ABB ACS880-M04 Hardware Manual Download

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Mechanical installation 49

Mechanical installation

Contents of this chapter

The chapter describes the mechanical installation procedure of the drive.

Contents of the package

The drive is delivered in a cardboard box. To open, remove any banding and lift the
top off the box.

Summary of Contents for ACS880-M04

Page 1: ...ABB machinery drives Hardware manual ACS880 M04 drive ...

Page 2: ...nual 3AUA0000085685 ACS BP S Basic control panel user s manual 3AXD50000032527 ACS880 01 drives and ACS880 04 drive modules Common DC systems Application guide 3AUA0000127818 Drive IEC 61131 3 application programming manual 3AUA0000127808 FDPI 02 diagnostics and panel interface user s manual 3AUA0000113618 FSO 12 safety functions module user s manual 3AXD50000015612 Technical Guide No 3 EMC Compli...

Page 3: ...nual ACS880 M04 machinery drive 3AXD50000028613 Rev A EN EFFECTIVE 2016 04 11 2016 ABB Oy All Rights Reserved 1 Safety instructions Table of contents 5 Mechanical installation 7 Electrical installation 9 Start up ...

Page 4: ......

Page 5: ...manual Contents of this chapter 21 Applicability 21 Intended audience 21 Categorization according to frame size 21 Categorization according to the code 22 Contents of the manual 22 Quick installation and commissioning flowchart 24 Terms and abbreviations 26 3 Operation principle and hardware description Contents of this chapter 29 ACS880 M04 drive overview 29 Operation principle 30 Main circuit 30...

Page 6: ...mains choke 53 Installing EMC filter 53 Installing brake resistor 53 6 Planning the electrical installation Contents of this chapter 55 Checking the compatibility of the motor and drive 55 Selecting the supply disconnecting device 56 Requirements in European Union EU countries 56 Requirements in non EU countries 56 Selecting the power cables 57 Typical power cable sizes 58 Alternative power cable ...

Page 7: ...ts of relay outputs 71 7 Electrical installation Contents of this chapter 73 Removing the cover assembly 74 Checking the insulation of the assembly 75 Drives 75 Input power cable 75 Motor and motor cable insulation 75 Break resistor assembly insulation 75 Checking the compatibility with IT ungrounded and corner grounded TN systems 76 Disconnecting the internal EMC filter all frame sizes 76 Connect...

Page 8: ...pply 110 Nominal ratings with 400 V AC supply 110 Nominal ratings with 460 V AC supply 111 Nominal ratings with 500 V AC supply 112 Definitions 112 Derating 113 Ambient temperature derating 113 Altitude derating 113 Low motor noise derating 113 Dimensions and weights 116 Terminal and lead through data for power cables 116 Screwdrivers for the terminals of main circuit 116 Losses cooling data and n...

Page 9: ...Machinery Directive 142 Connecting the STO 143 Activation switch 143 Cable types and lengths 143 Grounding of protective shields 143 STO wiring single drive unit internal power supply 144 STO wiring multiple drive units internal power supply 145 STO wiring multiple drive units external power supply 146 STO operation principle 147 STO start up and acceptance test 147 Competency for testing STO func...

Page 10: ... chapter 169 When is du dt or common mode filtering required 169 Selecting the du dt filters 170 Additional requirements for ABB motors of types other than M2_ M3_ M4_ HX_ and AM_ 171 Additional requirements for the braking applications 171 Installing du dt and common mode filters 171 du dt filters data 172 du dt filter types 172 Common mode filter types 172 du dt filters dimensions and weights 17...

Page 11: ...nsions 186 EMC filters type JFI x1 187 JFI A1 187 JFI B1 188 EMC filters type JFI 0x 189 EMC filter JFI xx dimensions 190 Brake resistors type JBR xx 191 Brake resistor JBR xx dimensions 192 Further information Product and service inquiries 194 Product training 194 Providing feedback on ABB Drives manuals 194 Document library on the Internet 194 ...

Page 12: ...12 Table of contents ...

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

Page 14: ...age 117 Before you connect voltage to the drive make sure that the drive covers are on Keep the covers on during the operation Before you adjust the drive operation limits make sure that the motor and all driven equipment can operate throughout the set operation limits Before you activate automatic fault reset functions of the drive control program make sure that no dangerous situations can occur ...

Page 15: ... Disconnect any external power sources from the control circuits before you do work on the control cables CAUTION Risk of electric shock After disconnecting the input power always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive motor or motor cable 3 Protect any other energized parts in the work location against contact 4 Take special p...

Page 16: ...Compliance with the European EMC Directive on page 134 Use all ELV extra low voltage circuits connected to the drive only within a zone of equipotential bonding that is within a zone where all simultaneously accessible conductive parts are electrically connected to prevent hazardous voltages appearing between them You can accomplish this by a proper factory grounding that is make sure that all sim...

Page 17: ...e protective earth PE conductors is sufficient See section Selecting the power cables on page 57 Obey the local regulations Connect the power cable shields to the protective earth PE terminals of the drive Make a 360 grounding of the power and control cable shields at the cable entries to suppress electromagnetic disturbances Note You can use power cable shields as grounding conductors only when t...

Page 18: ...ate during work Make sure that no other system like hydraulic crawling drives can rotate the motor directly or through any mechanical connection like felt nip rope etc Measure that the installation is de energized Use a multimeter with an impedance of at least 1 Mohm Make sure that the voltage between the drive output terminals T1 U T2 V T3 W and the grounding PE busbar is close to 0 V Make sure t...

Page 19: ...he drive Give a stop command to the drive before you reset a fault If you have an external source for the start command and the start is on the drive will start immediately after the fault reset unless you configure the drive for pulse start See the firmware manual Before you activate automatic fault reset functions of the drive control program make sure that no dangerous situations can occur Thes...

Page 20: ...20 Safety instructions ...

Page 21: ...use and service the drive Read the manual before working on the drive The reader is expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols This manual is written for readers worldwide Both SI and imperial units are shown wherever appropriate Categorization according to frame size The ACS880 M04 drive is manufactured in frame sizes R1 to R4 So...

Page 22: ...g the cabinet installation guides in planning the installation of the drive module into a user defined cabinet Mechanical installation instructs how to place and mount the drive Planning the electrical installation instructs on the motor and cable selection the protections and the cable routing Electrical installation instructs on how to wire the drive Installation checklist contains a list for ch...

Page 23: ...ltering lists the du dt and common mode filtering options available for the drive Resistor braking describes how to select protect and wire brake resistors Dimension drawings contains the dimensional drawings of the drive and connected equipment ...

Page 24: ...uded Unpack and check the drive Check that all necessary optional modules and equipment are present and correct Only intact units may be started up Contents of the package on page 49 Delivery check and drive module identification on page 50 If the converter was non operational for more than one year reform the converter DC link capacitors For more information contact your ABB representative Check ...

Page 25: ...er cables Connecting the power cables on page 77 Connect the control and the auxiliary control cables Connecting the control unit on page 85 For optional equipment Mains chokes on page 155 EMC filters on page 159 Resistor braking on page 173 Manuals for any optional equipment Check the installation Installation checklist on page 99 Commission the drive Start up on page 101 Firmware manual 3AXD5000...

Page 26: ...ic compatibility FBA Fieldbus adapter FCAN 01 01 M Optional CANopen adapter module FCNA 01 ControlNet adapter module FDNA 01 Optional DeviceNet adapter module FECA 01 01 M Optional EtherCAT adapter module FENA 01 11 21 21 M Optional Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols FEPL 02 Ethernet POWERLINK adapter module FPBA 01 01 M Optional PROFIBUS DP adapter module...

Page 27: ...ory unit attached to the control unit of the drive ZCU The control unit of the drive module The ZCU is installed on top of the power unit The external I O control signals are connected to the ZCU or optional I O extensions mounted on it Term Abbreviation Explanation ...

Page 28: ...28 About the manual ...

