 158: ...158 Fault tracing ...

Page 159: ...B recommends annual drive inspections to ensure the highest reliability and optimum performance Note Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components Consult your local ABB Service representative for additional maintenance recommendations The tables below shows the maintenance tasks which can be done by th...

Page 160: ...scribed under Grounding on page 20 have been taken into consideration 3 When necessary clean the interior of the cabinet with a soft brush and a vacuum cleaner Action Description I Visual inspection and maintenance action if needed P Performance of on off site work commissioning tests measurements or other work R Replacement of component Action Target P Quality of supply voltage I Spare parts P DC...

Page 161: ...d do the steps in section Precautions before electrical work on page 18 before you start the work 2 Make sure that the drive is disconnected from the power line and all other precautions described under Grounding on page 20 have been taken into consideration 3 Undo the fastening screws of the handle plate of the drive module 4 Remove the handle plate 5 Vacuum the interior of the heatsink from the ...

Page 162: ...ooling fans of the drive module WARNING Obey the safety instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur Fan in the front panel 1 Stop the drive and do the steps in section Precautions before electrical work on page 18 before you start the work 2 Undo the mounting screw of the fan cassette 3 Unplug the power supply cable of the fan...

Page 163: ...page 18 before you start the work 2 Undo the mounting screw of the fan cassette 3 Pull the fan cassette out 4 Unplug the power supply cable of the fan 5 Undo the mounting screws of the fan 6 Install the 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 ...

Page 164: ...the power supply wires of the fans from the connector FAN1 PWR1 and FAN2 PWR2 3 Undo the mounting screws of the fan cassette 4 Pull the fan cassette out 5 Undo the mounting screws of the fan s Note 690 V drive modules have only one fan in the cassette 6 Install the new fans in reverse order For 690 V drive modules connect the fan power supply to connector FAN1 PWR1 For other drive modules connect ...

Page 165: ...before electrical work on page 18 before you start the work 2 Disconnect the power supply wire of the fan from connector FAN3 LCL 3 Undo the attaching screw of the fan cassette 4 Pull the fan cassette out 5 Undo the mounting screws of the fan The finger guard of the fan is attached by the same screws and is removed at the same time Keep the finger guard for reuse 6 Install the new fan in reverse o...

Page 166: ...le A It is heavy and its center of gravity is high The module overturns from a sideways tilt of 5 degrees Do not leave the module unattended on a sloping floor 1 Stop the drive and do the steps in section Precautions before electrical work on page 18 before you start the work 2 Remove the clear plastic shrouds on the power cables and parts in front of the drive module if present 3 Disconnect the p...

Page 167: ...upport legs 8 Remove the screws that connect the drive module to the LCL filter module from top and at the side 9 To prevent the drive module from falling attach its top lifting lugs with chains with chains to the cabinet frame 10 To open the support legs 90 degrees press each leg a little down and turn it aside 11 Adjust the extraction ramp to the correct height and attach it to the cabinet base ...

Page 168: ...he drive module carefully out of the cabinet preferably with help from another person 13 Install the new module in reverse order Replacing the LCL filter module Replace the LCL filter module in the same way as the drive module ...

Page 169: ...and do the steps in section Precautions before electrical work on page 18 before you start the work 2 To remove the left hand side upper and lower front covers of the drive module undoi the fastening screws M4 10 combi screws 2 N m For drive modules with an internal control unit option P905 and control panel option J414 Remove the control panel and the control panel cable from the internal control...

Page 170: ...rive module by undoing the fastening screws below the optional modules and turn the control unit and the cables aside Alternatively remove the clamp plate and disconnect the cables from the control unit 8 To prevent the drive module from falling attach its top lifting lugs with chains to the cabinet frame 9 Pull the drive module carefully out of the cabinet preferably with help from another person...

Page 171: ...lifespan of the capacitor can be prolonged by lowering the ambient temperature It is not possible to predict a capacitor failure The capacitor failure is usually followed by damage to the unit and an input cable fuse failure or a fault trip Contact ABB if a capacitor failure is suspected Replacements are available from ABB Do not use other than ABB specified spare parts Reforming the capacitors If...

Page 172: ... battery holder 6 Close the control unit cover 7 Tighten the M4 8 T20 screws 8 Install the XD2D terminal block Memory unit When a drive module is replaced the parameter settings can be retained by transferring the memory unit from the defective drive module to the new module One memory unit is located in the external control unit see page 38 another on the line side converter control unit WARNING ...

