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ABB ACS880-37LC-0390A-7 Hardware Manual Download Page 178

Inverter modules used

LCL filter(s) used

Supply module(s) used

Frame size

ACS880-
37LC-…

Type

ACS880-104LC-…

Qty

Type

Qty

Type

ACS880-104LC-…

Qty

0600A-7+E205

2

BLCL-24LC-7

1

0600A-7

2

2×R8i + 2×R8i

1170A-7

0670A-7+E205

2

BLCL-24LC-7

1

0670A-7

2

2×R8i + 2×R8i

1270A-7

0750A-7+E205

2

BLCL-25LC-7

1

0750A-7

2

2×R8i + 2×R8i

1470A-7

0850A-7+E205

2

BLCL-25LC-7

1

0850A-7

2

2×R8i + 2×R8i

1620A-7

0670A-5+E205

3

BLCL-24LC-7

2

0670A-7

3

3×R8i + 3×R8i

1940A-7

0750A-7+E205

3

BLCL-24LC-7

2

0750A-7

3

3×R8i + 3×R8i

2180A-7

0850A-7+E205

3

BLCL-24LC-7

2

0850A-7

3

3×R8i + 3×R8i

2390A-7

0750A-7+E205

4

BLCL-25LC-7

2

0750A-7

4

4×R8i + 4×R8i

2880A-7

0850A-7+E205

4

BLCL-25LC-7

2

0850A-7

4

4×R8i + 4×R8i

3160A-7

0750A-7+E205

5

BLCL-24LC-7

3

0750A-7

5

5×R8i + 5×R8i

3580A-7

0850A-7+E205

5

BLCL-24LC-7

4

0850A-7

6

6×R8i + 5×R8i

4050A-7

0850A-7+E205

6

BLCL-24LC-7

4

0850A-7

6

6×R8i + 6×R8i

4700A-7

0850A-7+E205

7

BLCL-25LC-7

4

0850A-7

8

8×R8i + 7×R8i

5650A-7

0850A-7+E205

8

BLCL-25LC-7

4

0850A-7

8

8×R8i + 8×R8i

6260A-7

Fuses

￭

AC fuses

Notes:

•

Fuses with higher current rating than the recommended ones must not be used.

•

Fuses from other manufacturers can be used if they meet the ratings and the melting
curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.

AC fuses

ACS880-
37LC-…

Type

Manufacturer

V

A

2

s at

660 V

A

Qty

U

N

= 690 V

170M6410

Bussmann

690

210000

630

3

0390A-7

170M6411

Bussmann

690

300000

700

3

0430A-7

170M6412

Bussmann

690

465000

800

3

0480A-7
0520A-7

170M6413

Bussmann

690

670000

900

3

0600A-7

170M6414

Bussmann

690

945000

1000

3

0670A-7

170M6416

Bussmann

690

1950000

1250

3

0750A-7

170M6417

Bussmann

690

2450000

1400

3

0830A-7

170M7061

Bussmann

690

2050000

1600

3

1000A-7

170M7062

Bussmann

690

3950000

2000

3

1170A-7
1270A-7

170M7063

Bussmann

690

7800000

2500

3

1470A-7
1620A-7

170M7061

Bussmann

690

2050000

1600

6

1940A-7

178 Technical data

Summary of Contents for ACS880-37LC-0390A-7

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 37LC drives Hardware manual ...

Page 2: ......

Page 3: ...S880 37LC drives Hardware manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation 9 Start up 3AXD50000251407 Rev B EN Original instructions EFFECTIVE 2022 04 20 ...

Page 4: ......

Page 5: ...er 25 Target audience 25 Categorization by frame size and option code 26 Use of component designations 26 Quick installation commissioning and operation flowchart 27 Terms and abbreviations 27 Related manuals 3 Operation principle and hardware description 29 Contents of this chapter 29 Supply unit 30 AC voltage and current waveforms 30 Charging 30 Inverter unit 31 Overview circuit diagram of the d...

Page 6: ... terminal cubicle option H359 42 Thermal protection with PTC relays options L505 2L505 L513 2L513 L536 L537 42 L505 2L505 L513 2L513 43 L536 L537 43 Thermal protection with Pt100 relays options nL506 nL514 44 Starter for auxiliary motor fan options M600 M610 44 What the option contains 44 Description 45 Type designation label 45 Type designation key 46 Option codes 4 Mechanical installation 51 Con...

Page 7: ...s of types other than M2_ M3_ M4_ HX_ and AM_ 77 Additional requirements for braking applications 77 Additional requirements for the regenerative and low harmonics drives 77 Additional requirements for ABB high output and IP23 motors 77 Additional requirements for non ABB high output and IP23 motors 78 Additional note for sine filters 79 Selecting the power cables 79 General guidelines 79 Typical ...

Page 8: ... and motor 90 Protecting the contacts of relay outputs 91 Implementing a motor temperature sensor connection 91 Connecting a motor temperature sensor to the drive through an option module 6 Electrical installation 93 Contents of this chapter 93 Warnings 93 Measuring the insulation 93 Measuring the insulation resistance of the drive 93 Measuring the insulation resistance of the motor and motor cabl...

Page 9: ... input 128 DIIL input 128 The XD2D connector 129 Safe torque off XSTO XSTO OUT 129 FSO safety functions module connection X12 129 SDHC memory card slot 130 Connector data 133 BCU x2 ground isolation diagram 8 Installation checklist 135 Contents of this chapter 135 Checklist 9 Start up 137 Contents of this chapter 137 Start up procedure 139 Switching off the drive 10 Fault tracing 141 Contents of t...

Page 10: ...U control unit types 162 Replacing the memory unit 162 Replacing the BCU control unit battery 163 Functional safety components 12 Internal cooling circuit 165 Contents of this chapter 165 Applicability 165 Internal cooling system 167 Connection to a cooling unit 167 Connection to an ACS880 1007LC cooling unit 167 Connection to a custom cooling unit 167 General requirements 167 Coolant temperature ...

Page 11: ...4 Electrical power network specification 185 Motor connection data 185 Relay contact data for control of external main contactor breaker 185 General 186 K3 contact data 186 K62 contact data 186 Efficiency 187 Energy efficiency data ecodesign 187 Optical components 187 Protection classes 188 Ambient conditions 188 Colors 189 Materials 189 Drive 189 Packaging of drive 189 Packaging of options 189 Ma...

Page 12: ...0 mm bottom cable exit 212 Cubicle width 300 mm top cable exit 213 Cubicle width 400 mm bottom cable exit 214 Cubicle width 400 mm top cable exit 215 Cubicle width 600 mm bottom cable exit 216 Cubicle width 600 mm top cable exit 15 The Safe torque off function 217 Contents of this chapter 217 Description 218 Compliance with the European Machinery Directive and the UK Supply of Machinery Safety Reg...

Page 13: ...16 Resistor braking Further information Table of contents 13 ...

Page 14: ...14 ...

Page 15: ...you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity which can cause injury or death or...

Page 16: ...pacity and condition of lifting equipment and for training of personnel The lifting bars attached to large drive cabinets are heavy Be careful when removing or reinstalling the bars Whenever possible use a lifting device attached to the designated lifting points Attach the drive cabinet to the floor to prevent it from toppling over The cabinet has a high center of gravity When you pull out heavy c...

Page 17: ...vate the automatic fault reset or automatic 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 UL 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMA...

Page 18: ...y with plenty of water Do not syphon it by mouth If you swallow or get it into the eyes seek medical advice Before the drive power up make sure that the internal cooling circuit is filled up with coolant and the cooling is in operation coolant is circulating Make sure that coolant meets the ABB specification See the appropriate hardware manual of the drive unit To avoid breaking the coolant pipes ...

Page 19: ...possible disconnecting devices that isolate the drive from dangerous voltage sources In the liquid cooling unit if present open the switch disconnector of the cooling pumps If you have a permanent magnet motor connected to the drive disconnect the motor from the drive with a safety switch or by other means Disconnect all dangerous external voltages from the control circuits After you disconnect po...

Page 20: ...nd notes WARNING Obey these instructions If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work Keep the cabinet doors closed when the drive is powered With the doors open a risk of a potentially fatal electric shock arc flash or high energy arc blast exists Make sure that the electrical ...

Page 21: ...band when you handle printed circuit boards Do not touch the boards unnecessarily The boards contain components sensitive to electrostatic discharge Grounding These instructions are for all personnel who are responsible for the grounding of the drive WARNING Obey these instructions If you ignore them injury or death or equipment malfunction can occur and electromagnetic interference can increase I...

Page 22: ...These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN UL 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY Note The maximum number of drive power ups is five in ten minutes Too frequent power ups can damage the charging circuit of the DC c...

Page 23: ...cal safety precautions page 19 Install temporary grounding to the drive output terminals T1 U T2 V T3 W Connect the output terminals together as well as to the PE During the start up Make sure that the motor cannot run overspeed for example driven by the load Motor overspeed causes overvoltage that can damage or destroy the capacitors in the intermediate circuit of the drive Safety in operation WA...

Page 24: ...24 ...

Page 25: ...tion code Some instructions technical data and dimension drawings which concern only certain frame sizes are marked with the symbol of the frame size The frame size indicates the number of power modules that form the supply and inverter units respectively For example the marking 2 R8i 2 R8i refers to a drive that has a supply unit consisting of two frame R8i supply modules and an inverter unit con...

