ABB ACS880-37LC Hardware Manual Download Page 110

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BCU-x2 ground isolation diagram

Control units of the drive 137

Ground isolation diagram

XPOW

+24VI

GND

+24VI

GND

XAI

+VREF

-VREF

AGND

AI1+

AI1-

AI2+

AI2-

XAO

AO1

AGND

AO2

AGND

XD2D

BGND

SHIELD

XRO1, XRO2, XRO3

COM

XD24

+24VD

DICOM

+24VD

DIOGND

XDIO

DIO1

DIO2

DIOGND

XDI

DI1

DI2

DI3

DI4

DI5

DI6

DIIL

XSTO

OUT

SGND

IN1

IN2

XSTO OUT

IN1

SGND

IN2

SGND

Common mode voltage
between each AI input and
AGND is +30 V

Ground

*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 50 V.

110 Control units of the drive

Summary of Contents for ACS880-37LC

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

Page 2: ......

Page 3: ...37LC drives Hardware manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation 9 Start up 2019 ABB Oy All Rights Reserved 3AXD50000251407 Rev A EN EFFECTIVE 2019 06 30 ...

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Page 5: ...ization by frame size and option code 22 Use of component designations 22 Quick installation commissioning and operation flowchart 23 Terms and abbreviations 23 Related manuals 3 Operation principle and hardware description 25 Contents of this chapter 25 Supply unit 26 AC voltage and current waveforms 26 Charging 26 Inverter unit 27 Overview circuit diagram of the drive 28 Cabinet line up and layo...

Page 6: ...2 Checking the delivery 43 Moving and unpacking the drive 43 Moving the drive in its packaging 43 Lifting the crate with a forklift 44 Lifting the crate with a crane 45 Moving the crate with a forklift 45 Removing the transport package 46 Moving the unpacked drive cabinet 46 Lifting the cabinet with a crane 47 Moving the cabinet on rollers 47 Moving the cabinet on its back 48 Final placement of th...

Page 7: ...he cables 67 General guidelines IEC 67 Continuous motor cable shield or enclosure for equipment on the motor cable 68 Separate control cable ducts 68 Implementing thermal overload and short circuit protection 68 Protecting the input cabling and the drive upon a short circuit 68 Protecting the motor and motor cable in short circuits 68 Protecting the drive and the power cables against thermal overl...

Page 8: ...abinet entry 83 Routing the control cables inside the cabinet 83 Connecting control cabling 85 Connecting the motor cables units without common motor terminal cubicle 85 Motor connection diagram without option H366 86 Procedure 88 Connecting the motor cables units with common motor terminal cubicle 88 Output busbars 88 Connection diagram 88 Procedure 89 Connecting an external brake resistor assemb...

Page 9: ...nce intervals 121 Cabinet 121 Cleaning the interior of the cabinet 121 Power connections and quick connectors 121 Retightening the power connections 122 Fans 122 Frame R8i fan replacement 123 Replacing the heat exchanger fan in the filter cubicle 124 Replacing the fan in the incoming cubicle 125 Replacing the fan in the auxiliary control cubicle 125 Replacing the common motor terminal cubicle fan ...

Page 10: ...ntervals 140 Technical data 140 Coolant specification 140 Coolant type 140 Temperature limits 142 Pressure limits 142 Coolant flow rate limits 142 Cooling circuit materials 13 Technical data 145 Contents of this chapter 145 Ratings 146 Definitions 146 Derating 146 Ambient temperature derating 147 Coolant temperature derating 147 Antifreeze content derating 147 Altitude derating 147 Switching frequ...

Page 11: ...finitions 161 Category C3 162 Category C4 163 RCM marking 163 EAC Eurasian Conformity marking 163 Tightening torques 163 Electrical connections 163 Mechanical connections 163 Insulation supports 164 Cable lugs 164 Disclaimers 164 Generic disclaimer 164 Cybersecurity disclaimer 14 Dimensions 165 Cabinet line up dimensions 167 Dimension drawing examples 167 ACS880 37LC 0390A 7 with main contactor 16...

Page 12: ...pean Machinery Directive 185 Wiring 185 Activation switch 185 Cable types and lengths 185 Grounding of protective shields 186 Dual channel connection with internal power supply 187 Single channel connection of activation switch 188 Multiple drives 188 Internal power supply 189 External power supply 190 Operation principle 191 Start up including acceptance test 191 Competence 191 Acceptance test re...

Page 13: ...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 14: ...careful when removing or reinstalling the bars Whenever possible use a lifting device attached to the designated lifting points Secure 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 components or power modules there is a risk of overturning Secure the cabinet also to the wall when necessary Do not stand or walk on th...

Page 15: ...tors Validate any safety circuits for example Safe torque off or emergency stop in start up See separate instructions for the safety circuits Note If you select an external source for the start command and it is on the drive will start immediately after fault reset unless you configure the drive for pulse start See the firmware manual Depending on the wiring and parametrization of the drive the st...

Page 16: ...er system If you need to store the drive in temperature below 15 C 5 F drain the cooling circuit or make sure that it is filled with the coolant specified by ABB Drives with the cooling unit Do not open the cooling unit pump inlet or outlet valves before filling up the coolant circuit The pumps are filled with a mixture at the factory to prevent corrosion and the valves are closed at the factory D...

Page 17: ... cooling unit if present open the motor protective circuit breaker s 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 Make sure that re connection is not possible Lock out and tag out Disconnect any dangerous external voltages from the control circuits After you disconnect power from the driv...

Page 18: ...re the cabinet by arc welding If you have to obey the welding instructions in the drive manuals Note The motor cable terminals of the drive are at a dangerous voltage when the input power is on regardless of whether the motor is running or not When the input power is on the drive DC bus is at a dangerous voltage If brake chopper and resistor are in use they are at a dangerous voltage Options D150 ...