Page 173: ...t slot To remove the memory unit from the line side converter control unit Replacing the line side converter control unit memory unit 1 Stop the drive and do the steps in section Precautions before electrical work on page 18 before you start the work 2 Remove the cover on the memory unit 3 Pull the memory unit out 4 Install the new memory unit in reverse order X205 2 3 ...

Page 174: ...174 Maintenance ...

Page 175: ...er parts must be sourced from a third party by the system integrator For a listing refer to the kit specific installation instructions available at https www151 abb com spaces lvacdrivesengineeringsupport content For access contact your local ABB representative Brake choppers and resistors See section Resistor braking on page 229 Output du dt filters See section du dt filters on page 239 Sine filt...

Page 176: ...uded Enclosure width Degree of protection Kit code Ordering code Illustration 400 mm IP20 A 4 X 021 3AUA0000117002 Instruction code 3AUA0000116879 400 mm IP42 A 4 X 024 3AUA0000117007 Instruction code 3AUA0000116873 400 mm IP54 A 4 X 027 3AXD50000009184 Instruction code 3AXD50000009989 ...

Page 177: ...116880 600 mm IP42 A 6 X 025 3AUA0000117008 Instruction code 3AUA0000116874 600 mm IP54 A 6 X 028 3AXD50000009185 Instruction code 3AXD50000009990 800 mm IP20 A 8 X 023 3AUA0000117005 Instruction code 3AUA0000116887 Enclosure width Degree of protection Kit code Ordering code Illustration ...

Page 178: ...on code 3AXD50000010001 Enclosure width Degree of protection Qty Kit code Ordering code Illustration 400 mm IP20 1 A 4 X 062 3AUA0000125203 Instruction code 3AXD50000001982 Note Fan to be ordered separately 800 mm IP20 2 600 mm IP20 1 A 6 X 063 3AUA0000125204 Instruction code 3AXD50000001980 Note Fan to be ordered separately Enclosure width Degree of protection Kit code Ordering code Illustration ...

Page 179: ...ction code 3AUA0000115152 Note Fan to be ordered separately 400 mm IP54 IEC 1 A 4 X 064 3AXD50000009187 Instruction code 3AXD50000010284 Note Fan to be ordered separately 800 mm IP54 IEC 2 400 mm IP54 UL 1 A 4 X 067 3AXD50000010362 Instruction code 3AXD50000010284 Note Fan to be ordered separately 800 mm IP54 UL 2 Enclosure width Degree of protection Qty Kit code Ordering code Illustration ...

Page 180: ... separately Enclosure width Degree of protection Component Qty Ordering code Name Data IEC 400 mm IP54 Fan RB4C 355 170 1 3AXD50000006934 Capacitor MSB MKP 6 603 E1679 1 3AXD50000006959 Connector SPB2 5 7 2 5 mm2 12AWG 1 3AXD50000000723 Connector SC 2 5 RZ 7 2 5 mm2 12AWG 1 3AXD50000000724 600 mm IP54 Fan CRBB 4 400 188 1 3AXD50000006111 Capacitor MSB MKP 12 603 E1679 1 3AXD50000006885 Connector S...

Page 181: ... 2 5 RZ 7 2 5 mm2 12AWG 1 3AXD50000000724 600 mm IP54 Fan CRBB 4 400 188 1 3AXD50000006111 Capacitor MSB MKP 12 603 E1679 1 3AXD50000006885 Connector SPB2 5 7 2 5 mm2 12AWG 1 3AXD50000000723 Connector SC 2 5 RZ 7 2 5 mm2 12AWG 1 3AXD50000000724 800 mm IP20 IP42 Fan R2E225 RA92 17 230 V 2 3AXD50000000514 Capacitor MSB MKP 3 5 603 E1679 2 3AXD50000000882 Connector SPB2 5 7 2 5 mm2 12AWG 2 3AXD500000...

Page 182: ...20 shrouds for covering the input and motor cabling area as standard The shrouds can be excluded with option 0B051 Kit Option code Ordering code Common mode filter kit E208 3AXD50000026145 Full size cable connection terminals for input power cables H370 3AXD50000019542 Full size cable connection terminals for output power cables 3AXD50000019544 For frame R11 IP20 shrouds for covering the input and...