Page 26: ...5 Ambient conditions page 188 Check the installation site Mechanical installation page 51 Unpack and check the drive only intact units may be started up Make sure that all necessary optional modules and equipment are present and correct Install the drive mechanically Routing the cables page 84 Route the cables Electrical installation page 93 Connect the power cables Connect the control cables Inst...

Page 27: ...ermistor protection module for potentially explosive atmospheres FPTC 02 Physical size of the drive or power module Frame frame size Optional functional safety modules FSO 12 FSO 21 Insulated gate bipolar transistor IGBT Inverter module s under control of one control unit and related components One inverter unit typically controls one motor Inverter unit Series of optional liquid cooled brake chop...

Page 28: ...28 ...

Page 29: ...t line side converter 1 to 8 inverter modules forming the inverter unit motor side converter optional equipment The actual arrangement of the cubicles varies from type to type and the selected options Some optional equipment require additional cubicles See chapter Dimensions for examples of cabinet line ups Supply unit The supply unit rectifies three phase AC current to direct current for the inte...

Page 30: ...arging is needed to power up the DC link capacitors smoothly Discharged capacitors cannot be connected to the full supply voltage The voltage must be increased gradually until the capacitors are charged and ready for normal 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 ...

Page 31: ...it breaker as standard Q1 In that case the AC fuses are located at the input of each LCL filter Charging switch Q3 and fuses 6 Charging contactor Q4 7 Charging resistors R4 x 8 LCL filter 9 Supply module s T1 x The diagram shows two modules connected in parallel 10 Common mode filters R1 x at the output of each supply module 11 DC fuses at the output of each supply module F2 x and at the input of ...

Page 32: ...ins control electronics A Input cubicle IPU Contains the input power cable terminals B LCL filter cubicle LCL C Supply module cubicle ISU D Inverter module cubicle INU Contains the motor cable terminals E See also sections Door switches and lights page 36 and Control panel page 37 32 Operation principle and hardware description ...

Page 33: ...t A51 and inverter control unit A41 1 Control electronics 2 Auxiliary voltage transformers obscured 3 Heat exchanger 4 CIO module cooling fan obscured 5 Control cable entry 6 Auxiliary voltage disconnector 7 Main circuit breaker 8 Cooling fan and heat exchanger 9 Input power cable terminals 10 Inlet manifold with stop and drain valves 11 Outlet manifold with stop and drain valves 12 AC fuses 13 Ca...

Page 34: ...A input cubicle option F274 100 kA input cubicle option F274 increases the short circuit withstand rating of the drive The cubicle contains extra fuses The 100 kA cubicle is installed beside the standard 65 kA incoming cubicle or input cubicle at the factory The input power cables enter the 100 kA input cubicle All other customer cables enter the auxiliary control cubicle or other supply unit cubi...

Page 35: ...ly control unit A51 V1T R 9 11 13 12 14 Drive Fxxx Option modules can be inserted into slots 1 2 3 and 4 as follows 1 Slots Module type 1 2 3 Analog and digital I O extension modules 1 2 3 Feedback interface modules 1 2 3 Fieldbus communication modules 4 RDCO 04 DDCS communication option module standard equipment As standard a fiber optic link connects the supply and inverter control units 2 3 4 A...

Page 36: ...NG The main disconnecting device does not isolate the input power terminals AC voltage meters or the auxiliary voltage circuit from the power line To isolate the auxiliary voltage circuit open the auxiliary voltage switch Q21 To isolate the input power terminals and AC voltage meters open the main breaker of the supply transformer Auxiliary voltage switch Q21 The auxiliary voltage switch controls ...

Page 37: ... Reset Reference and the parameter settings for the inverter control program The control panel can be removed by pulling it forward by the top edge and reinstalled in reverse order For the use of the control panel see ACS AP I S W and ACH AP H W Assistant control panels user s manual 3AUA0000085685 English and the firmware manual Control by PC tools There is a USB connector on the front of the pan...

Page 38: ... IP42 against splashing water dust protected IP54 Marine construction option C121 The option includes the following accessories and features reinforced mechanics grab railings door flush bolt which allows the door to open 90 degrees and prevents it from slamming close self extinctive materials flat bars at base of the cabinet for fastening fastening brackets at the top of the cabinet Additional wi...

Page 39: ...elements increases when the surrounding air temperature is low and decreases when the surrounding air temperature is high The customer must stop the heating when it is not needed by disconnecting the heater supply voltage The customer must supply the heater from an external 110 240 V AC power source For the actual wiring see the circuit diagrams delivered with drive Cabinet lighting option G301 Th...

Page 40: ...Green or yellow green sleeving UPS input wiring option G307 Orange Pt100 sensor wiring with ATEX certified thermal protection option nL514 Light blue Markings As standard wires and terminals are marked as follows Main circuit terminals Connector identifier eg U1 marked on terminal or on insulating material close to the terminal Input and output main circuit cables are not marked Plug in connectors...

Page 41: ...ors that connect to equipment terminal blocks or detachable plug type connectors or are part of the wiring between power modules Fiber optic cables are marked in the same way Plug type connector identifications are marked on labels near the connectors The label holders are attached around conductor bundles Main circuit conductors are marked with white tape or printing Short and obvious connections...

Page 42: ...re rises to the thermistor wake up level the resistance of the sensor increases sharply The relay detects the change and indicates motor overtemperature through its contacts L505 2L505 L513 2L513 Option L505 provides a thermistor relay and a terminal block The terminal block has connections for the measuring circuit one to three PTC sensors in series an output indication of the relay and an option...

Page 43: ...perature supervision of motors equipped with Pt100 sensors For example there can be three sensors to measure the temperature of the motor windings and two sensors for the bearings As the temperature rises the sensor resistance increases linearly At an adjustable wake up level the monitoring relay de energizes its output The standard Pt100 relay options include three 3L506 five 5L506 or eight 8L506...

Page 44: ...tch with an adjustable current limit a contactor controlled by the drive and terminal block X601 for customer connections Description The output for the auxiliary fan is wired from the 3 phase supply voltage to terminal block X601 through a motor starter switch and a contactor The contactor is operated by the drive The 230 V AC control circuit is wired through a jumper on the terminal block the ju...

Page 45: ...s complete the serial number so that there are no two units with the same number 6 Type designation key The type designation contains information on the specifications and configuration of the drive The first digits from left express the basic drive type The optional selections are given thereafter separated by plus signs eg E202 Codes preceded by a zero eg 0J400 indicate the absence of the specif...

Page 46: ...n left C176 Plinth height 200 mm See section Plinth height options C164 and C179 page 38 C179 Marine product certification issued by DNV GL C205 Marine product certification issued by the American Bureau of Shipping ABS C206 Marine product certification issued by Lloyd s Register LR C207 Marine product certification issued by Bureau Veritas C209 Cooling unit pumps can run simultaneously C213 Marin...

Page 47: ...liary voltage transformer G344 Frequency monitoring device Only for installation altitudes up to 2000 meters 6561 ft G432 BAMU auxiliary measurement unit See section Voltage measurement with BAMU auxiliary meas urement unit option G442 page 41 G442 Power cabling entry from bottom See section Bottom cable entry exit options H350 and H352 page 42 H350 Power cabling entry from top See section Top cab...

Page 48: ...3 Starter for auxiliary motor fan trip limit 6 3 10 A M604 Starter for auxiliary motor fan trip limit 10 16 A M605 Starter for auxiliary motor fan trip limit 16 20 A M606 Pump motor in delta connection M633 Pump motor in star connection M634 Winder control program N5000 Crane control program N5050 Winch control program N5100 Test bench control program N5300 Override control program N5450 ESP Elect...

Page 49: ...igurable for category 0 or 1 with FSO safety functions module by opening the main breaker contactor Q978 Emergency stop configurable for category 0 or 1 with FSO safety functions module by activating the Safe torque off function Q979 PROFIsafe with FSO safety functions module and FPNO 21 Ethernet adapter module Q982 Emergency stop button monitoring Q984 FSPS 21 PROFIsafe safety functions module Q9...

Page 50: ...50 ...

Page 51: ...or that the drive cabinet is installed on is of non flammable material as smooth as possible and strong enough to support the weight of the unit Check the floor flatness with a spirit level The maximum allowed deviation from the surface level is 5 mm 0 2 in in every 3 meters 10 ft Level the installation site if necessary as the cabinet is not equipped with adjustable feet Necessary tools The tools...

Page 52: ...ntrol unit s at the factory appropriate drive and optional module manuals delivery documents Make sure that there are no signs of damage Before attempting installation and operation see the information on the type designation labels of the drive to verify that the delivery is of the correct type 52 Mechanical installation ...

Page 53: ... is to be moved in the upright position The center of gravity of the cabinet is high Be therefore careful when moving the unit Avoid tilting Moving the drive in its packaging Lifting the crate with a forklift WARNING Incorrect lifting can cause danger or damage Obey the local laws and regulations applicable to lifting such as requirements for planning the lift for capacity and condition of lifting...

Page 54: ...laws and regulations applicable to lifting such as requirements for planning the lift for capacity and condition of lifting equipment and for training of personnel max 20 b a Lifting point a Optimal position for the lifting sling as close to the traverse board as possible b 54 Mechanical installation ...

Page 55: ...kage Remove the transport package as follows 1 Undo the screws that attach the wooden parts of the transport crate to each other 2 Remove the wooden parts 3 Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws 4 Remove the plastic wrapping Mechanical installation 55 10 ...

Page 56: ... units is 2 meters 6 7 Removing the transport package Remove the transport package as follows 1 Undo the screws that attach the wooden parts of the transport crate together 2 Remove the wooden parts 3 Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws 4 Remove the plastic wrapping Moving the unpacked drive cabinet Lifting the cabinet...

