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ABB ACS880-07 Hardware Manual
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ABB ACS880-07 Hardware Manual

Industrial drives (45 to 630 kw, 50 to 700 hp)
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ABB industrial drives
Hardware manual
ACS880-07 drives
(45 to 630 kW, 50 to 700 hp)

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Summary of Contents for ABB ACS880-07

  • Page 1 ABB industrial drives Hardware manual ACS880-07 drives (45 to 630 kW, 50 to 700 hp)
  • Page 2 Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative. The QR code below opens an online listing of the manuals applicable to this product.
  • Page 3 Hardware manual ACS880-07 drives (45 to 630 kW, 50 to 700 hp) Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 10. Start-up  2014 ABB Oy. All Rights Reserved. 3AUA0000105718 Rev D EFFECTIVE: 2014-01-21...

  • Page 5: Table Of Contents

    Table of contents 1. Safety instructions Contents of this chapter ..........13 Use of warnings .
  • Page 6 CSA approved (option +C134) ......... 44 Resistor braking (options +D150 and +D151) .
  • Page 7 Additional requirements for the braking applications ..... . . 69 Additional requirements for ABB high-output and IP23 motors ....69 Additional requirements for non-ABB high-output and IP23 motors .
  • Page 8 Connecting a motor temperature sensor to the drive I/O ......85 6. Electrical installation Contents of this chapter ..........87 Warnings .
  • Page 9 Installation of safety functions modules (frames R6 to R9) ....114 installation of safety functions modules (frames R10 and R11) ....115 Case 1: FSO-xx safety functions module on Slot 2 .
  • Page 10 12. Maintenance Contents of this chapter ..........141 Maintenance intervals .
  • Page 11 Ambient conditions ........... . 192 Auxiliary circuit power consumption .
  • Page 12 Product training ............229 Providing feedback on ABB Drives manuals ....... . 229...

  • Page 13: Safety Instructions

    Safety instructions 13 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 14: General Safety In Installation, Start-Up And Maintenance

    14 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the drive and do maintenance work on WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 15 Safety instructions 15 • Do not use the module installation ramp with plinth heights which exceed the maximum height marked on the ramp. (The maximum plinth height is 50 mm [1.97 in] when the telescopic ramp is fully retracted and 150 mm [5.91 in] when the ramp is fully extended.) •...

  • Page 16: Electrical Safety In Installation, Start-Up And Maintenance

    16 Safety instructions Note: • If you select an external source for 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. • When the control location is not set to Local, the stop key on the control panel will not stop the drive.

  • Page 17: Additional Instructions And Notes

    Safety instructions 17 Additional instructions and notes  WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you are not a qualified electrician, do not do installation or maintenance work. •...

  • Page 18: Grounding

    18 Safety instructions Grounding  These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death and equipment malfunction can occur, and electromagnetic interference can increase. •...

  • Page 19: Additional Instructions For Permanent Magnet Motor Drives

    Safety instructions 19 Additional instructions for permanent magnet motor drives Safety in installation, start-up and maintenance  These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death and equipment malfunction can occur.
  • Page 20 20 Safety instructions...

  • Page 21: Introduction To The Manual

    Introduction to the manual 21 Introduction to the manual Contents of this chapter This chapter describes the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals.

  • Page 22: Related Manuals

    22 Introduction to the manual Electrical installation gives instructions on wiring the drive. Control unit of frames R6 to R9 contains the default I/O connection diagram, descriptions of the terminals and technical data for the control unit. Control unit of frames R10 and R11 contains the default I/O connection diagram and references for the descriptions of the terminals and technical data of the control unit.

  • Page 23: Terms And Abbreviations

    Introduction to the manual 23 Task Unpack and check the units (only intact units may be started up). Mechanical installation (page 53) Examine that all necessary option modules and equipment are If the drive has been non- present and correct. operational for more than one year, the converter DC link capacitors Mount the drive.
  • Page 24 24 Introduction to the manual Term/ Explanation Abbreviation FEPL-01 Optional Ethernet POWERLINK adapter module FENA-11 Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols FENA-21 Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols, 2-port FLON-01 Optional LonWorks®...

  • Page 25: Operation Principle And Hardware Description

    This chapter briefly describes the operation principle and construction of the drive. Product overview The ACS880-07 is an air-cooled cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors).