Page 183: ...N SN ILd PLd IHd PHd A A A kW kVA A kW A kW UN 400 V 246A 3 R11 212 412 246 132 170 234 132 206 110 293A 3 R11 257 492 293 160 203 278 160 246 132 363A 3 R11 321 586 363 200 251 345 200 293 160 442A 3 R11 401 726 442 250 306 420 250 363 200 505A 3 R11 401 726 505 250 350 480 250 363 200 585A 3 R11 505 884 585 315 405 556 315 442 250 650A 3 R11 569 1010 650 355 450 618 355 505 250 UN 500 V 240A 5 R...

Page 184: ...ltage of the drive I1N Nominal input current rms at 40 C 104 F SN Apparent power no overload Imax 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_start Maximum output current at start Available for two seconds only at start every seven seconds if start current limit is activated by parameter 30...

Page 185: ...ther than default Note The final derating factor is a multiplication of all applicable derating factors Ambient temperature derating In the temperature range 40 55 C 104 131 F the rated output current is derated by 1 for every added 1 C 1 8 F as follows Calculate the output current by multiplying the current given in the rating table by the derating factor 1 00 0 85 40 C 55 C 104 F 131 F Derating ...

Page 186: ...e filter low noise Table below gives the deratings 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 on page 240 is used and ABB sine filter in Parameter 95 15 Special HW settings is enabled Low noise optimization is selected in Parameter 97 09 Switching freq mode Derat...

Page 187: ...6 132 205 162 212 132 199 157 260A 5 247 160 235 228 234 160 222 216 229 160 216 210 361A 5 343 200 326 247 325 200 309 234 318 200 300 227 414A 5 393 250 373 343 373 250 354 325 365 250 343 315 460A 5 437 315 428 393 414 315 405 373 406 250 393 362 503A 5 478 355 467 437 453 315 443 414 443 315 430 402 UN 690 V 142A 7 119 132 119 105 122 132 122 107 66 75 63 55 174A 7 145 160 145 125 149 160 149 ...

Page 188: ...z A kW A A Hz A kW A A UN 400 V 246A 3 120 246 132 234 206 500 201 110 193 170 293A 3 120 293 160 278 246 500 240 132 229 203 363A 3 120 363 200 345 293 500 297 200 284 241 442A 3 120 442 250 420 363 500 362 250 346 299 505A 3 120 505 250 480 363 500 413 250 395 299 585A 3 120 585 315 556 442 500 479 315 458 364 650A 3 120 650 355 618 505 500 532 315 509 416 UN 460 V 302A 5 120 302 250 hp 302 260 ...

Page 189: ...ing 10 overload for 1 minute every 5 minutes PLd Typical motor power for light overload use IHd Continuous rms output current allowing 50 overload for 1 minute every 5 minutes Continuous rms output current allowing 40 overload for 1 minute every 5 minutes U Typical motor power in no overload use Un Nominal supply voltage of the drive For 3 types Un 400 V for 5 types Un 500 V For 7 types Un 690 V b...

Page 190: ... 2 293A 3 257 500 145 000 690 Bussmann 170M5410 2 363A 3 321 630 210 000 690 Bussmann 170M6410 3 442A 3 401 700 300 000 690 Bussmann 170M6411 3 505A 3 401 800 465 000 690 Bussmann 170M6412 3 585A 3 505 1000 945 000 690 Bussmann 170M6414 3 650A 3 569 1000 945 000 690 Bussmann 170M6414 3 UN 500 V 240A 5 169 315 42 000 690 Bussmann 170M4410 1 260A 5 205 400 74 000 690 Bussmann 170M5408 2 302A 5 257 5...

Page 191: ...t be used Drive type ACS880 34 Input current A Fuse A V Manufacturer Size Type DIN 43653 UN 400 V 246A 3 212 400 690 Bussmann 2 170M5408 293A 3 257 500 690 Bussmann 2 170M5410 363A 3 321 630 690 Bussmann 3 170M6410 442A 3 401 700 690 Bussmann 3 170M6411 505A 3 401 800 690 Bussmann 3 170M6412 585A 3 505 1000 690 Bussmann 3 170M6414 650A 3 569 1000 690 Bussmann 3 170M6414 UN 500 V 240A 5 169 315 690...

Page 192: ...hrouds and full size output power cable connection terminals Frame size Height Width Depth Weight mm in mm in mm in kg lb R11 1733 68 20 401 15 77 506 19 92 161 355 Optional selection H381 full power cabling panels Frame size Height Width Depth Weight mm in mm in mm in kg lb R11 1780 70 08 709 27 91 500 19 69 495 871 Weight of optional selections Frame size E208 H356 0H371 H370 0B051 kg lb kg lb k...