Page 57: ...Remove the rollers by lifting the unit with a crane forklift pallet truck or jack Moving the cabinet on its back WARNING Do not transport the drive with an LCL or L filter on its back It will damage the filter If the cabinet needs to be laid on its back support the cabinet from below alongside the cubicle seams 1 2 Cabinet back panel 1 Support 2 Mechanical installation 57 10 ...

Page 58: ...cement of the cabinet Move the cabinet into its final position with a slate bar spud bar Place a piece of wood between the edge of the cabinet and the bar to protect the cabinet frame 58 Mechanical installation ...

Page 59: ...ny height adjustment must be done before attaching the cabinet sections to the floor or to each other Height adjustment can be done by using metal shims between the cabinet bottom and floor Note 2 Depending on the size of the cabinet it has either bolt on lifting eyes or lifting bars with lifting holes Bolt on lifting eyes need not be removed unless the holes are used for attaching the cabinet If ...

Page 60: ...em to the floor with a bolt The recommended maximum distance between the clamps in the front edge is 800 mm 31 5 2 If floor mounting at the back is not possible attach the top of the cabinet to the wall with L brackets not included in the delivery bolted to the lifting eye bar holes and suitable hardware Attaching top to wall Clamping bottom to floor M16 60 Mechanical installation ...

Page 61: ... The recommended maximum distance between the front edge fastening points is 800 mm 31 5 2 If the back fastening holes are not accessible attach the top of the cabinet to the wall with L brackets not included in the delivery bolted to the lifting eye bar holes Attaching cabinet top to wall Attaching bottom to floor M16 Mechanical installation 61 10 ...

Page 62: ...2 screws 2 If there is not enough room behind the cabinet for installation clamp a the rear edges of the flat bars c to the floor See the figure below 3 Attach corner brackets d to the lifting eye holes Fasten the corner brackets to the rear wall and or roof with suitable hardware such as U brackets e M16 3 e d a b c 2 Corner bracket included d Clamp not included a U bracket not included e Back pa...

Page 63: ...n also act as a joining cubicle The screws required for the joining are enclosed in a plastic bag inside the cabinet 1 Fasten the first section to the floor 2 Remove any plates covering the rear post of the joining cubicle 3 Slide Axilock connectors onto the coolant pipes at the joint 4 Align the two sections The coolant pipe ends must be aligned as shown 5 15 mm 0 2 0 6 2 3 mm 0 12 Mechanical ins...

Page 64: ...the connector label 6 Fasten the front and rear posts of the joining cubicle to the posts of the other section with 16 screws 8 per post Tighten the screws to 5 N m 3 7 lbf ft 7 Fasten the second section to the floor The numbers in the figure below refer to the installation steps 1 3 5 4 4 4 7 6 6 6 4 64 Mechanical installation ...

Page 65: ...rs using the M10 bolts included Tighten to 35 40 N m 25 30 lbf ft Side Above a b c a b c Plain washer a Spring washer b Bolt c 9 Remove the shroud covering the DC busbars in the joining cubicle Mechanical installation 65 10 ...

Page 66: ... a a a a a a b a d a a a b a c a d a a a c a a Units with single DC busbars Units with double DC busbars Joint piece a Plain washer with electroplated zinc coating and blue chromate passivation b Spring washer with mechanically sprayed zinc coating c Nut M12 d 66 Mechanical installation ...

Page 67: ...ers in the correct order as shown For example placing an unpassivated zinc coated spring washer directly against the joint piece will cause corrosion WARNING Do not use any joining parts other than those delivered with the unit The parts are carefully selected to match the material of the busbars Other parts or materials can form a galvanic couple and cause corrosion 11 Reinstall any shrouding rem...

Page 68: ...ection fire protection and EMC compliance 500 19 68 50 1 97 500 19 68 50 1 97 Arc welding ABB does not recommend attaching the cabinet by arc welding However if arc welding is the only option connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0 5 meters 1 6 of the welding point Note The cabinet frame is zinc plated WARNING Make sure that the return wire...

Page 69: ...ng lugs and bars Certificate of conformity The certificate is available in ABB Library at www abb com drives documents document number 3AXD10001061361 Declarations of conformity Mechanical installation 69 10 ...

Page 70: ...70 Mechanical installation ...

Page 71: ...5 64301373 64301381 64301390 64301403 64301411 64456695 64456725 64456822 64456881 64456890 64456920 64485296 64485300 64485318 64485326 64485334 64485342 64485351 64485369 64485377 64485458 68775558 68775540 3AUA5000013498 3AUA5000013504 3AUA0000055356 3AXD50000435524 3AXD50000435548 Lifting lugs identified with material codes 64302621 64327151 used for lifting the following frequency converters ...

Page 72: ...of the Supply of Machinery Safety Regulations 2008 Authorized to compile the technical file ABB Oy Hiomotie 13 00380 Helsinki Finland Helsinki 28 May 2021 Signed for and on behalf of Peter Lindgren Vesa Tiihonen Vice President ABB Oy Manager Reliability and Quality ABB Oy 72 Mechanical installation ...

Page 73: ...re not followed the drive may experience problems that the warranty does not cover Selecting the supply disconnecting device The drive is equipped with a main disconnecting device as standard Depending on the size of the drive and the selected options the type of disconnecting device may vary Examples switch disconnector withdrawable air circuit breaker etc Selecting the main breaker option The dr...

Page 74: ...he drive not to the drive output voltage Protecting the motor insulation and bearings The drive employs modern IGBT inverter technology Regardless of frequency the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time The pulse voltage can almost double at the motor terminals depending on the attenuation and reflection properties of the motor cable and...

Page 75: ...ndard 500 V Un 600 V or N CMF N Reinforced N du dt CMF N du dt du dt Reinforced 600 V Un 690 V cable length 150 m N CMF N Reinforced 600 V Un 690 V cable length 150 m Pn 500 kW N CMF N CMF n a Standard 380 V Un 690 V Form wound HX_ and AM_ Pn 500 kW N du dt CMF N du dt with voltages over 500 V CMF Check with the motor manu facturer 380 V Un 690 V Old1 form wound HX_ and modular N CMF Enamelled wir...

Page 76: ...600 V 500 V Un 600 V or N CMF N or CMF Reinforced ÛLL 1800 V N du dt CMF du dt N du dt Reinforced ÛLL 1800 V 600 V Un 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 micro second rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed The abbre...

Page 77: ...requirements for the regenerative and low harmonics drives It is possible to increase the intermediate circuit DC voltage from the nominal standard level with a parameter in the control program If you choose to do this select the motor insulation system which withstands the increased DC voltage level Additional requirements for ABB high output and IP23 motors The rated output power of high output ...

Page 78: ...ze NEMA 500 N or CMF N or CMF Standard ÛLL 1300 V Un 420 V N du dt CMF du dt N or CMF Standard ÛLL 1300 V 420 V Un 500 V or N or CMF N or CMF Reinforced ÛLL 1600 V 0 2 microsecond rise time N du dt CMF du dt N or CMF Reinforced ÛLL 1600 V 500 V Un 600 V or N CMF N or CMF Reinforced ÛLL 1800 V N du dt CMF N du dt Reinforced ÛLL 1800 V 600 V Un 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 microsecond...

Page 79: ...00 V AC 1000 V AC cable is accepted for up to 690 V AC To comply with the EMC requirements of the CE mark use one of the preferred cable types See Preferred power cable types page 79 Symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation bearing currents and wear Metal conduit reduces electromagnetic emission of the whole dri...

Page 80: ...have good con tact with a properly grounded conductive surface For ex ample install the cables on a properly grounded cable tray Otherwise voltage may be come present on the non conductive outer sheath of the cables and there is even a risk of an electric shock A single core cable system three phase conductors and PE conductor on cable tray L1 L3 L2 L2 L1 L3 L3 L2 L1 Preferable cable arrangement t...

Page 81: ...shield 3 Inner insulation 4 Cable core 5 Grounding requirements This section gives general requirements for grounding the drive When you plan the grounding of the drive obey all the applicable national and local regulations The conductivity of the protective earth conductor s must be sufficient Unless local wiring regulations state otherwise the cross sectional area of the protective earth conduct...

Page 82: ... DC the minimum size of the protective earth conductor must comply with the local safety regulations for high protective earth conductor current equipment and you must use one of these connection methods 1 a fixed connection and a protective earth conductor with a minimum cross sectional area of 10 mm2 Cu or 16 mm2 Al as an alternative when aluminum cables are permitted or a second protective eart...

Page 83: ...able a b Signals in separate cables Run analog and digital signals in separate shielded cables Do not mix 24 V DC and 115 230 V AC signals in the same cable Signals that can be run in the same cable If their voltage does not exceed 48 V relay controlled signals can be run in the same cables as digital input signals The relay controlled signals should be run as twisted pairs Relay cable The cable t...

Page 84: ...rates the cable routing guidelines with an example drive min 300 mm 12 in min 300 mm 12 in min 500 mm 20 in min 500 mm 20 in min 200 mm 8 in 90 1 2 4 4 3 2 1 3 2 3 Motor cable 1 Input power cable 2 Control cable 3 Brake resistor or chopper cable if any 4 Continuous motor cable shield conduit or enclosure for equipment on the motor cable To minimize the emission level when safety switches contactor...

Page 85: ...l overload The drive protects itself and the input and motor cables against thermal overload when the cables are sized according to the nominal current of the drive No additional thermal protection devices are needed WARNING If the drive is connected to multiple motors use a separate circuit breaker or fuses for protecting each motor cable and motor against overload The drive overload protection i...