Page 29: ...uction of the drive module ACS880 M04 drive overview The ACS880 M04 is an air cooled IP20 drive module for controlling asynchronous induction motors permanent magnet motors and ABB synchronous reluctance motors It is optimized for cabinet mounting The drive is available in several frame sizes depending on the output power All frame sizes use the same control unit of ZCU type ...

Page 30: ...ent is measured for earth fault protection Motor output Brake chopper see chapter Resistor braking on page 173 UDC UDC V1 W1 U1 V2 W2 U2 R R AC supply ACS880 M04 drive Capacitor bank Rectifier CHK xx mains choke see chapter Mains chokes on page 155 JFI xx EMC filter see chapter EMC filters on page 159 JBR xx brake resistor see chapter Resistor braking on page 173 NOCHxxxx xx du dt filter see chapt...

Page 31: ...rol unit is mounted onto the module The control unit contains the basic I Os and slots for optional I O modules For descriptions of the I O terminals on the control unit see Connecting the control unit on page 85 Other optional equipments are primarily installed on separate mounting plates The modules are fitted with external DC fuses The frames R1 R4 modules have an internal capacitor pre charge ...

Page 32: ...red 3 Grounding clamping plates for power cables 4 ZCU 14 control unit 5 Power unit 6 Slots for optional I O modules 7 I O terminal blocks 8 Grounding clamping plate for control cables 9 Memory unit 10 Control panel connector 11 Air temperature sensor 12 Cover with recess for control panel can optionally be left out 13 Varistor board connecting screw VAR 7 6 6 6 9 8 1 2 4 5 10 3 3 12 11 13 ...

Page 33: ... cover 2 Motor output connection under connector cover 3 Grounding clamping plates for power cables 4 ZCU control unit 5 Power unit 6 Slots for optional I O modules 7 I O terminal blocks 8 Grounding clamping plate for control cables 9 Memory unit 10 Control panel connector 11 Air temperature sensor 12 Cover with panel mounting platform can optionally be left out 13 Varistor board connecting screw ...

Page 34: ...L2 L3 PE PE U2 V2 W2 M 3 t R UDC R UDC For more information on these connections see page 86 For specifications see page 125 Programmable Slot 1 Slot 2 FIO 01 Digital I O extension FIO 11 Analog I O extension FIO 21 Digital Analog I O extension FEN 01 Incremental TTL encoder interface FEN 11 Absolute encoder interface FEN 21 Resolver interface FEN 31 Incremental HTL encoder interface Slot 3 Fieldb...

Page 35: ...pe designation key below 2 Degree of protection 3 Frame size 4 Nominal ratings see Ratings on page 110 5 Valid markings 6 S N M YY W XXXX Serial number in format MYYWWXXXX where Manufacturer Year of manufacture 15 16 17 for 2015 2016 2017 Week of manufacture 01 02 03 for week 1 week 2 week 3 Running item number starting each week from 0001 1 2 3 4 5 6 ...

Page 36: ...chopper coated boards Safe torque off Primary control program Quick installation and start up Guide Current rating 04A8 For example 04A8 refers to a nominal output current of 4 8 A See Ratings on page 110 Voltage range 2 5 200 240 V 380 500 V Option codes plus codes Filters E E200 EMC filter C3 2nd Environment Unrestricted Earthed network External with frames R1 and R2 internal with frames R3 and ...

Page 37: ...ane control program Note The following technology library is required with the Crane control program N3050 Crane technology library N5000 Winder control program N8200 High speed control program Specialties P904 Extended warranty Printed hardware and firmware manuals in specified language The delivered manual set can include manuals in English if the translation is not available R R700 English R701...

Page 38: ...38 Operation principle and hardware description ...

Page 39: ...iscussed are essential for safe and trouble free use of the drive system Note The installation examples in this manual are provided only to help the installer in designing the installation Installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regul...

Page 40: ...es Check that The layout is spacious enough for easy installation and maintenance There should be sufficient space for cooling air flow obligatory clearances cables and cable support structures See the layout example in Cooling and degrees of protection on page 44 Grounding of mounting structures Make sure Proper grounding of all cross members or shelves on which the drive system components are mo...

Page 41: ... the modules are illustrated below See the free space requirements table below For dimensions of the drive modules refer to chapter Dimension drawings on page 181 Vertically alone or side by side a b Free space requirement Above a Below b On the sides c mm in mm in mm in 200 7 9 300 12 0 0 c 0 a b b a Do not install the drive upside down ...

Page 42: ...on Horizontally alone or side by side back installation Horizontally alone side installation This installation is recommended only with the R1 frame For this kind of installation with other frames use additional support c c c a b b a c ...

Page 43: ...lters of type JFI 0x see the dimension drawing of the filters on page 189 Note The temperature of the cooling air entering the unit must not exceed the maximum allowed ambient temperature see Ambient conditions on page 130 Consider this when installing heat generating components such as other drives mains chokes and brake resistors nearby 300 200 mm 7 9 300 mm 12 ...

Page 44: ...addition to the power loss of the drive module ventilate the heat dissipated by cables and other additional equipment Cooling of the modules is arranged such that the requirements meet the data in Losses cooling data and noise on page 117 Note The values apply to continuous nominal load If the load is less than nominal less cooling air is required Ambient temperature is within the limits specified...

Page 45: ...ons are listed below gratings that guide airflow at the air inlet and outlet air inlet and outlet at different sides of the cabinet cool air inlet in the lower part of the front door and an extra exhaust fan on the roof of the cabinet Inside the cabinet Prevent hot air circulation inside the cabinet with leak proof air baffle plates No gaskets are usually required HOT AREA Main airflow out Main ai...

Page 46: ... at the front part of the cabinet from the hot area back part The wall can be fastened to two vertical pillars on both left and right Since the air outlet at the top of the modules points directly upwards the air must be guided to the hot area using separate airflow guides See the example below Hot area Cool area SIDE VIEW Airflow guides Drive modules Wall Opening in the wall to allow airflow Airf...

Page 47: ...binet heater if there is a risk of condensation in the cabinet Although the primary function of the heater is to keep the air dry it may also be required for heating at low temperatures When placing the heater follow the instructions provided by its manufacturer ...

Page 48: ...48 Planning the cabinet installation ...

Page 49: ...ical installation Contents of this chapter The chapter describes the mechanical installation procedure of the drive Contents of the package The drive is delivered in a cardboard box To open remove any banding and lift the top off the box ...

Page 50: ... installed options Three cable clamp plates two for power cabling one for control cabling with screws Screw type terminal blocks to be attached to the headers on the ZCU control unit and the power unit EMC filter E200 if ordered with frames R1 and R2 only Control panel mounting kit J410 if ordered Printed quick guides Printed manuals if ordered Compartment for cable clamp plates Compartment for te...

Page 51: ...sion drawings from page 181 The operational conditions of the drive meets the Ambient conditions on page130 The surface on which the drive is to be mounted on is even as possible of non flammable material strong enough to carry the weight of the drive See sections Dimensions and weights page 116 and Free space requirements page 41 The installation site is sufficiently ventilated or cooled to trans...

Page 52: ...ossible installation directions and free space requirements on page 41 Installing the drive with screws 1 Mark the locations for the four holes The mounting points are shown in Dimension drawings 2 Fix the screws or bolts to the marked locations 3 Position the drive onto the screws on the surface Note Lift the drive only by its chassis 4 Tighten the screws W H ...

Page 53: ...ress the release lever on top of the drive as shown in the figure 2 Fasten the lower edge of the drive to the mounting base through the two fastening points Installing mains choke See chapter Mains chokes on page 155 Installing EMC filter See chapter EMC filters on page 159 Installing brake resistor See chapter Resistor braking on page 173 1 2 ...

Page 54: ...54 Mechanical installation ...

Page 55: ... whatsoever for any installation which breaches the local laws and or other regulations If recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Checking the compatibility of the motor and drive Use an asynchronous AC induction motor or a permanent magnet motor with the drive Several induction motors can be connected to the drive at a time...