Page 19: ...uctors is sufficient See the electrical planning instructions of the drive Obey the local regulations Connect the power cable shields to protective earth PE terminals of the drive to make sure of personnel safety Make a 360 grounding of the power and control cable shields at the cable entries to suppress electromagnetic disturbances In a multiple drive installation connect each drive separately to...

Page 20: ...ugh any mechanical connection like felt nip rope etc Do the steps in section Electrical safety precautions page 17 Measure that the installation is de energized Use a multimeter with an impedance greater than 1 Mohm Make sure that the voltage between the drive output terminals T1 U T2 V T3 W and the grounding PE busbar is close to 0 V Make sure that the voltage between the drive input power termin...

Page 21: ...gorization by frame size and option 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 m...

Page 22: ...ent conditions page 157 Check the installation site Mechanical installation page 41 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 67 Route the cables Electrical installation page 79 Connect the power cables Connect the control cables Installati...

Page 23: ...verter unit Series of optional liquid cooled brake chopper modules NBRW Common term for drive module inverter module supply module brake chopper module etc Power module Radio frequency interference RFI Safe torque off IEC EN 61800 5 2 STO Supply module s under control of one control board and related components Supply unit Related manuals Code Name Drive hardware manuals and guides 3AXD50000251407...

Page 24: ...nual for Safely limited speed with the encoder interface Q965 for ACS880 07 17 37 drives 3AXD50000014979 User s manual for ATEX certified motor thermal protection functions L513 Q971 and L514 Q971 for cabinet built ACS880 drives 3AUA0000145920 User s manual for Emergency stop configurable stop category 0 or 1 Q978 for ACS880 07 17 37 drives 3AUA0000145921 User s manual for Emergency stop configura...

Page 25: ...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 26: ...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 risen t...

Page 27: ...t 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 e...

Page 28: ...e input power cable terminals and switchgear auxiliary voltage switch charging switch and circuit breaker shown B LCL filter cubicle LCL 1 C LCL filter cubicle LCL 2 D Supply module cubicle ISU E Inverter module cubicle INU Contains the motor cable terminals F See also sections Door switches and lights page 30 and Control panel page 31 28 Operation principle and hardware description ...

Page 29: ... 1 2 3 Feedback interface modules 1 2 3 Fieldbus communication modules 4 RDCO xx DDCS communication option module standard equipment As standard a fiber optic link connects the supply and inverter control units 2 3 4 Additional modules can be installed on an optional FEA 03 extension adapter connected to an RDCO module on slot 4 Memory unit 5 Connection for FSO xx safety functions module 6 Control...

Page 30: ...iliary 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 To close the main disconnecting device auxiliary voltage must be switched on and the grounding switch if present must be open Auxiliary voltage switch Q21 The auxiliary vo...

Page 31: ... can be removed by pulling it forward by the top edge and reinstalled in reverse order For the use of the control panel see ACX AP x assistant control panel user s manual 3AUA0000085685 English and the firmware manual Control by PC tools There is a USB connector on the front of the panel that can be used to connect a PC to the drive When a PC is connected to the control panel the control panel key...

Page 32: ...on of persons against access to hazardous parts with finger 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 braces at the top of the cabinet Addit...

Page 33: ...vered with drive for the actual wiring Output for motor space heater option G313 The option contains load switch for providing electrical isolation during service miniature circuit breaker for overcurrent protection terminal block for heater and external heater supply connection When the drive is powered and not faulted the heater is switched off Otherwise the heater is controlled by the external ...

Page 34: ...e marked with white tape or printing Short obvious connections or conductors going to plug type connectors are not marked G339 class A2 T3 S Equipment pin identifiers are marked with snap on markers or equivalent on conductors that connect to equipment terminal blocks or detachable plug type connectors or are part of the wiring between power modules Plug type connector identifications are marked o...

Page 35: ...he option contains The option provides switched and protected connections for 3 phase auxiliary motor fans Each fan connection is equipped with fuses a manual motor starter switch with an adjustable current limit a contactor controlled by the drive and terminal block X601 for customer connections The number of connections must be specified when ordering The maximum number of connections available ...

Page 36: ...om left express the basic drive type The optional selections are given thereafter separated by plus signs eg E202 Codes preceded by a minus sign eg J400 indicate the absence of the specified feature The main selections are described below Not all selections are available for all types For more information refer to the ordering instructions available separately on request Description Code Basic cod...

Page 37: ...ght 200 mm See section Descriptions of options page 32 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 Marine product certification issued by ...

Page 38: ...on Descriptions of options page 32 H359 Gland plate out of 3 mm thick aluminum blind H364 Control cable entry through floor of cabinet H367 Control panel ACS AP W control panel with Bluetooth J400 Fieldbus adapters diverse communication options FDNA 01 DeviceNet adapter module K451 FLON 01 LonWorks adapter module K452 FPBA 01 PROFIBUS DP adapter module K454 FCAN 01 CANopen adapter module K457 FSCA...

Page 39: ...main breaker contactor Q952 Prevention of unexpected start up with safety relays by activating the Safe torque off function Only for installation altitudes up to 2000 meters 6561 ft Q957 Emergency stop category 0 with safety relays by activating the Safe torque off function Q963 Emergency stop category 1 with safety relays by activating the Safe torque off function Q964 Safely limited speed with F...

Page 40: ...h R705 Finnish R706 French R707 Spanish R708 Portuguese R709 Russian R711 Complete documentation user manuals in memory stick R715 Hard copies of documentation R716 Second set of hard copies of documentation R717 40 Operation principle and hardware description ...

Page 41: ...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 in every 3 meters Level the installation site if necessary as the cabinet is not equipped with adjustable feet Necessary tools The tools required for...