Page 86: ...o protect the unit against ground faults in the motor and motor cable This function is not a personnel safety or a fire protection feature See the firmware manual for more information An optional ground fault monitoring device Q954 is available for IT ungrounded systems The option includes a ground fault indicator on the drive cabinet door Residual current device compatibility The drive is suitabl...

Page 87: ...ermistor protection module for the drive option L537 or acquire and install an ATEX compliant protection relay do the necessary connections For cabinet built drives an ATEX certified motor thermal protection function is also available option L513 Q971 or L514 Q971 The drive is equipped with an ATEX certified Safe motor disconnection function and with ATEX compliant protection relays for PTC or Pt1...

Page 88: ...power loss lasts so long that the drive trips on undervoltage a fault reset and a fresh start command is required to continue operation Implement the power loss ride through function as follows 1 Enable the power loss ride through function of the drive parameter 30 31 2 Enable the automatic restart of the motor after a short power supply break Set the start mode to automatic parameter 21 01 or 21 ...

Page 89: ... 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 make sure that the connection steps are low enough not to cause voltage transients that would trip the drive 3 Make sure that the power fact...

Page 90: ...nsients when switched off The relay contacts on the drive control unit are protected with varistors 250 V against overvoltage peaks In spite of this it is highly recommended that inductive loads are equipped with noise attenuating circuits varistors RC filters AC or diodes DC to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductively to ot...

Page 91: ... maximum allowed voltage over the sensor 3 If there is basic insulation between the sensor and the live parts of the motor or if the insulation type is not known You can connect a sensor to a digital input of the drive via an external relay The sensor and the relay must form a double or reinforced insulation between the motor live parts and the digital input of the drive Make sure that the voltage...

Page 92: ...ector and drive control unit con nector No isolation between sensor connector and TTL encoder emulation output FEN 21 Reinforced insulation x x Galvanic isolation between sensor connector and drive control unit con nector No isolation between sensor connector and other connectors FEN 31 Reinforced or basic insula tion With basic insulation the other I O connectors of the option module must be kept...

Page 93: ...ny voltage withstand or insulation resistance tests on any part of the drive as testing can damage the drive Every drive has been tested for insulation between the main circuit and the chassis at the factory Also there are voltage limiting circuits inside the drive which cut down the testing voltage automatically Measuring the insulation resistance of the motor and motor cable WARNING Obey the saf...

Page 94: ...e more than 100 Mohm reference value at 25 C 77 F For the insulation resistance of other motors refer to the manufacturer s instructions Note Moisture inside the motor reduces the insulation resistance If you think that there is moisture in the motor dry the motor and do the measurement again 1000 V DC 100 Mohm U1 PE V1 PE W1 PE ohm M 3 U1 V1 W1 PE Measuring the insulation resistance of the input ...

Page 95: ... as described in section Connecting control cabling page 97 Grounding the outer shields of the control cables 360 at the cabinet entry Ground the outer shields of all control cables 360 degrees with the EMI conductive cushions at the cabinet entry The grounding principle is the same for top and bottom entry cables The illustrations show the bottom entry The actual design details can vary 1 If nece...

Page 96: ...e shielding continuous 1 A B C 2 2 3 4 Stripped cable A Conductive surface of the shield exposed B Stripped part covered with copper foil C Cable shield 1 Copper foil 2 Shielded twisted pair 3 Grounding wire 4 Routing the control cables inside the cabinet Use the existing trunking in the cabinet wherever possible Use sleeving if cables are laid against sharp edges When running cables to or from a ...

Page 97: ...ectly to a component such as the control unit Notes Do not ground the outer shield of the cable here since it is grounded at the cable entry Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by inductive coupling At the other end of the cable leave the shields unconnected or ground them indirectly via a high ...

Page 98: ...s equipped with a common motor terminal cubicle option H359 follow the instructions in section Connecting the motor cables units with common motor terminal cubicle page 102 Motor connection diagram without option H366 All parallel connected inverter modules are to be cabled separately to the motor 360 earthing is to be used at the cable entries U2 V2 W2 PE U2 V2 W2 M 3 U1 W1 V1 PE Inverter unit cu...

Page 99: ...wiring from the lower front mounting plate Remove the plate 5 Disconnect the wiring from the cooling fans 6 Remove the two retaining screws of each fan 7 Pull each fan outwards to separate them from the heat exchanger housing 8 Remove the inner shroud 9 Peel off 3 5 cm 1 2 2 inches of the outer insulation of the cables above the cable entry plate for 360 high frequency grounding 10 Prepare the end...

Page 100: ...le entries for the cables to be connected Cut adequate holes into the rubber grommets Slide the grommets onto the cables Slide the cables into the cubicle through the conductive sleeves and attach the grommets to the holes 100 Electrical installation ...

Page 101: ...the appropriate terminals Tighten the screws to the torque given in section Tightening torques page 194 15 Install the inner shroud 16 With each fan align the guide pins b at the rear of the fan cowling with the slots c in the module bottom guide then reinstall the retaining screws a a b c 17 Install the lower front mounting plate Connect the wiring to the components on the mounting plate 18 Insta...

Page 102: ...e cable by twisting the shield so that the flattened shield is wider than 1 5 of its length Connecting the motor cables units with common motor terminal cubicle Output busbars If the drive is equipped with option H359 the motor cables connect to a common motor terminal cubicle The location and dimensions of the busbars are visible in the dimensional drawings delivered with the drive Connection dia...

Page 103: ... 6 Connect any separate ground conductors cables to the PE busbar in the cubicle 7 Connect the phase conductors to the output terminals Use the tightening torques specified in section Tightening torques page 194 8 Refit any shrouding removed earlier and close the cubicle doors 9 At the motor connect the cables according to instructions from the motor manufacturer Pay special attention to the phase...

Page 104: ... of the input cable connection terminals and cable entries The location and dimensions of the busbars are visible in the dimensional drawings delivered with the drive Alternatively see the example dimension drawings in the manual Connection procedure WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section E...

Page 105: ...es PE PE 6 Remove rubber grommets from the cable entries for the cables to be connected Cut adequate holes into the rubber grommets Slide the grommets onto the cables Slide the cables into the cubicle through the conductive sleeves and attach the grommets to the holes 7 Attach the conductive sleeves to the cable shields with cable ties Tie up the unused conductive sleeves with cable ties Electrica...

Page 106: ...f the cabinet 9 Connect the phase conductors of the input cable to the L1 L2 and L3 terminals Tighten the screws to the torque given under Tightening torques page 194 10 Reinstall the shrouding removed earlier 11 Close the cubicle door 106 Electrical installation ...

Page 107: ... conductivity requirement for the drive protective earth conductor If that is not the case install separate PE cabling For the conductivity requirements refer to 3AXD50000048634 English the electrical planning instructions in this manual Connection procedure WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in s...

Page 108: ...o stripped aluminum conductors before attaching them to non coated aluminum cable lugs Obey the grease manufacturer s instructions Aluminum aluminum contact can cause oxidation in the contact surfaces 7 Remove rubber grommets from the cable entries for the cables to be connected Cut adequate holes into the rubber grommets Slide the grommets onto the cables Starting from back slide the cables into ...

Page 109: ...E busbar of the cabinet Tighten the screws to the torque given in section Tightening torques page 194 10 Connect the phase conductors of the input cable to the L1 L2 and L3 terminals Tighten the screws to the torque given in section Tightening torques page 194 11 Reinstall the shrouding and assembly plates removed earlier 12 Close the cubicle door Electrical installation 109 11 ...

Page 110: ...10 110 Electrical installation ...

Page 111: ...PC can be used to control several drives or inverter units supply units etc by constructing a panel bus This is done by daisy chaining the panel connections of the drives Some drives have the necessary twin panel connectors in the control panel holder those that do not require the installation of an FDPI 02 module available separately For further information see the hardware description and FDPI 0...

Page 112: ... TERMINATED position Make sure that bus termination is off on all other drives 4 On the control panel switch on the panel bus functionality Options Select drive Panel bus The drive to be controlled can now be selected from the list under Options Select drive If a PC is connected to the control panel the drives on the panel bus are automatically displayed in the Drive composer tool With twin connec...

Page 113: ...With FDPI 02 modules OPEN TERMINATED 1 1 2 2 OPEN TERMINATED 3 Electrical installation 113 11 ...

Page 114: ...requirements and for proper operation of the module Installation of an FSO safety functions module onto BCU WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur This procedure describes the installation of an FSO safety functions module onto the BCU control unit As an alternative the FSO module can be installed adjacent to the co...

Page 115: ...ghtens the connections and grounds the module It is essential for fulfilling the EMC requirements and for proper operation of the module 5 Connect the FSO module data cable between FSO connector X110 and BCU connector X12 6 To complete the installation refer to the instructions in the applicable FSO module user s manual Electrical installation 115 11 ...

Page 116: ... Wiring of option modules See the appropriate optional module manual for specific installation and wiring instructions 116 Electrical installation ...

Page 117: ... supply board built in a metal housing The supply and inverter units of the drive are each controlled by a dedicated BCU x2 control unit The designation of the supply control unit is A51 the inverter control unit is A41 Both are connected to the power modules ie supply and inverter modules respectively by fiber optic cables In this manual the name BCU x2 represents the control unit types BCU 02 an...