Page 56: ... Union EU countries To meet the European Union Directives according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types switch disconnector of utilization category AC 23B EN 60947 3 disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconne...

Page 57: ...ply with the EMC requirements of the CE mark use an approved cable type in Recommended power cable types on page 59 Use symmetrical shielded cable to reduce the following properties electromagnetic emission of the drive system stress on motor insulation bearing currents general drive wear The protective conductor must always have an adequate conductivity The table below shows the minimum cross sec...

Page 58: ...3 1 5 1 5 16 014A 2 5 R2 3 2 5 2 5 14 018A 2 5 R2 3 4 42 14 025A 2 5 R3 3 10 10 6 030A 2 5 R3 3 10 10 6 035A 2 5 R3 3 10 10 6 044A 2 5 R3 3 10 10 6 050A 2 5 R3 3 10 10 6 061A 2 5 R4 3 10 10 6 078A 2 5 R4 3 10 10 6 094A 2 5 R4 3 10 10 6 3AXD10000434191 xls 1 The cable sizing is based on max 6 cables laid on a cable ladder side by side ambient temperature 30 C PVC insulation surface temperature 70 C...

Page 59: ...Symmetrical shielded cable with three phase conductors and symmetrically constructed PE conductor and a shield The PE conductor must meet the requirements of IEC 61439 1 see page 57 A four conductor system three phase conductors and a protective conductor on a cable tray is not allowed for motor cabling it is allowed for input cabling A four conductor system three phase conductors and a PE conduct...

Page 60: ...nts Use type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used For the North American market 600 V AC cable is accepted for up to 500 V AC A 1 000 V AC cable is required above 500 V AC below 600 V AC The power cables must be rated for 75 C 167 F Conduit Couple separate parts of a conduit together brid...

Page 61: ...C continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers trade names in parentheses Anixter Wire Cable Philsheath BICC General Corp Philsheath Rockbestos Co Gardex Oaknite CLX Shielded power cables are available from the following suppliers Belden LAPPKABEL ÖLFLEX Pirelli ...

Page 62: ... DC and 115 230 V AC signals in the same cable Signals 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 type with braided metallic screen for example ÖLFLEX by LAPPKABEL Germany was tested and approved by ABB Control panel cabl...

Page 63: ...e cable is 3 m 9 8 ft FPBA 01 PROFIBUS DP adapter module connectors Frames R1 R4 The following connector types were tested to fit in the tight space for option slot 1 Phoenix Contact SUBCON PLUS PROFIB PG SC2 part number 2708245 Lead the cable through the control cable hole on the right in the lead through plate 1 Siemens part number 6GK1 500 0EA02 Lead the cable through the middle control cable h...

Page 64: ...nce caused by the rapid changes in the drive output voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive Make sure the cable trays have good electrical bonding to each other and to the grounding electrodes Aluminum tray systems can be used to improve local equalizing of potential Cab...

Page 65: ...he emission level when there are safety switches contactors connection boxes or similar equipments on the motor cable between the drive and the motor European Union Install the equipment in a metal enclosure with 360 degree grounding for the shields of both the incoming and outgoing cable or connect the shields of the cables otherwise together US Install the equipment in a metal enclosure in a way...

Page 66: ...d motor cable in short circuits The drive protects the motor cable and motor in a short circuit situation when the motor cable is sized according to the nominal current of the drive No additional protection devices are needed Protecting the drive and the input power and motor cables against thermal overload The drive protects itself and the input and motor cables against thermal overload when the ...

Page 67: ...e function to protect the unit against ground faults in the motor and motor cable This is not a personnel safety or a fire protection feature The ground fault protective function can be reduced with a parameter 31 20 Earth fault For more information see ACS880 M04 firmware manual 3AXD50000030629 English Residual current device compatibility The drive is suitable to be used with residual current de...

Page 68: ... control mode and motor coast stop or the scalar control mode open the contactor as follows 1 Give a stop command to the drive 2 Open the contactor WARNING In vector control mode do not open the output contactor when the drive controls the motor The vector control operates faster than the contactor opens its contacts If the contactor starts to open when the drive controls the motor the vector cont...

Page 69: ...h S11 Drive main contactor on off control Q4 Bypass circuit breaker S40 Motor power supply selection drive or direct on line K1 Drive main contactor S41 Start when motor is connected direct on line K4 Bypass contactor S42 Stop when motor is connected direct on line K5 Drive output contactor ...

Page 70: ...o direct on line with S40 4 Wait for 10 seconds to allow the motor magnetization to decrease 5 Start the motor with S41 Changing the motor power supply from direct on line to the drive 1 Stop the motor with S42 2 Change the motor power supply from direct on line to the drive with S40 3 Close the main contactor of the drive with switch S11 turn to position ST for two seconds and leave in position 1...

Page 71: ...er conductors and cause a malfunction in the system To protect the contacts of relay outputs Use a noise attenuating circuit varistors RC filters AC or diodes DC which minimizes the EMC emission of inductive loads at switch off Install the noise attenuating circuit as close as possible to the inductive load Do not install a noise attenuating circuit at the relay output 230 V AC 24 V DC 230 V AC Di...

Page 72: ...72 Planning the electrical installation ...

Page 73: ...an occur Make sure that the drive is disconnected from the input power during installation If the drive is already connected to the input power wait for 5 minutes after disconnecting the input power WARNING Installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation that breaches the local laws a...

Page 74: ...installation Removing the cover assembly Remove the cover assembly from the ZCU control unit before installing the option modules or before connecting the control cables See also the module layout diagram on page 31 ...

Page 75: ...the phase conductors and between each phase conductor and 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 or 77 F For the insulation resistance of other motors please consult the manufacturer s instructions Note Moisture inside the motor casing will reduce the insulation resistance If moistur...

Page 76: ...hrough the EMC filter capacitors of the drive This can cause danger or damage the drive Do not install the drive with the internal EMC filter connected on a corner grounded TN system otherwise the drive will be damaged Note When the internal EMC filter is disconnected the drive EMC compatibility is considerably reduced See section Compliance with the European EMC Directive on page 134 Disconnectin...

Page 77: ...nt see Motor cable shield on page 60 and the cable has no symmetrical ground conductors 1 PE PE 3 PE For alternatives see Planning the electrical installation Selecting the supply disconnecting device page 56 Optional brake resistor see Resistor braking page 173 L1 L2 L3 UDC UDC R R 2 U2 V2 W2 U1 V1 W1 3 Motor V1 W1 U1 ACS880 M04 CHK xx mains choke optional See Mains chokes page 155 JFI xx EMC fil...

Page 78: ...ted to ground potential through thevaristors filtersofthedrive Thismaycausedangerordamagetothedrive If a drive whose varistors filters are not disconnected is installed on a corner grounded TN system the drive will be damaged 3 Fasten the two cable clamp plates included to the drive see page 80 one at the top one at the bottom The clamp plates are identical Using the cable clamp plates as shown be...

Page 79: ...ables Install the covers again Tighten the screws to 3 N m 25 lbf in 12 Secure the cables outside the unit mechanically 13 Ground the other end of the supply cable shield or PE conductor s at the distribution board In case a mains choke and or an EMC filter option E200 is installed make sure the PE conductor is continuous from the distribution board to the drive Grounding the motor cable shield at...

Page 80: ...luded with the drive The picture below depicts a frame size R1 drive the installation is similar with other frame sizes Note Support the cables adequately within the installation enclosure especially if not using the cable clamps Frames R1 and R2 1 5 N m 13 lbf in Frames R3 and R4 3 N m 25 lbf in 1 5 N m 13 lbf in ...

Page 81: ... page 116 Supply cable Below cable clamp cover bare shield with insulating tape Cable clamp on bare shield 1 5 N m 13 lbf in 1 5 N m 13 lbf in 1 5 N m 13 lbf in 0 5 0 6 N m 4 4 5 3 lbf in 0 5 0 6 N m 4 4 5 3 lbf in Above cable clamp cover bare shield with insulating tape Cable clamp on bare shield 1 5 N m 13 lbf in Motor cable Brake resistor cable ...