Page 42: ...ontrol unit s at the factory appropriate drive and optional module manuals delivery documents Check that there are no signs of damage Before attempting installation and operation check the information on the type designation labels of the drive to verify that the delivery is of the correct type 42 Mechanical installation ...

Page 43: ...d door devices When you are using a pallet truck check its load capacity before you move the drive The drive cabinet 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 Mechanical installation 43 10 ...

Page 44: ...Lifting the crate with a crane max 20 b a Lifting point a Optimal position for the lifting sling as close to the traverse board as possible b 44 Mechanical installation ...

Page 45: ...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 45 10 ...

Page 46: ...sport 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 with a crane Lift the drive cabinet using its lifting eyes The lifting eyes can be removed after the cabinet is in its final position but their mountin...

Page 47: ...ose to its final location 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 Support the cabinet from below alongside the cubicle seams Cabinet back panel Support Mechanical installation 47 10 ...

Page 48: ...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 48 Mechanical installation ...

Page 49: ...inverter module replacement a b 120 w 250 mm 9 85 Note 1 Any height adjustment must be done before fastening 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 If the cabinet is delivered with lifti...

Page 50: ...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 fasten 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 Fastening top to wall Clamping bottom to floor M16 50 Mechanical installation ...

Page 51: ...bolts The recommended maximum distance between the front edge fastening points is 800 mm 31 5 2 If the back fastening holes are not accessible fasten the top of the cabinet to the wall with L brackets not included in the delivery bolted to the lifting eye bar holes Fastening top to wall Fastening bottom to floor M16 Mechanical installation 51 10 ...

Page 52: ...allation 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 Fastening to wall Fastening to floor with a clamp M16 3 e d a b c 2 3 Fastening the cabinet at the top 2 Clamping the cabinet to the floor at the back d Corner bra...

Page 53: ...bicle The screws required for the joining are enclosed in a plastic bag inside the cabinet The threaded bushings are already mounted on the cabinet posts 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 ...

Page 54: ...sts of the joining cubicle to the posts of the other section with 14 screws 7 per post Tighten the screws to 5 N m 3 7 lbf ft 7 Fasten the second section to the floor 1 3 5 4 4 4 8 Connect the PE busbars using the M10 bolts and nuts included Tighten to 35 40 N m 25 30 lbf ft b a c a 35 40 N m 25 30 lbf ft a Plain washer b Spring washer c Bolt and nut 54 Mechanical installation ...

Page 55: ...assivation c Spring washer with mechanically sprayed zinc coating d Nut WARNING Make sure you install the washers 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 ...

Page 56: ...C 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 thickness of the zinc plating of the cabinet frame is 100 to 200 micrometers 4 to 8 mil WARNING ...

Page 57: ...tallation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Selecting the 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 m...

Page 58: ... current See the appropriate parameters in the firmware manual 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 ...

Page 59: ...andard 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 wi...

Page 60: ... 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 in the applied drive...

Page 61: ...ditional 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 hig...

Page 62: ...eased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed in the applied drive operation range Additional note for sine filters A sine filter also protects the motor insulation system The peak phase to phase voltage with a sine filter is approximately 1 5 UN Check the availability of the sine filter from ABB Sele...

Page 63: ...otective earthing conductor shall be determined in a manner which produces a conductance equivalent to that which results from the application of this table Minimum cross sectional area of the corresponding protective conductor Sp mm2 Cross sectional area of the phase conductors S mm2 S1 2 S 16 16 16 S 35 S 2 35 S 1 Drive safety standard IEC EN 61800 5 1 use a protective earth conductor with a cro...

Page 64: ...ee phase conductors and a shield or armor and separ ate PE conductor cable1 1 A separate PE conductor is required if the conductivity of the shield or armor is not sufficient for the PE use Alternate power cable types Use as motor cabling Use as input power cabling Cable type Yes with phase conductor smaller than 10 mm2 8 AWG or motors up to 30 kW 40 hp Yes EMT Four conductor cabling in metal cond...

Page 65: ...ed power cable types Use as motor cabling Use as input power cabling Cable type No No PE Symmetrical shielded cable with in dividual shields for each phase conductor Power cable shield If the cable shield is used as the sole protective earth PE conductor make sure that its conductivity agrees with the PE conductor requirements To effectively suppress radiated and conducted radio frequency emission...

Page 66: ...l signals but single shielded b twisted pair cable is also acceptable a b Signals in separate cables Run analog and digital signals in separate shielded cables Do not mix 24 V DC and 115 230 V AC signals in the same cable Signals that can be 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 controll...

Page 67: ...ocal equalizing of potential This figure illustrates the cable routing guidelines with an example drive min 200 mm 8 in 90 min 500 mm 20 in 1 2 3 3 2 1 4 min 300 mm 12 in 2 4 3 min 300 mm 12 in Motor cable 1 Input power cable 2 Control cable 3 Brake resistor or chopper cable if any 4 Continuous motor cable shield or enclosure for equipment on the motor cable To minimize the emission level when saf...

Page 68: ...rding to the nominal current of the drive No additional protection devices are needed Protecting the drive and the power cables against thermal 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 mult...

Page 69: ...ase the ground leakage current and may cause nuisance faults in circuit breakers Implementing the emergency stop function You can order the drive with an emergency stop function See the appropriate manual for more information Code Name 3AUA0000119895 Emergency stop stop category 0 option Q951 for ACS880 07 17 17LC 37 37LC drives user s manual 3AUA0000119896 Emergency stop stop category 1 option Q9...

Page 70: ...stall a safety switch between the permanent magnet motor and the drive output The switch is needed to isolate the motor during any maintenance work on the drive Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate For vector control mode and motor ramp stop open the contactor as follows 1 Give a stop comma...