Page 118: ... AI2 I current U voltage AI2 Termination switch for drive to drive link D2D D2D TERM Ground selection Determines whether DICOM is separated from DIOGND ie the common reference for the digital inputs floats See the ground isolation diagram DICOM DIOGND 7 segment display Multicharacter indications are displayed as repeated se quences of characters U is indicated briefly before o Control program runn...

Page 119: ... modules 1 and 2 VxT transmitter VxR receiver V1T V1R V2T V2R Fiber optic connection to modules 3 7 BCU 12 22 only VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to modules 8 12 BCU 22 only VxT transmitter VxR receiver V8T V8R V12T V12R Data logger memory card for inverter module communication SD CARD Real time clock battery voltage is higher than 2 8 V If the LED is off when ...

Page 120: ...ooling fan monitoring CIO module B 5 5 6 7 8 A 6 BGND 7 Shield 8 Relay outputs XRO1 XRO2 XRO3 XRO1 Charging2 Energized Closes charging contactor 250 V AC 30 V DC 2 A Norm closed NC 11 22 23 31 32 11 12 13 21 33 Common COM 12 Norm open NO 13 XRO2 Fault 1 3 Energized Indicates no fault 250 V AC 30 V DC 2 A Norm closed NC 21 Common COM 22 Norm open NO 23 XRO3 MCB ctrl 2 Energized Closes main contacto...

Page 121: ... 6 7 8 Digital input ground DICOM 2 24 V DC 200 mA 5 24VD 3 Digital input output ground DIOGND 4 Ground selection switch6 DICOM DIOGND ON OFF Analog inputs reference voltage output XAI 10 V DC RL 1 10 kohm VREF 1 5 6 7 1 2 3 4 10 V DC RL 1 10 kohm VREF 2 Ground AGND 3 Not in use by default 0 2 10 V Rin 200 kohm7 AI1 4 AI1 5 Not in use by default 0 4 20 mA Rin 100 ohm8 AI2 6 AI2 7 AI1 current volta...

Page 122: ...ific circuit diagrams 4 This input only acts as a true Safe torque off input in inverter units In other applications such as a supply or brake unit de energizing the IN1 and or IN2 terminal will stop the unit but not constitute a true safety function 5 Total load capacity of these outputs is 4 8 W 200 mA at 24 V minus the power taken by DIO1 and DIO2 6 Determines whether DICOM is separated from DI...

Page 123: ...ediate units set termination to OFF D2D TERM ON OFF RS485 connection X485 Not in use by default B 5 5 6 7 8 A 6 BGND 7 Shield 8 Relay outputs XRO1 XRO2 XRO3 XRO1 Ready Energized Ready 250 V AC 30 V DC 2 A Norm closed NC 11 22 23 31 32 11 12 13 21 33 Common COM 12 Norm open NO 13 XRO2 Running Energized Running 250 V AC 30 V DC 2 A Norm closed NC 21 Common COM 22 Norm open NO 23 XRO3 Fault 1 Energiz...

Page 124: ...rated from DIOGND ie common reference for digital inputs floats ON DICOM connected to DIOGND OFF DICOM and DIOGND separate DICOM DIOGND ON OFF Analog inputs reference voltage output XAI 10 V DC RL 1 10 kohm VREF 1 5 6 7 1 2 3 4 10 V DC RL 1 10 kohm VREF 2 Ground AGND 3 Speed reference 0 2 10 V Rin 200 kohm5 AI1 4 AI1 5 Not in use by default 0 4 20 mA Rin 100 ohm6 AI2 6 AI2 7 AI1 current voltage se...

Page 125: ...op the unit when the input signal is removed This input does not have a SIL or PL classification 4 Total load capacity of these outputs is 4 8 W 200 mA at 24 V minus the power taken by DIO1 and DIO2 5 Current 0 4 20 mA Rin 100 ohm or voltage 0 2 10 V Rin 200 kohm input selected by switch AI1 Change of setting requires reboot of control unit 6 Current 0 4 20 mA Rin 100 ohm or voltage 0 2 10 V Rin 2...

Page 126: ... 3 I D DI4 DI5 6 I D DIIL 1 2 3 4 5 6 7 XD24 24VD M O C I D 24VD D N G O I D 5 6 7 8 1 XAI 1 2 3 4 5 6 7 F E R V F E R V D N G A AI1 AI1 AI2 AI2 XAO 1 2 3 4 AO1 AGND AO2 AGND XSTO 1 2 3 4 OUT SGND IN1 IN2 2 Fault 1 If necessary you can connect an emergency stop button to the XSTO terminal Refer to chapter The Safe torque off function 2 126 Control units of the drive ...

Page 127: ...ded directly at both ends if they are in the same ground line with no significant voltage drop between the end points See the firmware manual of the inverter unit for parameter settings 1 24V DI6 t t t t t t One to six PTC thermistors connected in series 1 WARNING As the inputs pictured above are not insulated according to IEC 60664 the connection of the motor temperature sensor requires double or...

Page 128: ...is lost Note This input is NOT SIL or PL certified The XD2D connector The XD2D connector provides an RS 485 connection that can be used for basic master follower communication with one master drive and multiple followers fieldbus control through the embedded fieldbus interface EFB or drive to drive D2D communication implemented by application programming See the firmware manual of the drive for th...

Page 129: ... IN1 and or IN2 terminals of other units supply DC DC converter or brake unit will stop the unit but not constitute a true safety function FSO safety functions module connection X12 Refer to the applicable FSO module user s manual SDHC memory card slot The BCU x2 has an on board data logger that collects real time data from the power modules to help fault tracing and analysis The data is stored on...

Page 130: ...ax 15 mA DI1 DI5 5 mA DI6 Connector pitch 5 mm wire size 0 5 2 5 mm2 22 12 AWG Start interlock input DIIL XDI 7 Tightening torque 0 45 N m 4 lbf in 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Input type NPN PNP Hardware filtering 0 04 ms digital filtering up to 8 ms Connector pitch 5 mm wire size 0 5 2 5 mm2 22 12 AWG Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 Tightening torque 0 45 N ...

Page 131: ... wire size 0 5 2 5 mm2 22 12 AWG RS 485 connection X485 Tightening torque 0 45 N m 4 lbf in Physical layer RS 485 Cable type Shielded twisted pair cable with a twisted pair for data and a wire or another pair for signal ground nominal impedance 100 165 ohm for example Belden 9842 Maximum length of link 50 m 164 ft Connector pitch 5 mm wire size 0 5 2 5 mm2 22 12 AWG Safe torque off connection XSTO...

Page 132: ...memory size 4 GB The terminals of the control unit fulfill the Protective Extra Low Voltage PELV requirements The PELV re quirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output 132 Control units of the drive ...

Page 133: ...D 3 DIOGND 4 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 DIIL 7 XSTO OUT 1 SGND 2 IN1 3 IN2 4 XSTO OUT IN1 5 SGND 6 IN2 7 SGND 8 Ground selector DICOM DIOGND settings DICOM DIOGND ON All digital inputs share a common ground DICOM connected to DIOGND This is the default setting DICOM DIOGND OFF Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO signal ground DIOGND Isolation voltage 5...

Page 134: ...134 ...

Page 135: ...e 19 before you start the work Make sure that The ambient operating conditions meet the drive ambient conditions specification and enclosure rating IP code The supply voltage matches the nominal input voltage of the drive See the type designation label The insulation resistance of the input power cable motor cable and motor is measured according to local regulations and the manuals of the drive Th...

Page 136: ...unding has also been measured according to the regulations If an external brake resistor is connected to the drive The brake resistor cable is connected to the correct terminals and the terminals are tightened to the correct torque If an external brake resistor is connected to the drive The brake resistor cable is routed away from other cables The control cables are connected to the correct termin...

Page 137: ...ed drive Always refer to the delivery specific circuit diagrams when proceeding with the start up WARNING Only qualified electrical professionals are permitted to do the work described in this chapter Note For certain options such as functional safety options Q950 Q951 Q952 Q957 Q963 Q964 Q978 Q979 additional start up instructions are given in their separate manuals Action Safety WARNING Obey the ...

Page 138: ...elay typically for example as follows 120 140 C when only tripping is in use alarm 120 140 C and trip 130 150 C when both alarm and tripping are used Powering up the auxiliary circuit of the drive Make sure that it is safe to connect voltage Make sure that nobody is working on the drive or circuits that have been wired from outside into the drive cabinet the cover of the motor terminal box is in p...

Page 139: ...the motor starts stops and follows the speed reference in the correct direction when controlled through the customer specific I O or fieldbus Drives in which the Safe torque off control circuit is in use Test and validate the operation of the Safe torque off function See section Start up including validation test page 225 Drives with an emergency stop circuit options Q951 Q952 Q963 Q964 Q978 Q979 ...

Page 140: ...140 ...

Page 141: ...low 2 8 V the battery is missing or the control unit is not powered Internal voltage OK Green PWR OK The control program indicates that the equipment is faulty See the appropriate firmware manual Red FAULT Writing to SD card in progress Yellow WRITE Control panel and panel platform holder LEDs The ACS AP control panel has a status LED The control panel mounting platform or holder has two status LE...

Page 142: ...ive converter inverter Blinking red The Bluetooth interface is enabled in discoverable mode and ready for pairing Blinking blue ACS AP W only Data is being transferred through the Bluetooth interface of the control panel Flickering blue ACS AP W only There is an active fault in the unit Red Control panel mounting platform or holder with the control panel removed Power supply for the control unit i...

Page 143: ...ule is available on the Internet https new abb com drives services maintenance preventive maintenance For more information consult your local ABB Service representative www abb com searchchannels Description of symbols Description Action Inspection visual inspection and maintenance action if needed I Performance of on off site work commissioning tests measurements or other work P Replacement R 11 ...