Page 82: ...oring mode One or more drives are connected to the AC supply depending on the power requirement In case two or more R1 R2 frames are connected to the AC supply each AC connection must be equipped with a mains choke to ensure even current distribution between the rectifiers The diagram below shows two configuration examples AC supply M 3 M 3 M 3 AC supply Mains chokes UDC UDC UDC UDC M 3 UDC UDC UD...

Page 83: ...ion ratings on page 123 For more information on common DC configurations see ACS880 01 drives and ACS880 04 drive modules Common DC systems Application guide 3AUA0000127818 English ____ _ _ _ ____ _ _ _ UDC UDC U1 V1 W1 R R U2 V2 W2 Pre charging circuit ACS880 M04 R1 R4 DC chokes only for frames R3 and R4 ...

Page 84: ...les proceed as follows 1 Remove the cover assembly from the ZCU control unit See Removing the cover assembly on page 74 2 Remove the protective cover if present from the connector of the slot 3 Insert the module carefully into its position on the drive 4 Fasten the screw Note Fix the screws correctly for fulfilling the EMC requirements and for proper operation of the module 5 Install the cover ass...

Page 85: ...igital inputs XSTO Safe torque off connection X12 Connector for FSO xx safety functions module optional X13 Control panel connection X202 Option slot 1 X203 Option slot 2 X204 Option slot 3 X205 Memory unit connection memory unit inserted in the drawing J1 J2 Voltage Current selection jumpers J1 J2 for analog inputs J3 Drive to drive link termination jumper J3 J6 Common digital input ground select...

Page 86: ... DC RL 1 10 kohm VREF 1 Analog outputs XAO Motor current 0 20 mA RL 500 ohm AGND 4 AO2 3 Motor speed rpm 0 20 mA RL 500 ohm AGND 2 AO1 1 Drive to drive link XD2D Drive to drive link 3 Shield 4 BGND 3 A 2 B 1 Drive to drive link termination 3 J3 Safe torque off XSTO Safe torque off Both circuits must be closed for the drive to start 4 IN2 4 IN1 3 SGND 2 OUT 1 Digital inputs XDI By default not in us...

Page 87: ...er J2 Note Changing the setting requires reboot of control unit 2 Current 0 4 20 mA Rin 100 ohm or voltage 0 2 10 V Rin 200 kohm input selected by jumper J1 Note Changing the setting requires reboot of control unit 3 See section Drive to drive link page 90 4 See chapter The Safe torque off function page 141 5 Constant speed 1 is defined by parameter 22 26 6 0 Acceleration deceleration ramps define...

Page 88: ...e that end of the shield unconnected See firmware manual for parameter settings WARNING As the inputs pictured above are not insulated according to IEC 60664 the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfill the requirement make sure of the following the I O board terminals is protected a...

Page 89: ...equires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfill the requirement the I O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I O terminals DIIL input The DIIL input can used for the connection of safety circuits By default the input is param...

Page 90: ...ROFIBUS compatible cable for the wiring For best immunity high quality cable is recommended Keep the cable as short as possible The maximum length of the link is 50 meters 164 ft Avoid unnecessary loops and running the cable near power cables such as motor cables Ground the cable shields as described in section Connecting the control cables all frame sizes on page 96 Example wiring diagram of driv...

Page 91: ...lies can be connected to BCU for redundancy Relay outputs RO1 RO3 XRO1 XRO3 Connector pitch 5 mm wire size 2 5 mm2 250 V AC 30 V DC 2 A Protected by varistors 24 V output XD24 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 Digital inputs DI1 DI6 XDI 1 XDI 6 Connector pitch 5 mm wire size 2 5 mm2 2...

Page 92: ... voltage input mode selection by jumpers switches Connector pitch 5 mm wire size 2 5 mm2 Current input 20 20 mA Rin 100 ohm Voltage input 10 10 V Rin 200 kohm Differential inputs common mode range 30 V Sampling interval per channel 0 25 ms Hardware filtering 0 25 ms adjustable digital filtering up to 8 ms Resolution 11 bit sign bit Inaccuracy 1 of full scale range Analog outputs AO1 and AO2 XAO Co...

Page 93: ...n X13 Connector RJ 45 Cable length 3 m The terminals of the control unit fulfil the Protective Extra Low Voltage PELV requirements The PELV requirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output ...

Page 94: ...1 5 AI2 6 AI2 7 XAO AO1 1 AGND 2 AO2 3 AGND 4 XD2D B 1 A 2 BGND 3 XRO1 XRO2 XRO3 NC 1 COM 2 NO 3 NC 1 COM 2 NO 3 NC 1 COM 2 NO 3 XD24 DIIL 1 24VD 2 DICOM 3 24VD 4 DIOGND 5 XDIO DIO1 1 DIO2 2 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 XSTO OUT1 1 GND 2 IN1 3 IN2 4 Ground Common mode voltage between channels 30 V ...

Page 95: ...und selector J6 settings All digital inputs share a common ground DICOM connected to DIOGND This is the default setting Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO signal ground DIOGND Isolation voltage 50 V ...

Page 96: ...n conductive turn the shield inside out as shown below and wrap copper foil around the cable to keep the shielding continuous Do not cut the grounding wire if present 3 Run the cables to the control unit of the drive or other connection point using cable trunking wherever possible 4 Only when running the cable to the drive module The drive control units have a clamp plate attached Remove the outer...

Page 97: ... appropriate terminals refer to chapter Control connections to the ZCU control unit 8 Refit any shrouds removed earlier 2 3 4 1 Keep as short as possible If no dedicated shield connector is provided ground the inner cable shields to the chassis SHIELD Where grounding clamps are not available twist the shield strands into a bundle crimp a lug terminal onto it and fasten the lug to the chassis Secur...

Page 98: ...98 Electrical installation ...

Page 99: ...ings Ambient conditions The unit is fastened properly to the cabinet See Planning the cabinet installation and Mechanical installation The cooling air will flow freely The motor and the driven equipment are ready for start See Planning the electrical installation Technical data Motor connection ELECTRICAL INSTALLATION See Planning the electrical installation Electrical installation The VAR frames ...

Page 100: ...f present is connected to R R and the terminals are tightened to specified torque The motor cable and brake resistor cable if present is routed away from other cables There are no power factor compensation capacitors in the motor cable The external control connections to the ZCU control unit are OK There are no tools foreign objects or dust from drilling inside the drive The supply input power vol...

Page 101: ...o the Installation checklist on page 99 2 Check that the motor and driven equipment are ready for start 3 Perform the start up tasks instructed by the cabinet installer of the drive module 4 Switch On the power 5 Set up the drive control program according to the start up instructions in the Firmware manual 6 Validate the Safe torque off function according to the STO acceptance test procedure on pa...

Page 102: ...102 Start up ...

Page 103: ...ult a local ABB Service representative for more details You can also check on the Internet Go to http www abb com drivesservices select Drive Services and Maintenance and Field Services Maintenance task object Interval Instruction DC capacitor reforming Every year of storage See Reforming the capacitors on page 107 Heatsink temperature check and cleaning Every 6 to 12 months depending on the dusti...

Page 104: ... dust entering the adjoining equipment perform the cleaning in another room 3 Refit the cooling fan Cooling fan replacement Every 3 years if used in clean operating environment Yearly inspection is highly recommended if used in dusty corroded or ambient temperature is higher than 40 C 104 F See Cooling fan on page 105 DC capacitor replacement Every 6 years if the ambient temperature is higher than...

Page 105: ...appearing Note Replacement fans are available from ABB Do not use spare parts other than ABB specified spare parts Replacing fan Frames R1 and R2 To replace the fan in frames R1 and R2 follow these steps 1 Detach the power cable clamp plate and terminal blocks 2 Release the retaining clips arrowed carefully using a screwdriver 3 Pull the fan holder out 4 Disconnect the fan cable 5 Carefully bend t...