  • Page 26: Single-Line Circuit Diagram Of The Drive

    26 Operation principle and hardware description Single-line circuit diagram of the drive  > Main switch-disconnector (switch fuse in frames R6 to R8, switch-disconnector and separate fuses in frames R9 to R11, or molded case circuit breaker and separate fuses [option +F289 for US market only]) Optional line contactor (+F250) Auxiliary voltage transformer supplying 24 V and 230/115 V control voltage for, eg, cabinet fan(s),...

  • Page 27: Block Diagram Of The Brake And Dc Options (+D150, +D151 And +H356)

    Operation principle and hardware description 27 Block diagram of the brake and DC options (+D150, +D151 and  +H356) Drive module cubicle Drive module Brake resistor cubicle Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter. Inverter.

  • Page 28: General Information On The Cabinet Layout

    28 Operation principle and hardware description General information on the cabinet layout  IP22/IP42 IP54 Example cabinet line-up UL Type 1 / UL Type 12 Frames R6 to R8: drive module cubicle. UL Type 1 Filtered Frames R9 to R11: two cubicles with one door (main switch and power cabling cubicle and drive module cubicle) Brake resistor cubicle with option +D151...

  • Page 29: Cabinet Layout Of Frames R6 To R8

    Operation principle and hardware description 29 Cabinet layout of frames R6 to R8  The cabinet layout without shrouds is shown below. Drive control panel Control unit, see page 119. Door switches and lights, see page 41. Optional terminal block for external control unit connections (X504, option +L504) Main switch handle Power cable connection terminals and du/dt...

  • Page 30: Cabinet Layout Of Frames R6 To R8 With Option +C129

    30 Operation principle and hardware description Cabinet layout of frames R6 to R8 with option +C129  The cabinet layout without shrouds is shown below. Drive control panel Buffering module C22 Door switches and lights, see page 41. Swing-out frame Main switch handle Mounting plate with connection terminals for options +G300, +G307, +G313 at the back...

  • Page 31: Cabinet Layout Of Frames R6 To R8 With Options +C129 And +F289

    Operation principle and hardware description 31 Cabinet layout of frames R6 to R8 with options +C129 and +F289  Option +C129 +F289 is available for US market only. The cabinet layout without shrouds is shown below. Drive control panel Auxiliary voltage transformer (T21) Door switches and lights, see page 41.
  • Page 32 32 Operation principle and hardware description Control cable lead-throughs Control unit, see page 119. Motor cable lead-throughs Optional terminal block for external control unit connections (X504, option +L504) Ground bar Common mode filter (option +E208) Motor cable connection terminals Connection terminals for options +F250, +Q951, +Q952, +Q963, +Q964+Q968, +Q954, +M600…+M605,+ L505, +L506.

  • Page 33: Cabinet Layout Of Frame R9

    Operation principle and hardware description 33 Cabinet layout of frame R9  The cabinet layout is shown below. See also the next page. A – Main breaker and power cabling cubicle B – Drive module cubicle Drive control panel Buffering module Operating switch Swing-out frame Main switch handle...
  • Page 34 34 Operation principle and hardware description The cabinet layout without shrouds, with the swing-out frame open is shown below. A – Main breaker and power cabling cubicle B – Drive module cubicle Auxiliary voltage transformer (T21) Control unit, see page 119. Swing-out frame Optional terminal block for external control unit connections (X504, option +L504)

  • Page 35: Cabinet Layout Of Frame R9 With Options +C129 And +F289

    Operation principle and hardware description 35 Cabinet layout of frame R9 with options +C129 and +F289  The cabinet layout is shown below. See also the next page. A – Main breaker and power cabling cubicle B – Drive module cubicle Drive control panel Buffering module Operating switch...
  • Page 36 36 Operation principle and hardware description The cabinet layout with the swing-out frame open is shown below. Control cable lead-through Connection terminals for external brake resistor and DC cables Swing-out frame Line contactor (option +F250) Drive module Connection terminals for options +F250, +Q951, +Q952, +Q963, +Q964+Q968, +Q954, +M600…+M605,+ L505, +L506.