Page 71: ...anual 3AXD50000027782 English CPTC 02 ATEX certified thermistor protection module Ex II 2 GD option L537 Q971 user s manual 3AXD50000030058 English Protecting the contacts of relay outputs Inductive loads relays contactors motors cause voltage transients when switched off The relay contacts on the drive control unit are protected with varistors 250 V against overvoltage peaks In spite of this it i...

Page 72: ...sensor con nector must be left unconnected x x x Basic insulation between sensor connector and drive control unit connector No insulation between sensor connector and other I O connectors FAIO 01 No special requirement x Reinforced insulation between sensor connector and other connect ors including drive control unit con nector FPTC xx1 1 Suitable for use in safety functions SIL2 PL c rated Protec...

Page 73: ...s Safe brake control SBC Safe stop 1 SS1 Safe stop emergency SSE Safely limited speed SLS and Safe maximum speed SMS The settings of the FSO xx module are at default when delivered from the factory The wiring of the external safety circuit and configuration of the FSO xx module are the responsibility of the user The FSO xx module reserves the standard Safe torque off STO connection of the inverter...

Page 74: ...er supply 230 or 115 V AC external fuse 16 A gG G313 Power supply connection for a motor space heater output 230 V AC external fuse 16 A gG Using power factor compensation capacitors with the drive Power factor compensation is not needed with AC drives However if a drive is to be connected in a system with compensation capacitors installed note the following restrictions WARNING Do not connect pow...

Page 75: ...protective component as close to the inductive load as possible Do not install protective components at the relay outputs 2 3 4 230 V AC 230 V AC 24 V DC 1 Relay output 1 Varistor 2 RC filter 3 Diode 4 Implementing a motor temperature sensor connection WARNING IEC 60664 and IEC 61800 5 1 require double or reinforced insulation between live parts and the surface of accessible parts of electrical eq...

Page 76: ...s that you can connect to each option module the temperature sensor insulation requirement in order to form together with the insulation of the option module a reinforced insulation between the motor live parts and the drive control unit Temperature sensor insulation requirement Temperature sensor type Option module Pt100 Pt1000 KTY PTC Insulation Isolation Type Reinforced insulation x x Galvanic ...

Page 77: ...nsulation requirement for the sensor to fulfill decisive voltage class A double insulation of IEC 60800 5 1 The table also shows the insulation of the factory installed relay plus code option for a cabinet installed drive and the insulation requirement for the sensor Temperature sensor insulation requirement Pt100 relay Insulation Type Basic insulation Basic insulation 6 kV External relay Double o...

Page 78: ...78 ...

Page 79: ...ARNING Do not make any 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 Checking the insulation of the motor and motor cable WARNING Obey...

Page 80: ...nd the Protective Earth conductor Use a measuring voltage of 1000 V DC The insulation resistance of an ABB motor must exceed 100 Mohm reference value at 25 C 77 F For the insulation resistance of other motors consult the manufacturer s instructions Note Moisture inside the motor casing reduces the insulation resistance If moisture is suspected dry the motor and repeat the measurement 1000 V DC 100...

Page 81: ...Connecting control cabling page 83 Grounding the outer shields of the control cables at the cabinet entry Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions as follows example constructions are shown below the actual hardware may vary 1 Loosen the tightening screws of the EMI conductive cushions and pull the cushions apart 2 Cut adequate holes to the rubber g...

Page 82: ... cables for each grommet as follows ensuring that each cable has a proper contact to the cushions on both sides Max number of cables per grommet Cable diameter in mm 4 13 3 17 2 25 1 25 5 Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions Electrical installation 99 5 Arrange the bunches according to size from thickest to the thinnest between the...

Page 83: ... cabling when connecting to a terminal block inside the cabinet The grounding is done in the same way when connecting directly 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 lead through Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caus...

Page 84: ...ground them indirectly via a high frequency capacitor with a few nanofarads eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points 84 Electrical installation ...

Page 85: ...rive is 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 88 Motor connection diagram without option H366 All parallel connected inverter modules are to be cabled separately to the motor 360 earthing is to be used at cable lead throughs U2 V2 W2 PE U2 V2 W2 M 3 U1 W1 V1 PE Inverter ...

Page 86: ...es 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 13 Attach the conductive sleeves to the cable shields with cable ties Tie up the unused conductive sleeves with cable ties 14 Seal the gap between the cable and mineral wool sheet if us...

Page 87: ...ground the cable by twisting the shield so that the flattened shield is wider than 1 5 of its length a b c 4 a 8 b 17 19 PE PE 10 13 12 Electrical installation 87 11 ...

Page 88: ...W1 V1 PE Inverter unit cubicle Common motor terminal cubicle The recommended cable types are given in chapter Technical data Procedure WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Electrical safety precautions page 17 before you start the work 2 Open the door of the cubicle and remove ...

Page 89: ...stors page 267 For the location of the terminals refer to the dimension drawings delivered with the unit or the dimension drawing examples in chapter Dimensions a b b 1 5 a Grommet 4 Cut the cables to suitable length Strip the cables and conductors 5 Twist the cable screens into bundles and connect the bundles to the PE busbar in the cubicle 6 Connect any separate ground conductors cables to the P...

Page 90: ...ee the example dimension drawings in the manual Connection procedure WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Electrical safety precautions page 17 before you start the work 2 Open the door of the incoming cubicle 3 Remove the shrouding covering the input terminals 4 Peel off 3 to ...

Page 91: ... 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 8 Attach the conductive sleeves to the cable shields with cable ties Tie up the unused conductive sleeves with cable ties Electrical installation 91 11 ...

Page 92: ...082 10 Connect the twisted shields of the cables to the PE busbar of the cabinet 11 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 163 12 Reinstall the shrouding removed earlier 13 Close the cubicle door 92 Electrical installation ...