Page 193: ...sulation For more information contact your local ABB representative Terminal data for the control cables See page 115 or 128 ACS880 34 142A 7 R11 2100 1279 5 280 75 ACS880 34 174A 7 R11 2100 1279 6 400 75 ACS880 34 210A 7 R11 2100 1279 8 000 75 ACS880 34 271A 7 R11 2100 1279 10 000 75 ACS880 34 330A 7 R11 2100 1279 12 600 75 ACS880 34 370A 7 R11 2100 1279 14 200 75 ACS880 34 430A 7 R11 2100 1279 1...

Page 194: ...etworks Values are measured at the input terminals of the drive Motor connection data Motor types Asynchronous AC induction motors permanent magnet motors AC induction servomotors and ABB synchronous reluctance motors SynRM motors Voltage U2 0 to U1 3 phase symmetrical This is indicated in the type designation label as typical output voltage level as 3 0 U1 Umax at the field weakening point Freque...

Page 195: ...3 10 5 ACS880 34 363A 3 10 5 ACS880 34 442A 3 10 5 ACS880 34 505A 3 10 5 ACS880 34 585A 3 14 0 ACS880 34 650A 3 14 0 UN 500 V ACS880 34 240A 5 10 5 ACS880 34 260A 5 10 5 ACS880 34 302A 5 10 5 ACS880 34 361A 5 10 5 ACS880 34 414A 5 10 5 ACS880 34 460A 5 14 0 ACS880 34 503A 5 14 0 UN 690 V ACS880 34 142A 7 5 3 ACS880 34 174A 7 5 3 ACS880 34 210A 7 5 3 ACS880 34 271A 7 5 3 ACS880 34 330A 7 5 3 ACS880...

Page 196: ...ses Class 3C2 Class 1C2 Class 2C2 Solid particles Class 3S2 No conductive dust allowed Class 1S3 packing must support this otherwise 1S2 Class 2S2 Pollution degree 2 Atmospheric pressure 70 to 106 kPa 0 7 to 1 05 atmospheres 70 to 106 kPa 0 7 to 1 05 atmospheres 60 to 106 kPa 0 6 to 1 05 atmospheres Vibration IEC 60068 2 6 2007 EN 60068 2 6 2008 Environmental testing Part 2 6 Tests Test Fc Vibrati...

Page 197: ...y Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing emergency stop device supply disconnecting device IEC EN 60529 1981 A1 1999 A2 2013 Degrees of protection provided by enclosures IP code EN 61000 3 12 2011 Electromagnetic compatibility EMC Part 3 12 Limits Limits for harmonic currents produced b...

Page 198: ...rive of rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Category C2 The drive complies with the standard with the following provisions Mark Description CE mark Product complies with the applicable European Union legislation For fulfilling the EMC requirements see section EMC compliance IEC EN 61800 3 2...

Page 199: ... potential through the EMC 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 and control cables are selected as specified in the hardware manual 3 The drive is installed according to the instructions given in the hardware manual 4 Maximum motor cable ...

Page 200: ...ough the manufacturer separately Retain the hard copies of the manuals with the drive Make sure that the drive type designation label includes the cULus Listed marking CAUTION Risk of electric shock After disconnecting the input power always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive motor or motor cable The drive is to be used in ...

Page 201: ...it breakers must not be used without fuses in the USA For suitable circuit breakers contact your local ABB representative 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 controller should be examined and replaced if damaged The d...

Page 202: ...202 Technical data EU Declaration of Conformity Machinery Directive ...

Page 203: ...rovide 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 application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and ...

Page 204: ...204 Technical data ...

Page 205: ...Dimension drawings 205 17 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules with optional parts for Rittal TS 8 cabinet assembly ...

Page 206: ...206 Dimension drawings Standard configuration 3AXD50000038012 ...

Page 207: ...Dimension drawings 207 Location of power cable connection terminals with options H370 H356 3AXD50000038012 ...

Page 208: ...208 Dimension drawings Drive module with options 0B051 H356 0H371 3AXD50000038012 ...

Page 209: ...Dimension drawings 209 Configuration with option H381 3AXD50000323210 ...