  • Page 37: Cabinet Layout Of Frames R10 And R11

    Operation principle and hardware description 37 Cabinet layout of frames R10 and R11  The cabinet layout is shown below. See also the next page. A – Main breaker and power cabling cubicle B – Drive module cubicle Drive control panel See the next page.
  • Page 38 38 Operation principle and hardware description The cabinet layout without shrouds, with the swing-out frame open is shown below. A – Main breaker and power cabling cubicle B – Drive module cubicle Main fuses for control devises, IP54 fan Drive module transformer (with option +B055), V-meter (option +G334), starter for auxiliary motor fan (option +M600)

  • Page 39: Overview Of Power And Control Connections

    Operation principle and hardware description 39 Overview of power and control connections  The diagram shows the power connections and control interfaces of the drive. Slot 1 X208 Slot 2 Slot 3 ..M 3 ~ UDC+ UDC-...
  • Page 40 40 Operation principle and hardware description The layout of external control connection terminals at the side of the drive cabinet is shown below. X250 -X250 Terminals for X250 Auxiliary contacts of optional line contactor (+F250) X951, Push buttons for emergency stop options +Q951, +Q952, -X951 X951 X952,...

  • Page 41: Door Switches And Lights

    Operation principle and hardware description 41 Door switches and lights  Label in English Label in local Description language READY Ready pilot light (option +G327) Run pilot light (option+G328) FAULT Fault pilot light (option +G329) MAIN CONT. Operating switch with option +F250 Opens the main contactor (Q2) and disables starting of the drive Closes the main contactor (Q2)

  • Page 42: Control Panel

    42 Operation principle and hardware description Control panel  The ACS-AP-I is the user interface of the drive. It provides the essential controls such as Start/Stop/Direction/Reset/Reference, and the parameter settings for the control program. One control panel can be used to control several drives through a panel link. The control panel can be removed by pulling it forward from the top edge and reinstalled in reverse order.

  • Page 43: Ip42 And Ul Type 1 Filtered (Option +B054)

    Operation principle and hardware description 43 all cabinet options is IP20. The live parts inside the cabinet are protected against contact with clear plastic shrouds or metallic gratings. IP42 and UL Type 1 Filtered (option +B054) This option provides the degree of protection of IP42 (UL type 1 Filtered). The air inlet gratings are covered with a metallic mesh between the inner metallic grating and the outer plastic grating.

  • Page 44: Csa Approved (Option +C134)

    44 Operation principle and hardware description CSA approved (option +C134)  The option includes the following accessories and features: • US/CSA type main switch fuse • bottom entry and exit of cables • US cable conduit entry (plain plate without ready-made holes) •...

  • Page 45: Terminals For External Un-Interruptible Control Voltage (Option +G307)

    Operation principle and hardware description 45 See also • Connecting the external power supply cables for the cabinet heater and lighting and motor heater (options +G300, +G301 and +G313) • Auxiliary circuit power consumption on page • circuit diagrams delivered with drive for the actual wiring. Terminals for external un-interruptible control voltage (option ...

  • Page 46: Us/Uk Gland/Conduit Plate (Option +H358)

    46 Operation principle and hardware description Additional markings +G342 Equipment identifications and terminal block pin numbers and remote addresses are marked with hoses or rings on wires between modules, and on wires connected to equipment, terminal blocks and detachable screw terminals. Plug-in connector identifications are marked on labels attached around the conductor bundles near the connectors.

  • Page 47: Pt100 Relays (Options +3L506, +5L506, +8L506)

    Operation principle and hardware description 47 The customer connects PTC sensors to the thermistor relay and the terminals of the auxiliary relay of the normally open contact, for example, to • main breaker control circuit of the drive for opening the breaker in case of motor overtemperature or •...

  • Page 48: Type Designation Label

    Type designation key The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (eg, ACS880-07-240A-5). The optional selections are given thereafter, separated by plus signs, eg, +E202. The main selections are described below.
  • Page 49 Operation principle and hardware description 49 CODE DESCRIPTION C134 CSA Approved (US/CSA type main switch fuse, bottom entry and exit of cables, 115 V AC auxiliary voltage, cable conduit entries, all components UL/CSA Listed or Recognized, max. supply voltage 600 V) C128 Air inlet through bottom C130...
  • Page 50 50 Operation principle and hardware description CODE DESCRIPTION Cabling H350 Bottom entry (only with +C129) H352 Bottom exit (only with +C129) H351 Top entry of cables (included with +C129) H353 Top exit of cables (included with +C129) H356 DC cable connection busbars H358 Cable conduit entry (included with +C129 and +C134) Fieldbus adapters...
  • Page 51 Operation principle and hardware description 51 CODE DESCRIPTION P912 Seaworthy packing P913 Special color P929 Container packing Safety functions Q950 Prevention of unexpected start with FSO-11 Q951 Emergency stop of Category 0 with opening the main breaker/contactor, see also +G331 Q952 Emergency stop of Category 1 with opening the main breaker/contactor, see also +G331 Q954...
  • Page 52 52 Operation principle and hardware description...