Page 144: ...r fans if present Batteries R Control panel battery R R Control unit battery Connections and environment P P P P P P P P P P P P P Quality of supply voltage Spare parts I I I I I I I I I I I I I Spare parts P P P P P P P P P P P P P DC circuit capacitor reforming spare invert er modules and spare capacitors Inspections I I I I I I I I I I I I I Checking tightness of cable and busbar terminals Tigh...

Page 145: ...nditions ABB recommends annual drive inspections to ensure the highest reliability and optimum performance 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 Maintenance 145 ...

Page 146: ...a soft brush 4 Clean the air inlets of the fans and air outlets of the modules top 5 Clean the air inlet gratings if any on the door 6 Close the door Cleaning the exterior of the drive WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation commissioning or ma...

Page 147: ...nt fans are available from ABB Do not use other than ABB specified spare parts Frame R8i fan replacement WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation commissioning or maintenance work WARNING Use the required personal protective equipment Wear prote...

Page 148: ...a b c 148 Maintenance ...

Page 149: ...ps described in section Electrical safety precautions page 19 before you start the work 2 Remove the shrouding in front of the fan if any 3 Disconnect the fan wiring Remove the CIO module 4 Remove the four screws and pull the fan unit out 5 Remove the two screws in front of the heat exchanger 6 Install a new fan in reverse order 4 5 Maintenance 149 ...

Page 150: ...otective equipment Wear protective gloves and long sleeves Some parts have sharp edges 1 Stop the drive and do the steps in section Electrical safety precautions page 19 before you start the work 2 Remove the shrouding in front of the fan if any 3 Disconnect the fan wiring Remove the CIO module 4 Remove the two screws and slide the fan unit out 5 Remove the four screws to detach the fan from the f...

Page 151: ...4 5 6 Maintenance 151 ...

Page 152: ...llar out 5 Detach the fan from the collar and replace the fan 6 Install the new fan in reverse order 4 Replacing the common motor terminal cubicle fan WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation commissioning or maintenance work WARNING Use the req...

Page 153: ...dule 4 Undo the fastening screws 5 Pull the fan housing up and out 6 Install a new fan in reverse order to the above Replacing the brake chopper and resistor cubicle fans options D150 and D151 See chapter Resistor braking page 239 Maintenance 153 ...

Page 154: ...lb ft 2 Select the braces 4 pcs according to the width of the cubicle and attach them to the supports 3 Attach the support feet to the platform and adjust them to the correct height 4 Attach the slide plate Put the hooks a at the back of the slide plate through the holes in the cabinet frame Align the slots b in the slide plate with the braces 5 Fix the slide plate into place with the index screws...

Page 155: ... coolant pipes do not overtighten the nuts of the unions Leave 2 to 3 millimeters 0 08 to 0 12 inches of thread visible 2 3 mm 0 08 0 12 WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges Removing the module 1 Do the steps in section Electrical safety precautions page 19 2 Assemble the service platform delivered with the drive...

Page 156: ... the inlet valve a and outlet valve located on the right hand side of the cubicle Lead the drain hoses b on both sides of the cubicle into a suitable container Open the drain valves c on both sides of the cubicle This will drain all modules in the cubicle a b c 8 After the module has drained disconnect the piping from the module 156 Maintenance ...

Page 157: ...dule from falling For information on using the lifting device see Converter module lifting device for drive cabinets hardware manual 3AXD50000210268 English Reinstalling the module 1 Push the module carefully into its bay 2 Fasten the retaining screws at the top and the bottom of the module 3 Reinstall the DC busbars at the top of the module 4 Reconnect the coolant pipes to the module Maintenance ...

Page 158: ...est page 225 Capacitors The DC link of the drive contains several electrolytic capacitors Operating time load and surrounding air temperature have an effect on the life of the capacitors Capacitor life can be extended by decreasing the surrounding air temperature Capacitor failure is usually followed by damage to the unit and an input cable fuse failure or a fault trip If you think that any capaci...

Page 159: ...n section Electrical safety precautions page 19 before you start the work 2 Open the door of the cubicle in which the fuses are 3 Remove the shrouding from in front of the fuses 4 Slacken the nuts of the headless screws of the fuses so that you can slide out the fuse blocks Make note of the order of the washers on the screws 5 Remove the screws nuts and washers from the old fuses and attach them t...

Page 160: ...ury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation commissioning or maintenance work WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges 1 Stop the drive and do the steps in section Electrical safety precautions page 19 before you start the work 2 Open the...

Page 161: ... 34 lbf ft for Mersen Ferraz Shawmut fuses 5 Attach the shrouding and close the door 4 3 Control panel Refer to ACS AP I S W and ACH AP H W Assistant control panels user s manual 3AUA0000085685 English Control units BCU control unit types There are three variants of the BCU control unit used in ACS880 drives BCU 02 BCU 12 and BCU 22 These have a different number of converter module connections 2 7...

Page 162: ...age 19 before you start the work 2 Make sure that the control unit is not powered 3 Remove the fastening screw and pull the memory unit out 4 Install a memory unit in reverse order Replacing the BCU control unit battery Replace the real time clock battery if the BATT OK LED is not illuminated when the control unit is powered 1 Stop the drive and do the steps in section Electrical safety precaution...

Page 163: ...piry of mission time terminates the certification and SIL PL classification of the safety function The following options exist Renewal of the whole drive and all optional functional safety module s and components Renewal of the components in the safety function circuit In practice this is economical only with larger drives that have replaceable circuit boards and other components such as relays No...

Page 164: ...164 ...

Page 165: ...d drives Except where otherwise indicated the information is also applicable to drives built out of ACS880 liquid cooled multidrive modules Internal cooling system Each cubicle has an inlet and an outlet manifold fitted with a stop valve and a drain valve The stop valves can be closed to isolate all modules in the cubicle from the main cooling circuit In cabinet line ups built by ABB valves are co...

Page 166: ...n IGBT supply unit each module has a dedicated air to liquid exchanger as shown for item 2 1 Inverter modules 2 To From cooling unit 3 Air to liquid heat exchanger A L Heat sink HS Inlet valve a Inlet side drain valve b Outlet valve c Outlet side drain valve d The coolant used with ACS880 liquid cooled drive systems is Antifrogen L 25 or 50 mixture See Coolant specification page 170 166 Internal c...

Page 167: ...he limits specified in Technical data page 170 Install a pressure regulator to make sure that the maximum permissible operating pressure is not exceeded Install a bleed valve at the highest point of the cooling circuit and a drain valve at the lowest point The materials that can be used are listed in Cooling circuit materials page 172 Coolant temperature control The temperature of the coolant in t...

Page 168: ...it The most practical location for the valve is usually near or at the cooling unit Observe the instructions given by the manufacturer of the cooling unit Pay special attention to filling up and bleeding the pumps properly as they may be damaged if operated when dry Draining coolant into the sewer system is not allowed 1 Open the bleed valve at the cooling unit 2 Open the inlet valve and the outle...

Page 169: ...14 After one to two minutes stop the pump or block the coolant flow with a valve 15 Re check the pressure and add coolant if necessary 16 Repeat steps 13 to 15 a few times until all air is let out of the cooling circuit Listen for a humming sound and or feel the piping for vibration to find out if there is still air left in the circuit Internal cooling circuit 169 ...

Page 170: ...uit with air fill the cooling circuit with coolant specified under Coolant specification page 170 drain the cooling circuit again Maintenance intervals As a general rule the quality of the coolant should be checked at intervals of two years This can be done by distributors of Antifrogen L see www clariant com if a 250 milliliter sample is provided Technical data Coolant specification Coolant type ...

Page 171: ...re 0 40 C 32 104 F no drive output current derating required 40 45 C 104 113 F drive output current must be derated by 2 percentage points per 1 C 1 8 F temperature increase as shown by curve a 45 50 C 113 122 F If components with a maximum operating temperature of 55 C 131 F are installed in the same space as the drive modules drive output current must be derated by 6 percentage points per 1 C 1 ...

Page 172: ...36 8 C Example Maximum temperature rise Depends on heat losses and mass flow Typically 10 C 18 F with nominal losses and flow Pressure limits Base pressure 250 kPa recommended 300 kPa maximum Base pressure denotes the pressure of the system compared with the atmospheric pressure when the cooling circuit is filled with coolant Air counterpressure in expansion vessel with ACS880 1007LC cooling unit ...

Page 173: ...le rubber WARNING If you connect external piping to the internal cooling circuit use only materials that are specified above Other materials can cause galvanic corrosion If the external piping contains other materials use a cooling unit with a heat exchanger for example ACS880 1007LC to keep the external piping separate from the internal cooling circuit Internal cooling circuit 173 ...

Page 174: ...174 ...

Page 175: ...A hp kW A kVA hp kW A A A UN 690 V 300 250 292 350 355 374 466 400 355 590 390 360 0390A 7 300 250 322 400 355 413 514 450 400 650 430 400 0430A 7 350 315 359 450 400 461 574 500 450 720 480 450 0480A 7 400 355 389 500 450 499 621 550 500 780 520 480 0520A 7 450 400 449 600 500 576 717 600 560 900 600 560 0600A 7 500 450 501 700 560 643 801 700 630 1010 670 620 0670A 7 600 500 561 700 630 720 896 ...