Page 210: ...210 Dimension drawings LCL filter module 3AXD50000206162 ...

Page 211: ...Dimension drawings 211 Bottom plate This drawing shows the dimensions of the bottom plate for Rittal TS 131 800 cabinet It is not an ABB product Insert nut PEM S M8 2 or equal 4 pcs ...

Page 212: ...ir baffles for the standard drive module These drawing show the dimensions of the air baffles around the standard drive module for Rittal TS 131 800 cabinet These are not ABB products 3AXD50000031793 Rear Front Rear Left Right ...

Page 213: ... with UL94 V 0 listing UV stability LEXAN FR700 or Valox FR1 only with special permission Unmarked bend radii 0 6 mm Air baffles for option H381 in Rittal TS 8 800 mm wide cabinet Additional air baffles for the cabling panels are shown below Two pieces These are not ABB products 3AUA0000138986 ...

Page 214: ...214 Dimension drawings External control unit 3axd50000011687 ...

Page 215: ...Example circuit diagram 215 18 Example circuit diagram Contents of this chapter This chapter shows an example circuit diagram for a cabinet installed drive module ...

Page 216: ...ivery plus code options other options to be acquired by the customer Motor temperature supervision ACS AP W control panel Switch fuse disconnector Main Supply Alarm Drive module ZCU control unit 3 Motor Cabinet Common mode filter du dt filter or Input and output signals see page 99 360 degree grounding recommended sine filter contactor V7 V2 QOIA V13 V8 INU STO X2 ZBIB X7 X8 1 2 V2 V1 V20 V21 X3 ...

Page 217: ...perations 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 of the power semiconductors of the drive output stage A see diagram below thus preventing the drive from generating the torque required to rotate the motor If the motor is running when Safe torque off i...

Page 218: ... of machinery Electrical equipment of machines Part 1 General requirements IEC 61326 3 1 2008 Electrical equipment for measurement control and laboratory use EMC requirements Part 3 1 Immunity requirements for safety related systems and for equipment intended to perform safety related functions functional safety General industrial applications IEC 61508 1 2010 Functional safety of electrical elect...

Page 219: ...r an FPTC 0x thermistor protection module can also be used For more information see the FSO xx module documentation Cable types and lengths We recommend double shielded twisted pair cable see page 67 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 drive Note that the volta...

Page 220: ...ion Single drive internal power supply Dual channel connection Single channel connection 24 V OUT1 SGND IN2 T1 U2 T2 V2 T3 W2 Control logic UDC UDC Control unit A K IN1 ACS880 34 24 V OUT1 SGND IN2 K IN1 Control unit ACS880 34 ...

Page 221: ...torque off function 221 Multiple drives internal power supply 24 V OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 K XSTO Control unit XSTO Control unit XSTO Control unit ACS880 34 ACS880 34 ACS880 34 ...

Page 222: ...torque off function Multiple drives external power supply OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 24 V Control unit 24 V DC K XSTO Control unit XSTO Control unit XSTO ACS880 34 ACS880 34 ACS880 34 ...

Page 223: ... Competence The acceptance test of the safety function must be carried out by a competent person with adequate expertise and knowledge of the safety function as well as functional safety as required by IEC 61508 1 clause 6 The test procedures and report must be documented and signed by this person Acceptance test reports Signed acceptance test reports must be stored in the logbook of the machine T...

Page 224: ...tays at a standstill and the drive operates as described 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 wire coming to IN1 If the motor was running it sho...

Page 225: ...agnet motors or 180 2p degrees with synchronous reluctance SynRM motors regardless of the activation of the Safe torque off function p denotes the number of pole pairs Notes If the Safe torque off function is activated when the drive is running the control voltage of the power semiconductors is cut off and the motor coasts to a stop If this causes danger or is not otherwise acceptable stop the dri...

Page 226: ... machine logbook Competence The maintenance and proof test activities of the safety function must be carried out by a competent person with adequate expertise and knowledge of the safety function as well as functional safety as required by IEC 61508 1 clause 6 Fault tracing The indications given during the normal operation of the Safe torque off function are selected by drive parameter 31 22 The d...

Page 227: ...49 1 Classification of the safety related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition and which is achieved by the structural arrangement of the parts fault detection and or by their reliability The categories are B 1 2 3 and 4 CCF EN ISO 13849 1 Common cause failure DC EN ISO 13849 1 Diagnostic coverage FIT IEC 61508 Fail...