  • Page 53: Mechanical Installation

    Mechanical installation 53 Mechanical installation Contents of this chapter This chapter describes the mechanical installation procedure of the drive. Examining the installation site Examine the installation site: • The installation site is sufficiently ventilated or cooled to transfer away the drive losses.

  • Page 54: Necessary Tools

    54 Mechanical installation Note: For easy maintenance, do not install the drives of frames R10 and R11 on a higher level than the floor in front of it. Otherwise the ramp supplied with the drive cannot be used when replacing the drive modules that run on wheels. Necessary tools The tools required for moving the unit to its final position, fastening it to the floor and wall and tightening the connections are listed below:...

  • Page 55: Moving And Unpacking The Drive

    Mechanical installation 55 Moving and unpacking the drive Move the drive in its original pallet, preferably in the original package to installation site as shown below to avoid damaging the cabinet surfaces and door devices. When you use a pallet truck, check its load capacity before you move the drive. 1088 Lifting the transport package with slings.

  • Page 56: Unpacking The Transport Package

    56 Mechanical installation Unpacking the transport package  Unpack the transport package as follows: 1. Undo the screws that hold the wooden elements of the transport crate together. 2. Remove the elements. 3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws.

  • Page 57: Lifting The Drive Cabinet

    Mechanical installation 57 Lifting the drive cabinet  Lift the drive cabinet using its lifting lugs. Maximum allowed lifting angle of IP22 (UL Type 1) and IP42 (UL Type 1 Filtered) cabinets is 30°. Allowed minimum height of lifting slings of IP54 (UL Type 12) cabinets is 2 meters (6.5 ft).

  • Page 58: Moving The Cabinet On Rollers

    58 Mechanical installation Moving the cabinet on rollers  Remove the wooden bottom frame which is part of the shipment. Lay the cabinet on the rollers and move it carefully until close to its final location. Remove the rollers by lifting the unit with a crane, fork-lift, pallet truck or jack.

  • Page 59: Fastening The Cabinet To The Floor And Wall Or Roof (Non-Marine Units)

    Mechanical installation 59 Fastening the cabinet to the floor and wall or roof (non- marine units) General rules  • The drive must be installed in an upright vertical position. • The cabinet can be installed with its back against a wall (a), or back-to-back with another unit (b).

  • Page 60: Fastening Methods

    60 Mechanical installation Fastening methods  Fasten the cabinet to the floor by using clamps along the edge of the cabinet bottom, or by bolting the cabinet to the floor through the holes inside (if they are accessible). Alternative 1 – Clamping ...

  • Page 61: Fastening The Cabinet To The Floor And Roof/Wall (Marine Units)

    Mechanical installation 61 Fastening the cabinet to the floor and roof/wall (marine units) Follow the general rules given in section General rules on page 59. See the dimension drawing delivered with the drive for the locations of the fastening holes in the flat bars below the cabinet and for fastening points at the top of the cabinet.

  • Page 62: Miscellaneous

    62 Mechanical installation Miscellaneous Cable duct in the floor below the cabinet  A cable duct can be constructed below the 500 mm wide middle part of the cabinet. The cabinet weight lies on the two 50 mm wide transverse sections which the floor must carry. Prevent the cooling air flow from the cable duct to the cabinet by bottom plates.

  • Page 63: Calculating The Required Static Pressure Difference

    = 17 Pa The required pressure in the exit air duct is then, 1.5…2 • 17 Pa = 26…34 Pa, below the pressure in the room. For more information: Contact ABB. Arc welding  Fastening the cabinet by arc welding is not recommended. However, if the arc welding is the only mounting option, proceed as follows: Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1.5 ft) of the welding point.
  • Page 64 64 Mechanical installation...