Page 93: ...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 02 diagnostics and panel interface user s manual 3AUA0000113618 English The maximum allowed length of the cable chain is 100 m 328 ft 1 Connect the panel to one driv...

Page 94: ...witch 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 connectors in the control panel holder 1 2 3 1 94 Electrical installation ...

Page 95: ...ATED 3 Installing option modules Mechanical installation of I O extension fieldbus adapter and pulse encoder interface modules See hardware description for the available slots for each module Install the option modules as follows Electrical installation 95 11 ...

Page 96: ...nto BCU WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur This procedure describes the installation of an FSO xx safety functions module onto the BCU control unit The FSO xx can alternatively be installed beside the control unit which is the standard with factory installed FSO xx modules For instructions see the FSO...

Page 97: ...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 xx data cable between FSO xx connector X110 and BCU x2 connector X12 6 To complete the installation refer to the instructions in the User s manual delivered with the FSO xx 126 Electrical installation 2 Tighten the FSO xx electronics grounding s...

Page 98: ... Wiring of optional modules See the appropriate optional module manual for specific installation and wiring instructions 98 Electrical installation ...

Page 99: ...r 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 a...

Page 100: ...for analog input 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 Cont...

Page 101: ...to modules 1 and 2 VxT transmitter VxR receiver V1T V1R V2T V2R Fiber optic connection to modules 3 7 BCU 12 22 only VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to modules 8 12 BCU 22 only VxT transmitter VxR receiver V8T V8R V12T V12R Data logger memory card for inverter module communication SD CARD Real time clock battery voltage is higher than 2 8 V If the LED is off whe...

Page 102: ...ertemperature 2 DI2 Run enable 3 1 run enable 3 DI3 MCB fb 2 0 main contactor breaker open 4 DI4 Not in use by default Can be used for eg auxiliary circuit breaker fault 5 DI5 Not in use by default Can be used for eg earth fault monitoring 6 DI6 Reset 3 0 1 fault reset 7 DIIL Not in use by default Can be used for eg emergency stop XDIO Digital input outputs 1 DIO1 Not in use by default 2 DIO2 Not ...

Page 103: ...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 DIOGND ie common reference for digital inputs floats DICOM DIOGND ON DICOM connected to DIOGND OFF DICOM and DIOGND separate 7 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 ...

Page 104: ...Digital input output ground DIOGND 3 Digital input output ground DIOGND 4 Auxiliary voltage output XD24 24 V DC 200 mA 6 24VD 5 Digital input ground DICOM 6 24 V DC 200 mA 6 24VD 7 Digital input output ground DIOGND 8 Ground selection switch 7 DICOM DIOGND Analog inputs reference voltage output AI 10 V DC RL 1 10 kohm VREF 1 10 V DC RL 1 10 kohm VREF 2 Ground AGND 3 Speed reference 0 2 10 V Rin 20...

Page 105: ...ws The sensor can alternatively be connected to FEN xx encoder interface module At the sensor end of the cable leave the shields unconnected or ground them indirectly via a high frequency capacitor with a few nanofarads for example 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 See the f...

Page 106: ...on 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 DIIL input The DIIL input is used for the connection of safety circuits The input is parametrized to stop the unit when the input signal is...

Page 107: ... chapter The Safe torque off function page 183 Note The XSTO input only acts as a true Safe torque off input on the inverter control unit De energizing the IN1 and or IN2 terminals of other units supply DC DC converter or brake unit will stop the unit but not constitute a true safety function FSO xx safety functions module connection X12 See the user manual of the FSO xx module Note that the FSO x...

Page 108: ...s V output 24 2 and XD24 4 Connector pitch 5 mm wire size 2 5 mm2 Total load capacity of these outputs is 4 8 W 200 mA 24 V minus the power taken by DIO1 and DIO2 tal inputs DI1 DI6 I 1 XDI 6 Connector pitch 5 mm wire size 2 5 mm2 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Input type NPN PNP DI1 DI5 NPN DI6 Hardware filtering 0 04 ms digital filtering up to 8 ms DI6 XDI 6 can alternatively be use...

Page 109: ... 30 V DC Logic levels 0 5 V 1 17 V Note For the unit to start both connections must be 1 This applies to all control units including drive inverter supply brake DC DC converter etc control units but true Safe torque off functionality is only achieved through the XSTO connector of the drive inverter control unit Current consumption 66 mA continuous per STO channel per R8i module EMC immunity accord...

Page 110: ...OGND 8 XDIO DIO1 1 DIO2 2 DIOGND 3 DIOGND 4 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 DIIL 7 XSTO OUT 1 SGND 2 IN1 3 IN2 4 XSTO OUT IN1 5 SGND 6 IN2 7 SGND 8 Common mode voltage between each AI input and AGND is 30 V Ground 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 di...

Page 111: ...at The ambient operating conditions meet the drive ambient conditions specification and enclosure rating IP code or UL enclosure type The supply voltage matches the nominal input voltage of the drive See the type designation label The drive cabinet has been attached to floor and if necessary due to vibration etc also by its top to the wall or roof If the drive is connected to a network other than ...

Page 112: ...ations If an external brake resistor has been connected to the drive The brake resistor has been connected to the appropriate terminals and the terminals have been tightened to the proper torque If an external brake resistor has been connected to the drive The brake resistor cable has been routed away from other cables The control cables have been connected to the appropriate terminals and the ter...

Page 113: ...customized drive Always refer to the delivery specific circuit diagrams when proceeding with the start up WARNING Only qualified electricians are allowed to do the work described in this chapter Note For certain options such as functional safety options Q950 Q951 Q952 Q957 Q963 Q964 Q978 Q979 additional start up instructions are given in their separate manuals Action Safety WARNING Obey the safety...