Page 106: ...sing the retaining clip arrowed carefully using a screwdriver 2 Pull the fan holder out 3 Disconnect the fan cable 4 Carefully bend the clips on the fan holder to free the fan 5 Install the new fan in the reverse order Note The airflow direction is bottom to top Install the fan so that the airflow arrow points up Airflow direction ...

Page 107: ...r control unit the existing parameter settings can be retained by transferring the memory unit from the defective unit to the new unit WARNING Do not remove or insert the memory unit when the control unit is powered To remove the memory unit 1 Undo the fastening screw 2 Pull out the memory unit After power up the drive scans the memory unit If a different control program or different parameter set...

Page 108: ...108 Maintenance ...

Page 109: ...ing data and noise 117 Supply cable fuses 118 Screwdrivers for the terminals of main circuit 116 Supply cable fuses 119 121 AC input supply connection 122 DC connection 123 Motor connection 124 ZCU control unit 125 Ground isolation diagram ZCU 128 Efficiency Cooling Protection classes Ambient conditions 129 Materials 132 Applicable standards 133 CE marking UL marking RCM marking 134 138 Compliance...

Page 110: ...5 7 5 035A 2 R3 30 35 44 7 5 10 32 7 5 10 29 7 5 10 044A 2 R3 35 44 53 11 15 41 11 15 35 7 5 10 050A 2 R3 42 50 66 11 15 46 11 15 44 11 15 061A 2 R4 54 61 78 15 20 57 15 20 52 11 15 078A 2 R4 64 78 100 18 5 25 74 18 5 25 69 15 20 094A 2 R4 81 94 124 22 30 90 22 30 75 18 5 25 3AXD10000434191 See symbol definitions on page 112 Drive type ACS880 M04 Frame size Input ratings Output ratings Nominal No ...

Page 111: ... 5 2 0 4 0 2 0 06A0 5 R1 5 5 9 4 6 0 8 8 3 0 5 5 3 0 5 0 3 0 08A0 5 R1 6 6 11 2 8 0 10 5 5 0 7 6 5 0 6 0 3 0 010A 5 R2 8 7 13 10 5 13 5 5 0 9 7 5 0 9 0 5 0 014A 5 R2 12 18 14 16 5 7 5 13 0 7 5 11 0 7 5 018A 5 R2 16 23 18 21 10 16 8 10 14 0 10 025A 5 R3 20 25 33 15 23 15 19 0 10 030A 5 R3 26 30 36 20 28 20 24 15 035A 5 R3 30 35 44 25 32 20 29 20 044A 5 R3 36 44 53 30 41 30 35 25 050A 5 R3 42 50 66 ...

Page 112: ... 90 55 75 45 3AXD10000434191 See symbol definitions below I1N Nominal input current rms at 40 C 104 F Without mains choke I2N Nominal output current IMax Maximum output current Available for at least 10 seconds at start otherwise as long as allowed by drive temperature PN Typical motor power for no overload use ILd Continuous rms output current 10 overload is allowed for 1 minute every 5 minutes P...

Page 113: ...udes from 1000 to 4000 m 3300 to 13123 ft above sea level the derating is 1 for every 100 m 328 ft For a more accurate derating use the DriveSize PC tool Note If the installation site is higher than 2000 m 6600 ft above sea level connection of the drive to an ungrounded IT or corner grounded delta network is not allowed Low motor noise derating Low motor noise is activated with a drive parameter s...

Page 114: ... 17 4 5 044A 2 R3 23 29 53 5 5 10 27 5 5 7 5 22 5 5 7 5 050A 2 R3 28 33 66 7 5 10 31 7 5 10 26 5 5 7 5 061A 2 R4 37 42 78 7 5 15 37 7 5 10 31 7 5 10 078A 2 R4 42 51 100 11 15 48 11 15 41 7 5 15 094A 2 R4 53 61 124 15 20 58 15 20 45 11 15 3AXD10000434191 Drive type ACS880 M04 Frame size Input ratings Output ratings Nominal No overload use Light overload use Heavy duty use I1N I1N I2N IMax PN ILd PL...

Page 115: ... R3 24 29 66 20 27 20 22 15 061A 5 R4 31 34 78 25 31 20 27 20 078A 5 R4 36 43 100 30 41 30 34 25 094A 5 R4 45 52 124 40 49 30 38 25 3AXD10000434191 Drive type ACS880 M04 Frame size Input ratings Output ratings Nominal No overload use Light overload use Heavy duty use I1N I1N I2N IMax PN ILd PLd IHd PHd A A A A kW A kW A kW 03A0 5 R1 1 6 2 7 2 1 4 4 0 75 1 9 0 75 1 5 0 55 03A6 5 R1 2 3 4 1 2 6 5 3 ...

Page 116: ...cable clamp plates W Width D Depth with control panel Weight mm in mm in mm in mm in kg lbs R1 364 14 33 480 18 89 90 3 54 237 9 33 3 2 7 1 R2 380 14 97 480 18 89 100 3 94 315 12 40 5 4 11 9 R3 467 18 37 558 21 96 168 6 60 316 12 44 15 6 34 4 R4 467 18 37 644 25 34 223 8 76 316 12 44 21 3 47 0 Frame size U1 2 V1 2 W1 2 UDC R Grounding terminals Max wire size T T mm2 N m N m R1 4 0 5 0 6 1 5 R2 10 ...

Page 117: ... 763 362 1236 531 1812 730 2492 290 171 70 078A 2 115 393 249 851 423 1444 636 2172 889 3034 290 171 70 094A 2 115 393 272 929 481 1641 741 2530 1054 3597 290 171 70 03A0 5 68 233 75 256 83 282 91 310 100 340 24 14 47 03A6 5 68 233 76 261 86 292 96 326 106 363 24 14 47 04A8 5 74 252 84 288 97 330 110 376 126 430 24 14 47 06A0 5 74 252 88 302 106 361 126 429 148 504 24 14 47 08A0 5 74 252 93 319 11...

Page 118: ... 12 06A0 2 06A0 5 9 0 10 500 gG 10 600 T 1 5 4 16 12 08A0 2 08A0 5 11 16 500 gG 15 600 T 1 5 4 16 12 010A 2 010A 5 13 16 500 gG 15 600 T 1 5 10 16 8 014A 2 014A 5 18 20 500 gG 20 600 T 1 5 0 16 8 018A 2 018A 5 23 25 500 gG 25 600 T 1 5 10 16 8 025A 2 025A 5 20 25 500 gG 25 600 T 6 35 9 2 030A 2 030A 5 26 32 500 gG 35 600 T 6 35 9 2 035A 2 035A 5 30 40 500 gG 35 600 T 6 35 9 2 044A 2 044A 5 36 50 5...

Page 119: ... 16000 500 ABB OFAF000H50 000 061A 2 63 20000 500 ABB OFAF000H63 000 078A 2 80 37000 500 ABB OFAF000H80 000 094A 2 100 65000 500 ABB OFAF000H100 000 UN 400 V 03A0 5 6 110 500 ABB OFAF000H6 000 03A6 5 6 110 500 ABB OFAF000H6 000 04A8 5 10 360 500 ABB OFAF000H10 000 06A0 5 10 360 500 ABB OFAF000H10 000 08A0 5 16 750 500 ABB OFAF000H16 000 010A 5 16 750 500 ABB OFAF000H16 000 014A 5 20 1500 500 ABB O...

Page 120: ...0 Bussmann 170M2698 00 061A 2 80 3600 690 Bussmann 170M2699 00 078A 2 100 6650 690 Bussmann 170M2700 00 094A 2 125 12000 690 Bussmann 170M2701 00 UN 400 V 03A0 5 25 125 690 Bussmann 170M2694 00 03A6 5 25 125 690 Bussmann 170M2694 00 04A8 5 25 125 690 Bussmann 170M2694 00 06A0 5 25 125 690 Bussmann 170M2694 00 08A0 5 25 125 690 Bussmann 170M2694 00 010A 5 25 125 690 Bussmann 170M2694 00 014A 5 40 4...