Page 176: ...h no over loading I2 Maximum output current Available for 10 seconds at start then as long as allowed by drive temper ature Imax Typical motor power in no overload use The horsepower ratings are typical NEMA motor sizes at 575 V PN Apparent power in no overload use SN Continuous rms output current allowing 10 overload for 1 minute every 5 minutes ILd Typical motor power in light overload use PLd C...

Page 177: ...ent is derated by 3 5 percentage points per each Hz For example the derating factor for 9 Hz is 0 895 Above the output frequency of 150 Hz the output current is derated by 1 percentage point per each 10 Hz For example the derating factor for 175 Hz is 0 975 Frame sizes and power module types Inverter modules used LCL filter s used Supply module s used Frame size ACS880 37LC Type ACS880 104LC Qty T...

Page 178: ...4 0850A 7 6 6 R8i 6 R8i 4700A 7 0850A 7 E205 7 BLCL 25LC 7 4 0850A 7 8 8 R8i 7 R8i 5650A 7 0850A 7 E205 8 BLCL 25LC 7 4 0850A 7 8 8 R8i 8 R8i 6260A 7 Fuses AC fuses Notes Fuses with higher current rating than the recommended ones must not be used Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse menti...

Page 179: ...they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table DC fuses at inverter module input ACS880 37LC Type Manufacturer V A2s Clearing at 1000 V A Qty UN 690 V 170M6546 Bussmann 1250 995000 800 2 2 0390A 7 0430A 7 170M6547 Bussmann 1100 1500000 900 2 2 0480A 7 170M6548 Bussmann 1100 2150000 1000 2 2 0520A 7 170M6549 Bussmann 1000...

Page 180: ...amic brake units see ACS880 607LC 3 phase dynamic brake units hardware manual 3AXD50000581627 English Dimensions and weights See chapter Dimensions page 197 Free space requirements The values are as required by cooling maintenance and or operation of the pressure relief if present Also obey the general mechanical installation instructions Above Sides Front in mm in mm in mm 9 85 250 0 0 59 1500 Co...

Page 181: ...1000A 7 70 44 31 7 120 5 0 19 1170A 7 70 50 31 7 120 5 0 19 1270A 7 70 55 31 7 120 5 0 19 1470A 7 70 63 31 7 120 5 0 19 1620A 7 72 70 51 192 7 7 29 1940A 7 72 81 51 192 7 7 29 2180A 7 72 93 51 192 7 7 29 2390A 7 73 105 59 224 10 0 38 2880A 7 73 121 59 224 10 0 38 3160A 7 74 132 78 296 12 7 48 3580A 7 75 151 95 360 13 7 52 4050A 7 75 182 99 376 15 58 4700A 7 76 208 112 424 18 68 5650A 7 76 286 133 ...

Page 182: ...9 1376 1637 1881 2237 2740 3229 262 318 368 425 486 572 659 1182 1492 1776 2042 2422 2967 3478 210 256 297 343 392 462 533 2 32 2 38 2 41 2 44 2 49 2 54 2 58 2 3 70 21 Cu 2 3 95 29 Cu 2 3 120 41 Cu 2 3 150 41 Cu 2 3 185 57 Cu 2 3 240 72 Cu 2 3 300 88 Cu 1881 2237 2740 3229 638 728 859 989 2042 2422 2967 3478 514 588 693 800 3 44 3 49 3 54 3 58 3 3 150 41 Cu 3 3 185 57 Cu 3 3 240 72 Cu 3 3 300 88 C...

Page 183: ...820 3329 4073 4779 274 334 386 446 510 602 696 2 32 2 38 2 41 2 44 2 50 2 55 2 58 2 3 70 35 2 3 95 50 2 3 120 70 2 3 150 70 2 3 185 95 2 3 240 120 2 3 300 150 1859 2139 2525 3099 3636 723 837 957 1128 1304 2441 2820 3329 4073 4779 579 669 765 903 1044 3 41 3 44 3 50 3 55 3 58 3 3 120 70 3 3 150 70 3 3 185 95 3 3 240 120 3 3 300 150 2139 2525 3099 3636 1116 1276 1504 1304 2820 3329 4073 4779 892 10...

Page 184: ...voltage Imbalance With main circuit breaker option F255 and without grounding earthing switch without option F259 Short circuit withstand strength IEC EN 61439 1 Rated peak withstand current Ipk 143 kA Rated short time withstand current Icw 65 kA 1 s All other configurations Rated peak withstand current Ipk 105 kA Rated short time withstand current Icw 50 kA 1 s Rated peak withstand current Ipk 22...

Page 185: ...tion outside the range of 12 150 Hz requires derating See the derating information See the rating tables Current 3 kHz typical The switching frequency can vary per frame and voltage For exact values contact your local ABB representative Switching frequency 500 m 1640 ft Maximum recommended motor cable length Note Longer cables cause a motor voltage decrease which limits the available motor power T...

Page 186: ...13 24 V DC 6 A 144 W 48 V DC 2 8 A 134 W 72 V DC 1 A 72 W 110 V DC 0 55 A 60 W 125 V DC 0 55 A 69 W 220 V DC 0 27 A 60 W 250 V DC 0 27 A 68 W 400 V DC 0 15 A 60 W 500 V DC 0 13 A 65 W 600 V DC 0 1 A 60 W Rated short time withstand current 100 A for 1 0 s 140 A for 0 1 s Minimum switching capacity 12 V 3 mA K62 contact data Switching power 3 VA or 3 W minimum 2000 VA or 200 W maximum Switching capa...

Page 187: ...mponent type is not directly related to the actual communication speed Note The optical components transmitter and receiver on a fiber optic link must be of the same type Plastic optical fiber POF cables can be used with both 5 MBd and 10 MBd optical components 10 MBd components also enable the use of Hard Clad Silica HCS cables which allow longer connection distances thanks to their lower attenua...

Page 188: ... presence of corrosive gases IEC 60721 3 2 1997 IEC 60721 3 1 1997 IEC EN 60721 3 3 2002 Contamination Chemical gases Class 2C2 Chemical gases Class 1C2 Chemical gases Class 3C2 Solid particles Class 2S2 Solid particles Class 1S3 packing must support this otherwise 1S2 Solid particles Class 3S2 No conductive dust al lowed 2 Pollution degree IEC EN 60664 1 IEC EN 60721 3 2 1997 IEC EN 60721 3 1 199...

Page 189: ... Internet Disposal The main parts of the drive can be recycled to preserve natural resources and energy Product parts and materials should be dismantled and separated Generally all metals such as steel aluminum copper and its alloys and precious metals can be recycled as material Plastics rubber cardboard and other packaging material can be used in energy recovery Printed circuit boards and large ...

Page 190: ...nmental Considerations UL 50 12th edition Enclosures for Electrical Equipment Environmental Considerations UL 50E 1st edition Enclosures for Electrical Equipment Non Environmental Considerations CSA C22 2 No 94 1 15 Enclosures for Electrical Equipment Environmental Considerations CSA C22 2 No 94 2 15 Markings These markings are attached to the drive CE mark Product complies with the applicable Eur...

Page 191: ...ther product or system within its locality First environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Drive of category C1 drive of rated voltage less than 1000 V and intended for use in the first environment Drive of category C2 dr...

Page 192: ...rk 1 Supply transformer 7 Neighboring network 2 Static screen 8 Point of measurement 3 Drive 9 Low voltage 4 Equipment victim 5 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available in Technical guide No 3 EMC compliant installation and configuration for a power drive system 3AFE61348280 English 3 The motor and control cables are selected and routed acc...

Page 193: ...than 100 kA rms symmetrical amperes 600 V maximum when protected by the UL fuses given elsewhere in this chapter The cables located within the motor circuit must be rated for at least 75 C in UL compliant installations The input cable must be protected with fuses or circuit breakers These protective devices provide branch circuit protection in accordance with the national regulations National Elec...

Page 194: ...f ft M6 8 8 24 N m 17 7 lbf ft M8 Insulation supports Strength class Max torque Size 8 8 5 N m 44 lbf in M6 8 8 9 N m 6 6 lbf ft M8 8 8 18 N m 13 3 lbf ft M10 8 8 31 N m 23 lbf ft M12 Cable lugs Strength class Max torque Size 8 8 15 N m 11 lbf ft M8 8 8 32 N m 23 5 lbf ft M10 8 8 50 N m 37 lbf ft M12 Disclaimers Generic disclaimer The manufacturer shall have no obligation with respect to any produ...

Page 195: ... establish and maintain any appropriate measures such as but not limited to the installation of firewalls prevention of physical access application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft ...

Page 196: ...196 ...

Page 197: ...imensions are in millimeters for inches divide by 25 4 The data given is preliminary ABB reserves the right to modify the design at any time without notice Consult ABB for up to date drive specific information Weight Width ACS880 37LC lbs kg mm UN 690 V 4500 2040 2000 0390A 7 0430A 7 0480A 7 0520A 7 0600A 7 0670A 7 0750A 7 0830A 7 5070 2300 2400 1000A 7 1170A 7 1270A 7 5400 2450 2500 1470A 7 1620A...

Page 198: ...80 37LC lbs kg mm 10470 4750 4600 3580A 7 13600 6170 5800 4050A 7 13980 6340 6000 4700A 7 17020 7720 7300 5650A 7 17590 7980 7600 6260A 7 Note The 100 kA input cubicle option F274 adds 600 mm to the width 198 Dimensions ...

Page 199: ... Dimension drawing examples ACS880 37LC 0390A 7 with main contactor Dimensions 199 ...

Page 200: ...ACS880 37LC 0600A 7 with brake chopper and resistors The brake resistor cubicle is air cooled and is to be installed separately 200 Dimensions ...