Page 228: ...s required to keep the SIL capability valid The same interval must be followed to keep the PL capability EN ISO 13849 valid See also section Maintenance page 225 TM EN ISO 13849 1 Mission time ie period of time that covers the intended use of safety function device After the mission time the safety device s must be replaced Note that any TM values given cannot be regarded as a guarantee or warrant...

Page 229: ...ted Planning the braking system Selecting the default brake circuit components 1 Calculate the maximum power generated by the motor during braking Pmax 2 Select a suitable drive brake chopper and brake resistor combination for the application see section Technical data on page 232 The braking power of the chopper and drive combination must be greater than or equal to the maximum power generated by...

Page 230: ...ielded single core cable can only be used if it is routed inside a cabinet that efficiently suppresses the radiated emissions Install the cables away from other cable routes Avoid long parallel runs with other cables The minimum parallel cabling separation distance should be 0 3 meters 1 ft Cross the other cables at right angles Keep the cable as short as possible in order to minimize the radiated...

Page 231: ...ted to a ventilation system make sure that the material withstands high temperatures Protect the resistor against contact Protecting the system against thermal overload The brake chopper protects itself and the resistor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive The drive control program includes a resistor and resistor cable therm...

Page 232: ... page 231 WARNING The ENABLE input terminal block of the brake chopper is at intermediate circuit potential when the line side converter of the drive is running This voltage is extremely dangerous and can cause serious damage or injury if the isolation level and protection conditions for the thermal switches are not sufficient Insulate the thermal switches correctly over 2 5 kV and shroud them aga...

Page 233: ...6120 503A 5 630 Bussmann 170M8635 120 NBRA 659 403 502 16120 UN 690 V 142A 7 400 Bussmann 170M5142 120 NBRA 669 403 364 16120 174A 7 400 Bussmann 170M5142 120 NBRA 669 403 364 16120 210A 7 400 Bussmann 170M5142 120 NBRA 669 403 364 16120 271A 7 400 Bussmann 170M5142 120 NBRA 669 403 364 16120 330A 7 400 Bussmann 170M5142 120 NBRA 669 403 364 16120 370A 7 400 Bussmann 170M5142 120 NBRA 669 403 364 ...

Page 234: ... 54 503A 5 2xSAFUR200F500 1 10800 287 2 2 70 mm2 357 167 208 54 UN 690 V 142A 7 2xSAFUR200F500 1 10800 287 2 2 70 mm2 259 167 151 54 174A 7 2xSAFUR200F500 1 10800 287 2 2 70 mm2 259 167 151 54 210A 7 2xSAFUR200F500 1 10800 287 2 2 70 mm2 259 167 151 54 271A 7 2xSAFUR200F500 1 10800 287 2 2 70 mm2 259 167 151 54 330A 7 2xSAFUR200F500 1 10800 287 2 2 70 mm2 259 167 151 54 370A 7 2xSAFUR200F500 1 108...

Page 235: ...power Pbr max Example 2 The duration of a braking cycle T is three minutes The braking time tbr is 40 seconds Result The maximum allowed braking power for the cycle is 50 of the rated value given for the reference cycle SAFUR resistors The degree of protection of SAFUR resistors is IP00 The resistors are not UL listed The thermal time constant of the resistors is 555 seconds n Number of the brakin...

Page 236: ...236 Resistor braking Dimensions and weights 234 300 1320 Ø 7 345 1270 Brake resistor type Weight SAFUR125F500 25 kg 55 lb SAFUR200F500 30 kg 66 lb ...

Page 237: ...er type ABB ordering code UN 400 V NBRA 658 59006428 NBRA 659 59006436 NBRA 659 59006436 NBRA 659 59006436 NBRA 659 59006436 NBRA 659 59006436 NBRA 659 59006436 UN 500 V NBRA 658 59006428 NBRA 659 59006436 NBRA 659 59006436 NBRA 659 59006436 NBRA 659 59006436 NBRA 659 59006436 NBRA 659 59006436 UN 690 V NBRA 669 59012517 NBRA 669 59012517 NBRA 669 59012517 NBRA 669 59012517 NBRA 669 59012517 NBRA ...

Page 238: ...238 Resistor braking ...