Page 121: ...Bussmann 170M1566 000 061A 2 100 4650 690 Bussmann 170M1567 000 078A 2 125 8500 690 Bussmann 170M1568 000 094A 2 160 16000 690 Bussmann 170M1569 000 UN 400 V 03A0 5 25 130 690 Bussmann 170M1561 000 03A6 5 25 130 690 Bussmann 170M1561 000 04A8 5 25 130 690 Bussmann 170M1561 000 06A0 5 25 130 690 Bussmann 170M1561 000 08A0 5 25 130 690 Bussmann 170M1561 000 010A 5 25 130 690 Bussmann 170M1561 000 01...

Page 122: ... max 5 kA short circuit current An input choke should be used to achieve 100 kA Short circuit current protection UL 61800 5 1 CSA C22 2 No 274 13 US and Canada The drive is suitable for use on a circuit capable of delivering not more than 100 kA symmetrical amperes rms at 500 V maximum when protected by fuses given in the Supply cable fuses on page 118 Frequency 50 60 Hz 5 Imbalance Max 3 of nomin...

Page 123: ... 12 690 URC 03A6 3 9 120 16 690 aR 12 690 URC 04A8 4 8 240 16 690 aR 12 690 URC 06A0 6 5 240 16 690 aR 12 690 URC 08A0 8 7 240 16 690 aR 12 690 URC 010A 12 370 20 690 aR 16 690 URC 014A 15 740 32 690 aR 32 690 URD 018A 20 740 32 690 aR 32 690 URD 025A 29 670 63 690 aR 63 690 URQ 030A 38 670 63 690 aR 63 690 URQ 035A 44 1000 100 690 aR 100 690 URQ 044A 54 1000 100 690 aR 100 690 URQ 050A 54 1000 10...

Page 124: ...witching frequency 3 kHz default Maximummotor cable length Frames R1 and R2 150 m 492 ft Frames R3 and R4 300 m 984 ft 100 m with EN 61800 3 Category C3 filter Terminals Frame R1 Detachable screw terminal block for 0 25 4 mm2 wire Frame R2 Detachable screw terminal block for 0 5 6 mm2 wire Frames R3 and R4 Screw lugs for 6 70 mm2 wire included Suitable crimp lugs can be used instead ...

Page 125: ...se outputs is 4 8 W 200 mA 24 V minus the power taken by DIO1 and DIO2 Digital inputs DI1 DI6 XDI 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 used as an input for a PTC thermistor 0 4 kohm 1 1 5 kohm Imax 15 mA DI1 DI5 5 mA DI6 Sta...

Page 126: ...ed to 200 mA Reference voltage for analog inputs VREF and VREF XAI 1 and XAI 2 Connector pitch 5 mm wire size 2 5 mm2 10 V 1 and 10 V 1 Rload 1 10 kohm Analog inputs AI1 and AI2 XAI 4 XAI 7 Current voltage input mode selection by jumpers switches Connector pitch 5 mm wire size 2 5 mm2 Current input 20 20 mA Rin 100 ohm Voltage input 10 10 V Rin 200 kohm Differential inputs common mode range 30 V S...

Page 127: ...s 0 5 V 1 17 V For the drive to start both connections must be 1 Current consumption 66 mA continuous per STO channel per drive module EMC immunity according to IEC 61326 3 1 Control panel connection X13 Connector RJ 45 Cable length 3 m The terminals of the control unit fulfill the Protective Extra Low Voltage PELV requirements The PELV requirements of a relay output are not fulfilled if a voltage...

Page 128: ...AI2 6 AI2 7 XAO AO1 1 AGND 2 AO2 3 AGND 4 XD2D B 1 A 2 BGND 3 XRO1 XRO2 XRO3 NC 1 COM 2 NO 3 NC 1 COM 2 NO 3 NC 1 COM 2 NO 3 XD24 DIIL 1 24VD 2 DICOM 3 24VD 4 DIOGND 5 XDIO DIO1 1 DIO2 2 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 XSTO OUT1 1 GND 2 IN1 3 IN2 4 Ground Common mode voltage between channels 30 V ...

Page 129: ...wer level Cooling Method Internal fan flow from bottom to top Air cooled heatsink See Cooling and degrees of protection on page 44 Free space around the unit See Free space requirements on page 41 Protection classes Environmental limits for the drive are given below The drive must be used in a heated indoor controlled environment Degree of protection IEC EN 60529 IP20 UL open type See Cooling and ...

Page 130: ...o frost allowed See section Derating on page 113 40 to 70 C 40 to 158 F 40 to 70 C 40 to 158 F Relative humidity 0 to 95 Max 95 Max 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 No conductive dust allowed According to IEC 60721 3 3 Chemical gases Class 3C2 Solid particles Class 3S...

Page 131: ...ding to IEC 60721 3 3 mechanical conditions Class 3M4 2 9 Hz 3 0 mm 0 12 9 200 Hz 10 m s2 33 ft s2 Shock IEC 60068 2 27 ISTA 1A According to ISTA 1A Max 100 m s2 330 ft s2 11 ms According to ISTA 1A Max 100 m s2 330 ft s2 11 ms Free fall Not allowed 76 cm 30 76 cm 30 ...

Page 132: ...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 DC capacitors C1 1 to C1 x need selective treatment according to IEC 62635 guidelines To aid recycling plastic parts are marked with an appropriate identification code Contact your local ABB distributor...

Page 133: ... requirements and specific test methods EN 60204 1 2006 A1 2009 AC 2010 Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing emergency stop device supply disconnecting device the drive module into a cabinet EN60529 1991 A1 2000 A2 2013 Degrees of protection provided by enclosures ...

Page 134: ...unity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 2004 covers requirements stated for drives See section Compliance with the EN 61800 3 2004 below Compliance with the European ROHS Directive The RoHS Directive defines the restriction of the use of certain hazardous substances in electrical and electronic equipment Compliance with the Eur...

Page 135: ...e Do not install a drive with the internal or external EMC filter E200 on IT ungrounded systems The supply network connects to the ground potential through the internal EMC filter capacitors which may cause danger or damage to the drive For disconnecting the EMC filter see instructions on page 76 Environment Category Description First environment Includes establishments connected to a low voltage ...

Page 136: ...ve is used on such a network Category C4 If the provisions under Category C3 cannot be met the requirements of the standard can be met as follows 1 It is ensured that no excessive emission is propagated to neighboring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and ...

Page 137: ...manual 4 The drive is installed according to the instructions given in this manual WARNING A drive of category C4 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network ...

Page 138: ...mmetrical amperes 500 V or 240 V maximum when protected by the UL fuses given in the table on page118 The ampere rating is based on tests done according to the appropriate UL standard The cables located within the motor circuit must be rated for at least 75 C 167 F in UL compliant installations Integral solid state short circuit protection does not provide branch circuit protection The input cable...

Page 139: ...y 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 installation of anti virus programs etc to protect the product the network its syste...

Page 140: ...140 Technical data ...

Page 141: ...enance operations like cleaning or work on non electrical parts of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage of the power semiconductors of the drive output stage A see diagram below thus preventing the drive from generating the torque required to rotate the motor If the motor is running when Safe torq...

Page 142: ...rial applications IEC 61508 1 2010 Functional safety of electrical electronic programmable electronic safety related systems Part 1 General requirements IEC 61508 2 2010 Functional safety of electrical electronic programmable electronic safety related systems Part 2 Requirements for electrical electronic programmable electronic safety related systems IEC 61511 2003 Functional safety Safety instrum...

Page 143: ...e of a type that can be locked out to the open position The contacts of the switch or relay must open close within 200 ms of each other An FSO xx safety functions module can also be used For more information see the FSO xx module documentation Cable types and lengths Double shielded twisted pair cable is recommended Maximum cable lengths 30 m 100 ft between activation switch K and drive control un...