Page 114: ...disconnectors supplying the auxiliary voltage circuits Close the cabinet doors Close the main breaker of the supply transformer Switch on the auxiliary voltage Q21 Drives of frame size 1 R8i 1 R8i Close the main switch disconnector Q1 1 This will power up the main circuit of the drive as well as the auxiliary voltage circuit Setting up the supply unit parameters Check the voltage range setting in ...

Page 115: ...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 acceptance test page 191 Drives with an emergency stop circuit options Q951 Q952 Q963 Q964 Q978 Q979 Test and validate the operation of the emergency stop circuit See the delivery specific circuit diagrams and wiring s...

Page 116: ...116 ...

Page 117: ... BATT OK battery voltage is below 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 ACX AP x control panel has a status LED The control panel mounting plat...

Page 118: ...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 con trol panel removed Power supply for the control unit ...

Page 119: ...representative www abb com searchchannels Years from start up Maintenance task object 12 11 10 9 8 7 6 5 4 3 2 1 0 Coolant P P P P P P P P P P P P P Checking coolant antifreeze concentration P P P P P P Checking coolant quality R R Coolant draining and replacement See ACS880 1007LC liquid cooling unit user s manual 3AXD50000129607 English ABB cooling unit if present Cooling fans R Supply module cu...

Page 120: ...ess corrosion temperature I I I I I I I I I I I I I Checking coolant pipe connections 3AXD10000578918 F Symbols Inspection visual inspection and maintenance action if needed I Performance of on off site work commissioning tests measurements or other work P Replacement R Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified r...

Page 121: ...art the work 2 Open the cabinet door 3 Clean the interior of the cabinet Use a vacuum cleaner and 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 Power connections and quick connectors Retightening the power connections WARNING Obey the instructions in chapter Safety instructions If you ignore the...

Page 122: ...ts Frame R8i fan replacement WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Repeat the steps described in section Electrical safety precautions page 17 2 Remove any shrouding in front of the cooling fan 3 Disconnect the fan wiring 4 Undo the two retaining screws a 5 Pull the fan outwards to separate it from the heat exchanger housing 6 Install new fan in reverse orde...

Page 123: ...eat the steps described in section Electrical safety precautions page 17 before you start the work 2 Remove the shrouding in front of the fan if any 3 Disconnect the fan wiring 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 123 ...

Page 124: ...lectrical safety precautions page 17 before you start the work 2 Remove the shrouding in front of the fan if any 3 Disconnect the fan wiring 4 Remove the two screws and slide the fan unit out 5 Remove the four screws to detach the fan from the fan unit 6 Remove the eight screws surrounding the fan unit 7 Install a new fan in reverse order 4 5 6 124 Maintenance ...

Page 125: ...ng screws of the fan collar and slide the fan with the collar 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 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 17 before you start the work 2 Remov...

Page 126: ... Replacing the brake chopper and resistor cubicle fans options D150 and D151 See chapter Resistor braking page 199 126 Maintenance ...

Page 127: ...ing the coolant High pressure warm coolant 6 bar max 50 C is present in the internal cooling circuit when it is in operation WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges Removing the module 1 Repeat the steps described in section Electrical safety precautions 2 Remove the shrouding in front of the module 3 Undo the locki...

Page 128: ... on both sides of the cubicle into a suitable container Open the drain valves c on both sides of the cubicle This will drain all modules in the cubicle a b c 7 After the module has drained disconnect the piping from the module 8 Remove the module retaining screws at the top and the bottom of the module 128 Maintenance ...

Page 129: ... into overtemperature warnings and faults if the heatsink is not clean When necessary clean the heatsink as follows 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 electrician do not do installation or maintenance work WARNING Use a vacuum cleaner with antistatic hose and nozzle Using a normal vacu...

Page 130: ...itors must be reformed if the drive has not been powered either in storage or unused for a year or more The manufacturing date is on the type designation label For information on reforming the capacitors see Converter module capacitor reforming instructions 3BFE64059629 English in the ABB Library https library abb com en If the drive module has been stored for one to three years turn on the mains ...

Page 131: ...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 to the new fuses Make sure to keep the washers in the original ord...

Page 132: ...000085685 English Cleaning the control panel Use a soft damp cloth to clean the control panel Avoid harsh cleaners which could scratch the display window Replacing the control panel battery For instructions on how to replace the control panel battery see the separate ACx AP x assistant control panels user s manual document 3AUA0000085685 English 132 Maintenance ...

Page 133: ...ew control unit WARNING Do not remove or insert the memory unit when the control unit is powered 1 Stop the drive and do the steps in section Electrical safety precautions page 17 before you start the work 2 Make sure that the control unit is not powered 3 Undo the fastening screw and pull the memory unit out 4 Install a memory unit in reverse order Replacing the BCU control unit battery Replace t...

Page 134: ...5 Set the real time clock 134 Maintenance ...

Page 135: ...s applicable to cabinet built ACS880 liquid cooled drives Except where otherwise indicated the information is also applicable to drives built out of ACS880 liquid cooled multidrive modules Internal cooling system Note This section describes cabinet built liquid cooled ACS880 drives The information in this section can be used as guidelines for building a drive system out of ACS880 liquid cooled mod...

Page 136: ... 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 water mixture See Coolant specification page 140 136 Internal cooling circuit ...

Page 137: ...e limits specified in Technical data page 140 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 142 Coolant temperature control The temperature of the coolant in th...

Page 138: ...on 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 outlet side drain valve of one cu...

Page 139: ... 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 139 ...

Page 140: ...t with coolant specified under Coolant specification page 140 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 Antifrogen L by Clariant Internation...