Page 239: ...80 34 du dt filter type Drive module type ACS880 34 du dt filter type Drive module type ACS880 34 du dt filter type UN 400 V UN 500 V UN 690 V 246A 3 FOCH0260 7x 240A 5 FOCH0260 7x 142A 7 FOCH0260 7x 293A 3 FOCH0260 7x 260A 5 FOCH0260 7x 174A 7 FOCH0260 7x 363A 3 FOCH0320 5x 302A 5 FOCH0320 5x 210A 7 FOCH0260 7x 442A 3 FOCH0320 5x 361A 5 FOCH0320 5x 271A 7 FOCH0260 7x 505A 3 FOCH 0610 70 414A 5 FO...

Page 240: ... IP22 3AXD50000030047 FOCH0260 70 IP00 68490308 FOCH0260 72 IP22 3AXD50000030048 FOCH 0610 70 IP00 68550505 Drive module type ACS880 34 Sine filter type Drive module type ACS880 34 Sine filter type Drive module type ACS880 34 Sine filter type UN 400 V UN 500 V UN 690 V 246A 3 B84143V0230S229 240A 5 B84143V0230S229 142A 7 B84143V0130S230 293A 3 B84143V0390S229 260A 5 B84143V0230S229 174A 7 B84143V0...

Page 241: ...installation and technical data of the sine filters See Sine filters hardware manual 3AXD50000016814 English and manuafacturer s site on the Internet https en tdk eu tdk en 1029890 products product catalog emc components output filters epcos ...

Page 242: ...242 du dt and sine filters ...

Page 243: ...drive configuration in Rittal TS 8 800 mm wide cabinet 243 Step by step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet 360 Rittal TS 131 800 Rittal TS 8612 580 1752 5 69 00 Tapping screw M6 12 Torx T30 8 N m ...

Page 244: ...244 Step by step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet Combi screw M8 30 Hex 20 N m Tapping screw M6 12 Torx T30 Hex 8 N m ...

Page 245: ...step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet 245 Combi screw M4 8 Torx T20 2 N m Combi screw M4 8 Torx T20 2 N m Combi screw M4 8 Torx T20 2 N m 1 ...

Page 246: ...step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet Combi screw M8 24 N m Combi screw M8 24 N m Screws M10 30 and washer M6 Serpress 8 N m M6 Serpress 8 N m ...

Page 247: ... drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet 247 Combi screw M4 8 Torx T20 2 N m Combi screw M4 8 Torx T20 2 N m Combi screw M12 25 70 N m M10 30 FAN3 LCL ...

Page 248: ...ion example of standard drive configuration in Rittal TS 8 800 mm wide cabinet Combi screw M6 12 Torx T25 8 N m Combi screw M12 25 Hex Delta 70 N m 8 N m T1 U2 T2 V2 T3 W2 T1 U2 T2 V2 T3 W2 T1 U2 T2 V2 T3 W2 T1 U2 T2 V2 T3 W2 T1 U2 T2 V2 T3 W2 ...

Page 249: ... by step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet 249 T1 U2 T2 V2 T3 W2 T1 U2 T2 V2 T3 W2 T1 U2 T2 V2 T3 W2 T1 U2 T2 V2 T3 W2 T1 U2 T2 V2 T3 W2 ...

Page 250: ...drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet 1 2 3 4 5 6 7 8 Combi screw M6 20 Torx T25 2 N m Combi screw M6 20 Torx T25 2 N m Combi screw M4 10 Torx T20 2 N m ...

Page 251: ...nstallation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet 251 1 2 3 4 Hex screw M12 35 full thread 70 N m Hex nut M12 70 N m L3 W1 L2 V1 L1 U1 UDC L3 W1 L2 V1 L1 U1 UDC UDC UDC L3 W1 L2 V1 L1 U1 UDC UDC ...

Page 252: ...ngs for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet Combi screw M4 10 Torx T20 2 N m Combi screw M4 10 Torx T20 2 N m Combi screw M6 20 Torx T25 2 N m L3 W1 L2 V1 L1 U1 UDC UDC ...

Page 253: ...Step by step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet 253 737 29 02 Tapping screw M6 12 Torx T30 Hex 8 N m ...

Page 254: ...254 Step by step drawings for an installation example of standard drive configuration in Rittal TS 8 800 mm wide cabinet ...

Page 255: ...vigating to www abb com searchchannels Product training For information on ABB product training navigate to www abb com drives and select ABB University Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www abb com drives and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product docum...

Page 256: ...Contact us www abb com drives www abb com drivespartners 3AXD50000035191 Rev B EN 2018 09 28 ...

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