Page 144: ...144 The Safe torque off function STO wiring single drive unit internal power supply 24 V OUT1 SGND IN2 U2 V2 W2 Control logic UDC UDC Drive unit Control unit A K IN1 ...

Page 145: ...off function 145 STO wiring multiple drive units internal power supply 24 V OUT1 IN1 IN2 Drive unit OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 Drive unit Drive unit K XSTO Control unit XSTO Control unit XSTO Control unit SGND ...

Page 146: ...off function STO wiring multiple drive units external power supply OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 Drive unit 24 V Drive unit Control unit Drive unit 24 V DC K XSTO Control unit XSTO Control unit XSTO ...

Page 147: ...he function by performing an acceptance test The acceptance test must be performed in these conditions at initial start up of the safety function after any changes related to the safety function circuit boards wiring components settings etc after any maintenance work related to the safety function Competency for testing STO function The acceptance test of the safety function must be carried out by...

Page 148: ...tes an indication if parameter 31 22 STO indication run stop see the firmware manual is defined for stopped state 2 Give a start command to verify that the STO function blocks the operation of the drive Expected outcome The motor should not start 3 Close the STO circuit 4 Reset any active faults 5 Restart the drive and check that the motor runs normally Testing the operation of STO function when m...

Page 149: ...in and auxiliary circuits from the drive You must carry out any maintenance work on electrical parts of the drive or the motor can only after isolating the drive from the main supply WARNING The Safe torque off functionality is achieved only through the XSTO connector of the drive control unit True Safe torque off functionality is not achieved through the XSTO connectors of other control units suc...

Page 150: ... appropriate stop mode before activating the Safe torque off function The Safe torque off function overrides all other functions of the drive unit The Safe torque off function is ineffective against deliberate sabotage or misuse The Safe torque off function was designed to reduce the recognized hazardous conditions In spite of this it is not always possible to eliminate all potential hazards The a...

Page 151: ...other maintenance procedures are carried out on the machinery Include the Safe torque off operation test described above in the routine maintenance program of the machinery that the drive runs If any wiring or component change is needed after start up or the parameters are restored follow the STO acceptance test procedure on page 148 Record all maintenance and proof test activities in the machine ...

Page 152: ...non redundant manner for example activating only one channel triggers the same reaction See the drive firmware manual 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 diagnostics Any failures of the Safe torque off function must be reported to ABB Relevant failure modes The STO trips spuriously safe ...

Page 153: ... a R1 to R4 3 3 e 98 8 3 23E 09 2 99E 06 24293 90 3 1 80 20 T Number of on off cycles per year 71 66 C 670 cycles 61 66 C 1340 cycles 10 0 C 30 cycles Board temperature of time 32 C 2 0 60 C 1 5 85 C 2 3 Safety component Type A as defined in IEC 61508 2 STO reaction time shortest detectable break 1 ms STO response time Frame sizes R1 R4 2 ms typical 5 ms maximum Fault detection time Channels in di...

Page 154: ...erval under stated conditions PFD IEC 61508 Probability of failure on demand PFHD IEC 61508 Probability of dangerous failures per hour PL EN ISO 13849 1 Performance level Levels a e correspond to SIL SC IEC 61508 Systematic capability SFF IEC 61508 Safe failure fraction SIL IEC 61508 Safety integrity level 1 3 SILCL IEC EN 62061 Maximum SIL level 1 3 that can be claimed for a safety function or su...

Page 155: ...and R2 the need for an external choke should be determined on a case by case basis With frames R3 and R4 the drive modules have an internal mains choke The main choke typically reduces harmonics in the input current reduces the r m s input current reduces supply disturbance and low frequency interference increases the allowed DC bus continuous power ensures even current distribution in common DC c...

Page 156: ...on page 186 Drive type ACS880 M04 Type Inductance µH 03A0 2 03A0 5 CHK 01 6370 03A6 2 03A6 5 04A8 2 04A8 5 CHK 02 4610 06A0 2 06A0 5 08A0 2 08A0 5 010A 2 010A 5 CHK 03 2700 014A 2 014A 5 018A 2 018A 5 CHK 04 1475 025A 2 025A 5 030A 2 030A 5 035A2 035A 5 044A 2 044A 5 Internal choke as standard 050A 2 050A 5 061A 2 061A 5 078A 2 078A 5 094A 2 094A 5 3AXD10000434191 ...

Page 157: ...the same conductive surface Ensure the choke does not block the airflow through the drive module and that the air rising from the choke is deflected away from the air inlet of the drive module Keep the cable between the drive and the choke as short as possible WARNING The surface of the mains choke becomes hot when in use Connecting the mains choke AC supply ACS880 M04 CHK xx mains choke JFI xx EM...

Page 158: ...158 Mains chokes ...

Page 159: ...C requirements stated for drives tested with motor and cable within the EU Standard Description EN 55011 or EN 61000 6 3 4 These EMC standards apply to industrial and household equipments and systems including drive components inside neither specify cable length nor require a motor to be connected as a load EN 61800 3 Drive units complying with this standard are always compliant with comparable ca...

Page 160: ...ilter is internal An external EMC filter of the type JFI 0x is required in order to meet the category C2 level with the drive module installation including a motor with a max 100 m cable This level corresponds to the A limits for Group 1 equipment according to EN 55011 WARNING An EMC filter must not be installed if the drive is connected to an IT power system i e an ungrounded or a high resistance...

Page 161: ...pe ACS880 M04 Filter type EN 61800 3 2004 Category C3 EN 61800 3 2004 Category C2 03A0 2 03A0 5 Option code E200 external filter JFI A1 JFI 02 03A6 2 03A6 5 04A8 2 04A8 5 06A0 2 06A0 5 08A0 2 08A0 5 010A 2 010A 5 Option code E200 external filter JFI B1 JFI 03 014A 2 014A 5 018A 2 018A 5 025A 2 025A 5 Option code E200 internal filter JFI 05 030A 2 030A 5 035A2 035A 5 044A 2 044A 5 050A 2 050A 5 061...

Page 162: ...uidelines Connect the filter directly to the drive input connectors For optimal operation of the filter mount the drive and the filter on the same conductive surface JFI x1 filter connection diagram AC supply ACS880 M04 CHK xx mains choke if present JFI x1 EMC filter L1 L2 L3 PE DC supply U1 V1 W1 UDC UDC ...

Page 163: ...ing bracket 3 to the drive module base with two screws 4 Tighten to 1 5 N m 13 lbf in 3 Push the filter into place through the mounting bracket 4 Fasten the filter to the mounting bracket with two screws 5 Tighten to 1 5 N m 13 lbf in 5 Fasten the top edge of the filter to the mounting base with two screws 6 6 Fasten the power cable clamp plate at the top of the filter Tighten to 1 5 N m 13 lbf in...

Page 164: ...164 EMC filters 7 Attach the terminal blocks to the filter 1 6 5 4 3 ...

Page 165: ...er power cable clamp plate 2 from the drive 2 Push the filter into the connectors 3 Fasten the filter to the drive module base with two screws 3 Tighten to 1 5 N m 13 lbf in 4 Fasten the top edge of the filter to the mounting base with two screws 4 5 Fasten the power cable clamp plate at the top of the filter Tighten to 1 5 N m 13 lbf in ...

Page 166: ...166 EMC filters 6 Attach the terminal blocks to the filter 1 2 3 4 ...

Page 167: ... the connection diagram below For optimal operation of the filter the drive and the filter must be mounted on the same conductive surface Ensure the filter does not block the airflow through the drive module Keep the cable between the drive and the filter as short as possible JFI 0x filter connection diagram AC supply ACS880 M04 CHK xx mains choke if present JFI 0x EMC filter L1 L2 L3 L1 L2 U1 V1 ...

Page 168: ...168 EMC filters ...

Page 169: ...ergo the following situation The voltage of the pulses can be almost double at the motor terminals depending on the attenuation and reflection properties of the motor cable and the terminals This in turn can cause additional stress on the motor and motor cable insulation Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses th...