Page 201: ...ACS880 37LC 1270A 7 with common motor terminal cubicle Dimensions 201 ...

Page 202: ...ACS880 37LC 1940A 7 with common motor terminal cubicle 202 Dimensions ...

Page 203: ...Cabinet height and depth Side view marine construction option C121 bottom cable exit Side view bottom cable exit Dimensions 203 ...

Page 204: ...Side view top cable exit without common motor terminal cubicle Side view top cable exit with common motor terminal cubicle 204 Dimensions ...

Page 205: ...Location and size of input terminals Contact ABB for details Dimensions 205 ...

Page 206: ... 100 kA input cubicle option F274 206 Dimensions ...

Page 207: ...Location and size of output terminals Units without common motor terminal cubicle Inverter module cubicle with one R8i module bottom cable exit Dimensions 207 ...

Page 208: ...Inverter module cubicle with two R8i modules bottom cable exit 208 Dimensions ...

Page 209: ...Inverter module cubicle with three R8i modules bottom cable exit Dimensions 209 ...

Page 210: ...Brake chopper cubicle 210 Dimensions ...

Page 211: ... Units with common motor terminal cubicle H359 Cubicle width 300 mm bottom cable exit Dimensions 211 ...

Page 212: ...Cubicle width 300 mm top cable exit 212 Dimensions ...

Page 213: ...Cubicle width 400 mm bottom cable exit Dimensions 213 ...

Page 214: ...Cubicle width 400 mm top cable exit 214 Dimensions ...

Page 215: ...Cubicle width 600 mm bottom cable exit Dimensions 215 ...

Page 216: ...Cubicle width 600 mm top cable exit 216 Dimensions ...

Page 217: ...ectrical parts of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage for the power semiconductors of the drive output stage thus preventing the drive from generating the torque required to rotate the motor If the motor is running when Safe torque off is activated it coasts to a stop The Safe torque off function...

Page 218: ...08 2 2010 Functional safety Safety instrumented systems for the process industry sector IEC 61511 1 2017 Adjustable speed electrical power drive systems Part 5 2 Safety require ments Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related electrical elec tronic and programmable electronic control systems IEC 62061 2021 EN 62061 2005 AC 2010 A1 2013 A...

Page 219: ... switch K and drive control unit 60 m 200 ft between multiple drives 60 m 200 ft between external power supply and first control unit 30 m 100 ft between BCU control unit and last inverter module in the chain Note A short circuit in the wiring between the switch and an STO terminal causes a dangerous fault Therefore it is recommended to use a safety relay including wiring diagnostics or a wiring m...

Page 220: ... CH1 STO IN X52 24VDC CH2 FE GND CH2 24VDC CH1 GND CH1 STO OUT X51 24VDC CH2 FE GND CH2 24VDC CH1 GND CH1 STO IN X52 24VDC CH2 FE GND CH2 24VDC CH1 GND CH1 STO OUT X51 24VDC CH2 FE GND CH2 1 2 2 3 Drive control unit 1 Inverter module s 2 To remaining inverter modules 3 Activation switch K 220 The Safe torque off function ...

Page 221: ...he activation switch Otherwise no SIL PL classification is given Pay special attention to avoiding any potential failure modes for the wiring For example use shielded cable For measures for fault exclusion of wiring see eg EN ISO 13849 2 2012 table D 4 Drive 1 Control unit 2 Activation switch K The Safe torque off function 221 ...

Page 222: ...power supply 24 V OUT SGND IN1 IN2 OUT SGND IN1 IN2 OUT SGND IN1 IN2 K XSTO XSTO XSTO 1 1 1 2 2 2 Drive 1 Control unit 2 Activation switch K Terminal designation may vary depending on drive type 222 The Safe torque off function ...

Page 223: ... OUT SGND IN1 IN2 OUT SGND IN1 IN2 OUT SGND IN1 IN2 24 V 24 V DC K XSTO XSTO XSTO 1 2 1 2 1 2 Drive 1 Control unit 2 Activation switch K Terminal designation may vary depending on drive type The Safe torque off function 223 ...

Page 224: ... this occurs Note This parameter does not affect the operation of the STO function itself The STO function will operate regardless of the setting of this parameter a running drive will stop upon removal of one or both STO signals and will not start until both STO signals are restored and all faults reset Note The loss of only one STO signal always generates a fault as it is interpreted as a malfun...

Page 225: ...de documentation of start up activities and test results references to failure reports and resolution of failures Any new validation tests performed due to changes or maintenance shall be logged into the logbook Validation test procedure After wiring the Safe torque off function validate its operation as follows Note If the drive is equipped with safety option L513 L514 L536 L537 Q950 Q951 Q952 Q9...

Page 226: ...ibed above in testing the operation when the motor is stopped Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Test the operation of the failure detection of the drive The motor can be stopped or running Open the 1st channel of the STO circuit If the motor was running it should coast to a stop The drive generates a FA81 Safe Torque Off 1 loss f...

Page 227: ... functionality is not achieved through the XSTO connectors of other control units such as the supply control unit or the brake control unit The Safe torque off function is supported by any ACS880 inverter or drive control program It is not supported by supply DC DC converter or brake firmware WARNING The drive cannot detect or memorize any changes in the STO circuitry when the drive control unit i...

Page 228: ...ctions of the drive The Safe torque off function is ineffective against deliberate sabotage or misuse The Safe torque off function has been designed to reduce the recognized hazardous conditions In spite of this it is not always possible to eliminate all potential hazards The assembler of the machine must inform the final user about the residual risks 228 The Safe torque off function ...

Page 229: ...tegrity requirement for the safety function is SIL 2 HFT 1 or PL d cat 3 the proof test for the function must be performed at least every 12 months The STO function of the drive does not contain any electromechanical components In addition to proof testing it is a good practice to check the operation of the function when other maintenance procedures are carried out on the machinery Include the Saf...

Page 230: ...function is performed and the drive trips on an STO hardware failure fault An attempt to use the STO in a non redundant manner for example activating only one channel will trigger the same reaction See the firmware manual of the drive control program for the indications generated by the drive and for details on directing fault and warning indications to an output on the control unit for external d...

Page 231: ...0 23970 1 1E 06 4 5E 07 5 0E 11 99 e 3 R8i 20 80 1 3 3 90 16330 1 3E 06 5 5E 07 6 2E 11 99 e 3 2 R8i 20 80 1 3 3 90 12390 1 6E 06 6 5E 07 7 3E 11 99 e 3 3 R8i 20 80 1 3 3 90 9980 1 9E 06 7 6E 07 8 4E 11 99 e 3 4 R8i 20 80 1 3 3 90 8360 2 1E 06 8 6E 07 9 5E 11 99 e 3 5 R8i 20 80 1 3 3 90 7190 2 4E 06 9 6E 07 1 1E 10 99 e 3 6 R8i 20 80 1 3 3 90 6310 2 6E 06 1 1E 06 1 2E 10 99 e 3 7 R8i 20 80 1 3 3 9...

Page 232: ...ter 31 22 delay 500 ms STO warning indication parameter 31 22 delay 1000 ms Terms and abbreviations Description Reference Term or abbre viation 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 re...

Page 233: ...robabilistic failure rate PFH or PFD for the safety function or subsystem Per forming a proof test at a maximum interval of T1 is required to keep the SIL capability valid The same interval must be followed to keep the PL capability EN ISO 13849 valid IEC 61508 6 T1 See also section Maintenance Mission time the period of time covering the intended use of the safety function device After the missio...

Page 234: ...xR8i ACS880 liquid cooled multidrives identified with serial numbers beginning with 1 or 8 with regard to the safety functions Safe torque off Safe motor temperature with FPTC 01 module option code L536 Safe Stop 1 SS1 t with FSPS 21 module Q986 Safe stop 1 SS1 t and SS1 r Safe stop emergency Safely limited speed Safe maximum speed Safe brake control Prevention of unexpected start up with FSO 12 m...

Page 235: ... of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 13849 2 2012 Safety of machinery Safety related parts of the control systems Part 2 Validation EN 60204 1 2018 Safety of machinery Electrical equipment of machines Part 1 General requirements The following other standard has been applied IEC 61508 2010 parts 1 3 Functional safety of electrical electro...

Page 236: ...80 liquid cooled multidrives identified with serial numbers beginning with 1 or 8 with regard to the safety functions Safe torque off Safe motor temperature with FPTC 01 module option code L536 Safe Stop 1 SS1 t with FSPS 21 module Q986 Safe stop 1 SS1 t and SS1 r Safe stop emergency Safely limited speed Safe maximum speed Safe brake control Prevention of unexpected start up with FSO 12 module opt...

Page 237: ...of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 13849 2 2012 Safety of machinery Safety related parts of the control systems Part 2 Validation EN 60204 1 2018 Safety of machinery Electrical equipment of machines Part 1 General requirements The following other standards have been applied EN 61508 2010 parts 1 3 Functional safety of electrical electro...

Page 238: ...238 ...

Page 239: ...0 chopper and D151 resistors Three phase ACS880 607LC 3 phase dynamic brake units with control of current and power by modulation For more information refer to ACS880 607LC 1 phase brake units hardware manual 3AXD50000481491 English ACS880 607LC 3 phase dynamic brake units hardware manual 3AXD50000581627 English 16 Resistor braking 239 ...

Page 240: ...240 ...

Page 241: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

Page 242: ...www abb com drives 3AXD50000251407B Copyright 2022 ABB All rights reserved Specifications subject to change without notice 3AXD50000251407 Rev B EN 2022 04 20 ...

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