Page 141: ... If there are no components with a maximum operating temperature of 55 C 131 F installed in the same space as the drive modules drive output current must be derated by 2 percentage points per 1 C 1 8 F temperature increase as shown by curve b The drawing below shows the derating factor k in relation to coolant temperature Internal cooling circuit 131 The drawing below shows the derating factor k i...

Page 142: ... compared with the atmospheric pressure when the cooling circuit is filled with coolant Air counterpressure in the expansion tank 40 kPa Design pressure PS 600 kPa Nominal pressure difference between main in out lines 120 kPa with 25 75 volume coolant solution 150 kPa with 50 50 volume coolant solution This has to be taken into account when dimensioning the liquid cooling circuit Maximum pressure ...

Page 143: ...umstances Even minor dissolution of copper can cause copper precipitation on aluminum and subsequent galvanic corrosion The liquid cooling system must not contain any zinc eg galvanized pipes If the plant incorporates normal iron pipes or cast iron accessories eg motor housings a cooling unit with a heat exchanger such as the ACS880 1007LC must be used to separate the systems Internal cooling circ...

Page 144: ...144 ...

Page 145: ...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 146: ... with 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 P...

Page 147: ...ng factor for 5 kHz is 0 84 Output frequency derating Below the output frequency of 12 Hz the output current 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 In...

Page 148: ... 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...

Page 149: ...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 2800000 1100 2 2 0600A 7 ...

Page 150: ...weights See chapter Dimensions page 165 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 5 90 150 Cooling data noise Noise Heatdissipa tion Coolant flow Coolant volume ACS880 37LC dB A kW US gal min l min US gal l UN...

Page 151: ... 31 7 120 5 0 19 1270A 7 61 55 31 7 120 5 0 19 1470A 7 61 63 31 7 120 5 0 19 1620A 7 62 70 51 192 7 7 29 1940A 7 62 81 51 192 7 7 29 2180A 7 62 93 51 192 7 7 29 2390A 7 63 105 59 224 10 0 38 2880A 7 63 121 59 224 10 0 38 3160A 7 64 132 78 296 12 7 48 3580A 7 64 151 95 360 13 7 52 4050A 7 65 182 99 376 15 58 4700A 7 66 208 112 424 18 68 5650A 7 66 238 116 440 20 75 6260A 7 Technical data 151 ...

Page 152: ...262 1182 210 2 32 2 3 70 21 Cu 1376 318 1492 256 2 38 2 3 95 29 Cu 1637 368 1776 297 2 41 2 3 120 41 Cu 1881 425 2042 343 2 44 2 3 150 41 Cu 2237 486 2422 392 2 49 2 3 185 57 Cu 2740 572 2967 462 2 54 2 3 240 72 Cu 3229 659 3478 533 2 58 2 3 300 88 Cu 1881 638 2042 514 3 44 3 3 150 41 Cu 2237 728 2422 588 3 49 3 3 185 57 Cu 2740 859 2967 693 3 54 3 3 240 72 Cu 3229 989 3478 800 3 58 3 3 300 88 Cu ...

Page 153: ...0 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 1020...

Page 154: ...ed to a terminal block in the drive cubicle see the drive specific circuit diagrams for details The external voltage switched by the contacts is to be connected to the same terminal block K3 contact data Rated operational AC current Ie IEC EN 60947 5 1 AC 15 24 127 V 50 60 Hz 6 A 220 240 V 50 60 Hz 4 A 400 440 V 50 60 Hz 3 A 500 V 50 60 Hz 2 A 690 V 50 60 Hz 2 A Rated making breaking capacity IEC ...

Page 155: ...ts defined in IEEE519 Harmonic distortion THD Current THD Voltage Rsc 2 51 3 20 2 5 4 0 with types 0390A 0520A 7 1 0 8 100 In nth harmonic component IN nominal current 1 Other loads may influence the THD value THD Total Harmonic Distortion THD The voltage THD depends on the short circuit ratio Rsc The spectrum of the distortion also contains interharmonics Rsc Isc IN Isc short circuit current at p...

Page 156: ...Avago Technologies Versatile Link range Note that the optical component 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...

Page 157: ...roups of environmental paramet ers and their severities Stationary use of weather protected locations Contamination Chemical gases Class 2C2 Solid particles Class 2S2 Chemical gases Class 1C2 Solid particles Class 1S3 packing must support this otherwise 1S2 Chemical gases Class 3C2 Solid particles Class 3S2 No conductive dust al lowed IEC EN 60721 3 2 1997 IEC EN 60721 3 1 1997 IEC EN 60721 3 3 20...

Page 158: ...t be arranged Cabinets are fastened to the pallet with screws and braced from the top end to the package walls to prevent swaying inside the package Package elements are at tached to each other with screws The main parts of the drive can be recycled to preserve natural resources and en ergy Product parts and materials should be dismantled and separated Generally all metals such as steel aluminum c...

Page 159: ...propriate European harmonized standards Compliance with the European EMC Directive The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 2004 covers requirements stated for drives See also the separate section about the Compliance with EN 61800 3 Compliance with the European RoHS Directive Th...

Page 160: ...y C4 drive 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 C3 The drive complies with the standard with the following provisions 1 The drive is equipped with EMC filter E210 and common mode filter E208 2 The motor and control cables are selected as specified in the hardware manual 3 The dri...

Page 161: ...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 C2 drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the f...

Page 162: ...les is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings can be used 1 2 3 4 5 6 7 8 9 4 6 Medium voltage network 1 Neighboring network 2 Point of measurement 3 Low voltage 4 Equipment victim 5 Equipment 6 Supply transformer 7 Static screen 8 Drive 9 2 An EMC plan for preventing disturbances is drawn up for the installation A template is...