Page 170: ...Nominal AC supply voltage Requirement for Motor insulation system ABB du dt and common mode filters insulated N end motor bearings PN 100 kW and frame size IEC 315 PN 134 hp and frame size NEMA 500 ABB motors Random wound M2_ M3_ and M4_ UN 500 V Standard Form wound HX_ and AM_ UN 500 V Standard Old form wound HX_ and modular UN 500 V Check with the motor manufacture r N CMF Random wound HX_ and A...

Page 171: ...this voltage increase when you specify the motor insulation requirements if the motor will be braking a large part of its operation time Example Select the motor insulation system for a 400 V AC line voltage application as if the drive were supplied with 480 V Installing du dt and common mode filters Follow the instructions provided with the filters Abbreviation Definition UN Nominal AC line volta...

Page 172: ...10A 5 014A 2 014A 5 018A 2 018A 5 025A 2 025A 5 NOCH0030 60 3 phase 030A 2 030A 5 035A2 035A 5 044A 2 044A 5 NOCH0070 60 3 phase 050A 2 050A 5 061A 2 061A 5 078A 2 078A 5 094A 2 094A 5 NOCH0120 60 1 phase three filters included in kit 3AXD10000434191 Filter type Height mm inches Width mm inches Depth mm inches Weight kg lbs NOCH0016 60 195 7 68 140 5 51 115 4 53 2 4 5 3 NOCH0030 60 215 8 46 165 6 ...

Page 173: ... drives have a built in brake chopper as standard equipment to handle the energy generated by a decelerating motor When the brake chopper is enabled and a resistor is connected the chopper starts conducting when the DC link voltage of the drive reaches UDC_BR 30 V The maximum braking power is achieved at UDC_BR 30 V Pre selected resistors See the available ABB brake choppers shown in the Brake cho...

Page 174: ...ng rules apply The resistance of the custom resistor must be at least Rmin The braking power capacity with different resistance values can be calculated from the following formula WARNING Never use a brake resistor with a resistance below the value specified for the particular drive type The drive and the chopper are not able to handle the overcurrent caused by the low resistance The maximum braki...

Page 175: ... 0 3 0 9 0 25 06A0 2 1 5 0 8 1 4 0 75 1 3 0 35 08A0 2 010A 2 2 8 1 0 2 7 0 9 2 25 0 75 4 0 80 014A 2 4 1 1 3 3 9 1 2 3 3 1 1 7 3 40 018A 2 5 3 1 7 5 1 1 6 4 25 1 4 025A 2 6 8 3 8 6 5 3 4 5 25 2 7 15 4 20 030A 2 7 8 4 4 7 4 4 0 6 3 1 035A 2 044A 2 11 4 6 4 10 8 5 7 8 75 4 5 22 0 13 050A 2 061A 2 20 2 14 0 20 0 11 8 18 8 078A 2 094A 2 03A0 5 1 0 0 4 1 0 0 4 0 9 0 3 5 5 120 03A6 5 1 5 0 5 1 4 0 5 1 3...

Page 176: ...raking time exceeds 30 seconds Pbrmax Maximum braking power of the drive drive and chopper The drive drive and chopper withstands this braking power for 1 second within every 10 seconds Note The listed resistors withstand this braking power for 1 second within every 120 seconds Rmin The minimum allowed resistance of the brake resistor ...

Page 177: ...e maximum allowable temperature Note All brake resistors must be installed outside the drive module Brake resistors degree of protection Note The SACE resistors are not UL listed Drive type ACS880 M04 Example brake resistor JBR xx Example brake resistor SACExxxxx Type R ohm Pn W Epulse kJ Type R ohm PRcont kW ER kJ 03A0 2 03A0 5 JBR 01 120 105 22 03A6 2 03A6 5 04A8 2 04A8 5 06A0 2 06A0 5 08A0 2 08...

Page 178: ...r braking Brake resistors dimensions See dimensions drawings of Brake resistors type JBR xx on page 191 For details of dimensions wire sizes and tightening torques see Brake resistor JBR xx dimensions on page 192 ...

Page 179: ...r is hundreds of degrees Celsius Protect the resistor against contact The maximum length of the resistor cable s is 20 m 65 ft For the connections see Cable routing diagram on page 64 Contactor protection of drive The drive must be equipped with a main contactor for safety reasons Wire the contactor so that it opens in case the resistor overheats This is essential for safety since the drive will n...

Page 180: ...Overvoltage control 3 Adjust any other relevant parameters in group 43 Brake chopper WARNING If the drive is equipped with a brake chopper but the chopper is not enabled by the parameter setting the internal thermal protection of the drive against resistor overheating is not in use In this case the brake resistor must be disconnected Note Some brake resistors are coated with oil film for protectio...

Page 181: ...d the related accessories are show below The dimensions are given in millimetres and inches See Frame size R1 on page 182 Frame size R2 on page 183 Frame size R3 on page 184 Frame size R4 on page 185 Mains chokes type CHK 0x on page 186 EMC filters type JFI x1 on page 187 EMC filters type JFI 0x on page 189 Brake resistors type JBR xx on page 191 ...

Page 182: ...Dimension drawings 182 Frame size R1 H1 H2 W D ...

Page 183: ...Dimension drawings 183 Frame size R2 H2 H1 W D ...

Page 184: ...Dimension drawings 184 Frame size R3 D W H1 H2 ...

Page 185: ...Dimension drawings 185 Frame size R4 W H1 H2 D ...

Page 186: ... 100 3 94 100 3 94 dim D mm in 77 3 03 105 4 13 105 4 13 105 4 13 dim E mm in 114 4 49 148 5 83 148 5 83 148 5 83 F screw size M5 M5 M5 M5 Weight kg lbs 1 8 4 0 3 8 8 4 5 4 11 9 5 2 11 5 Wire size Main terminals mm2 AWG 0 5 10 20 6 0 5 10 20 6 0 5 10 20 6 0 5 10 20 6 Tightening torque Main terminals N m lbf in 1 5 13 1 5 13 1 5 13 1 5 13 PE Chassis terminals M4 M5 M5 M5 Tightening torque PE Chassi...

Page 187: ...187 Dimension drawings EMC filters type JFI x1 JFI A1 ...

Page 188: ...Dimension drawings 188 JFI B1 ...

Page 189: ...189 Dimension drawings EMC filters type JFI 0x ...

Page 190: ... 65 2 56 Dim G mm in 5 4 0 21 5 4 0 21 5 4 0 21 6 5 0 26 Dim H mm in 1 0 04 1 0 04 1 0 04 1 5 0 06 Dim I mm in 22 0 87 25 0 98 39 1 54 45 1 77 Dim J M5 M5 M6 M10 Dim K mm in 22 5 0 89 25 0 98 42 5 1 67 45 1 77 Dim L mm in 29 5 1 16 39 5 1 56 26 5 1 04 64 2 52 Weight kg lbs 0 8 1 75 1 1 2 4 1 8 4 0 3 9 8 5 Wire size solid mm2 AWG 0 2 10 AWG24 8 0 5 16 AWG20 6 6 35 AWG8 2 16 50 AWG4 1 0 Wire size st...

Page 191: ...191 Dimension drawings Brake resistors type JBR xx ...

Page 192: ... 6 69 Dim D mm in 345 13 58 465 18 31 595 23 43 Dim E mm in 210 8 27 330 12 99 460 18 11 Dim F mm in 110 4 33 230 9 06 360 14 17 Weight kg lbs 0 75 1 7 0 8 1 8 1 8 4 0 3 0 6 6 3 9 8 6 Max wire size Main terminals 10 mm2 AWG6 Tightening torque Main terminals 1 5 1 8 N m 13 16 lbf in Max wire size Thermal switch terminals 4 mm2 AWG12 Tightening torque Thermal switch terminals 0 6 0 8 N m 5 3 7 1 lbf...

Page 193: ...193 Dimension drawings ...

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