Page 163: ... Belarus and Kazakhstan Tightening torques Unless a tightening torque is specified in the text the following torques can be used Electrical connections Note Torque Size Strength class 4 6 8 8 0 5 N m 4 4 lbf in M3 Strength class 4 6 8 8 1 N m 9 lbf in M4 Strength class 8 8 4 N m 35 lbf in M5 Strength class 8 8 9 N m 6 6 lbf ft M6 Strength class 8 8 22 N m 16 lbf ft M8 Strength class 8 8 42 N m 31 ...

Page 164: ...e information and data via a network interface It is Customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls application of authentication measures encryption of data in...

Page 165: ...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 166: ...Weight Width ACS880 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 7 166 Dimensions ...

Page 167: ... Dimension drawing examples ACS880 37LC 0390A 7 with main contactor Dimensions 167 ...

Page 168: ...ACS880 37LC 0600A 7 with brake chopper and resistors The brake resistor cubicle is air cooled and is to be installed separately 168 Dimensions ...

Page 169: ...ACS880 37LC 1270A 7 with common motor terminal cubicle Dimensions 169 ...

Page 170: ...ACS880 37LC 1940A 7 with common motor terminal cubicle 170 Dimensions ...

Page 171: ...Cabinet height and depth Marine construction option C121 IP42 side view Non marine IP42 side view Dimensions 171 ...

Page 172: ...Location and size of input terminals Contact ABB for details 172 Dimensions ...

Page 173: ...Location and size of output terminals Units without common motor terminal cubicle Inverter module cubicle with one R8i module bottom cable exit Dimensions 173 ...

Page 174: ...Inverter module cubicle with two R8i modules bottom cable exit 174 Dimensions ...

Page 175: ...Inverter module cubicle with three R8i modules bottom cable exit Dimensions 175 ...

Page 176: ...Brake chopper cubicle D150 176 Dimensions ...

Page 177: ... Units with common motor terminal cubicle H359 Cubicle width 300 mm bottom cable exit Dimensions 177 ...

Page 178: ...Cubicle width 300 mm top cable exit 178 Dimensions ...

Page 179: ...Cubicle width 400 mm bottom cable exit Dimensions 179 ...

Page 180: ...Cubicle width 400 mm top cable exit 180 Dimensions ...

Page 181: ...Cubicle width 600 mm bottom cable exit Dimensions 181 ...

Page 182: ...Cubicle width 600 mm top cable exit 182 Dimensions ...

Page 183: ...utput stage A see the diagrams below 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 has a redundant architecture that is both channels must be used in the safety function implementation The safety data given in this manual is calculated for redundant use and...

Page 184: ...C 61511 1 2016 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 2005 A1 2012 A2 2015 EN 62061 2005 AC 2010 A1 2013 A2 2015 Safety of machinery Safety related parts of control systems Part 1 ...

Page 185: ...ontrol unit 60 m 200 ft between multiple drives or inverter units 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 meth...

Page 186: ...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 Inverter control unit 1 Inverter module s 2 To remaining inverter modules 3 Activation switch K 186 The Safe torque off function ...

Page 187: ...ctivation 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 Inverter unit 1 Control unit 2 Activation switch K The Safe torque off function 187 ...

Page 188: ...4 V OUT SGND IN1 IN2 OUT SGND IN1 IN2 OUT SGND IN1 IN2 K XSTO XSTO XSTO 1 1 1 2 2 2 Drive Inverter unit 1 Control unit 2 Activation switch K Terminal designation may vary depending on drive inverter unit type 188 The Safe torque off function ...

Page 189: ...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 Inverter unit 1 Control unit 2 Activation switch K Terminal designation may vary depending on drive inverter unit type The Safe torque off function 189 ...

Page 190: ...en 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 malf...

Page 191: ...hall include documentation of start up activities and test results references to failure reports and resolution of failures Any new acceptance tests performed due to changes or maintenance shall be logged into the logbook Acceptance test procedure After wiring the Safe torque off function validate its operation as follows Note If the drive is equipped with safety option L536 L537 Q950 Q951 Q952 Q9...

Page 192: ...he 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 should coast to a stop The drive generates a FA81 Safe Torque Off 1 loss fault...

Page 193: ...upply 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 With permanent magnet or synchronous reluctance SynRM motors only In case of a multiple IGBT power semiconductor failure the drive can produce an alignment torque which maximally rotates the mo...

Page 194: ...grity 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 Safe ...

Page 195: ...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 196: ...ions 670 on off cycles per year with ΔT 71 66 C 1340 on off cycles per year with ΔT 61 66 C 30 on off cycles per year with ΔT 10 0 C 32 C board temperature at 2 0 of time 60 C board temperature at 1 5 of time 85 C board temperature at 2 3 of time The STO is a type B safety component as defined in IEC 61508 2 Relevant failure modes The STO trips spuriously safe failure The STO does not activate whe...

Page 197: ...cified safety function over a given period of time IEC 61508 PFH Performance level Levels a e correspond to SIL EN ISO 13849 1 PL Systematic capability IEC 61508 SC Safe failure fraction IEC 61508 SFF Safety integrity level 1 3 IEC 61508 SIL Maximum SIL level 1 3 that can be claimed for a safety function or subsystem IEC EN 62061 SILCL Safe torque off IEC EN 61800 5 2 STO Proof test interval T1 is...

Page 198: ...198 ...

Page 199: ...Resistor braking The ACS880 37LC employs ACS880 607LC 1 phase brake units For more information refer to ACS880 607LC 1 phase brake units hardware manual 3AXD50000481491 English 16 Resistor braking 199 ...

Page 200: ...200 ...

Page 201: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

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Summary of Contents for ACS880-37LC

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ABB ACS880-37LC, Hardware Manual

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Summary of Contents for ACS880-37LC

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