  • Page 65: Guidelines For Planning The Electrical Installation

    ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 66: Examining The Compatibility Of The Motor And Drive

    Examining the compatibility of the motor and drive Use an asynchronous AC induction motor, permanent magnet synchronous motor, AC induction servomotor or ABB synchronous reluctance motor (SynRM motor) with the drive. Several induction motors can be connected to the drive at a time.

  • Page 67: Requirements Table

    Motor Nominal AC Requirement for type supply voltage Motor ABB du/dt and common mode filters, insulated N-end insulation motor bearings system < 100 kW 100 kW < P < 350 kW > 350 kW and frame size <...

  • Page 68: Additional Requirements For Explosion-Safe (Ex) Motors

    68 Guidelines for planning the electrical installation Motor Nominal AC Requirement for type supply voltage Motor ABB du/dt and common mode filters, insulated N-end insulation motor bearings system < 100 kW 100 kW < P < 350 kW > 350 kW and frame size <...

  • Page 69: Hx_ And Am

    Additional requirements for ABB high-output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 (2001). This table shows the requirements for ABB random-wound motor series (for example, M3AA, M3AP and M3BP).

  • Page 70: Additional Requirements For Non-Abb High-Output And Ip23 Motors

    The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 (2001). The table below shows the requirements for random- wound and form-wound non-ABB motors with nominal power smaller than 350 kW. For bigger motors, consult the motor manufacturer.

  • Page 71: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    Guidelines for planning the electrical installation 71 Additional data for calculating the rise time and the peak line-to-line voltage If you need to calculate the actual peak voltage and voltage rise time considering the actual cable length, proceed as follows: •...

  • Page 72: Selecting The Power Cables

    72 Guidelines for planning the electrical installation Selecting the power cables General rules  Select the input power and motor cables according to local regulations: • Select a cable capable of carrying the drive nominal current. See section Ratings (page 175) for the rated currents. •...

  • Page 73: Typical Power Cable Sizes

    For the cable sizes accepted by the drive cabinet lead- throughs and connection terminals, see page 184. Drive type Frame size Cu cable type Al cable type Cu cable type AWG/kcmil per phase = 400 V ACS880-07-0105A-3 3×50 3×70 ACS880-07-0145A-3 3×95 3×120 ACS880-07-0169A-3 3×120 3×150 ACS880-07-0206A-3 3×150...

  • Page 74: Alternative Power Cable Types

    74 Guidelines for planning the electrical installation Drive type Frame size Cu cable type Al cable type Cu cable type AWG/kcmil per phase ACS880-07-0271A-7 3×240 2 × (3×120) 400 MCM ACS880-07-0330A-7 2 × (3×120) 3 × (3×120) 2×250 MCM or 3×2/0 ACS880-07-0370A-7 2 ×...

  • Page 75: Not Allowed Power Cable Types

    Guidelines for planning the electrical installation 75 Not allowed power cable types Symmetrical shielded cable with individual shields for each phase conductor is not allowed on any cable size for input and motor cabling. Motor cable shield  If the motor cable shield is used as the sole protective earth conductor of the motor, make sure that the conductivity of the shield is sufficient.

  • Page 76: Planning The Braking System

    Relay cable type  The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel cable length and type  In remote use, the cable connecting the control panel to the drive must not be longer than three meters (10 ft).

  • Page 77: Routing The Cables

    Guidelines for planning the electrical installation 77 Routing the cables Route the motor cable away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. The motor cable, input power cable and control cables should be installed on separate trays.

  • Page 78: Implementing Thermal Overload And Short-Circuit Protection

    78 Guidelines for planning the electrical installation motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: • European Union: Install the equipment in a metal enclosure with 360 degree grounding for the shields of both the incoming and outgoing cable, or connect the shields of the cables otherwise together.

  • Page 79: Protecting The Drive And The Input Power And Motor Cables Against Thermal Overload

    Guidelines for planning the electrical installation 79 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 cables are sized according to the nominal current of the drive. No additional thermal protection devices are needed.

  • Page 80: Implementing The Safe Torque Off Function

    User’s manual Manual code code (English) +Q951 Category 0 emergency stop for ACS880-07 (45…250 kW, 60…300 hp) drives 3AUA0000119895 +Q952 Category 1 emergency stop for ACS880-07 (45…250 kW, 60…300 hp) drives 3AUA0000119896 +Q963 Category 0 emergency stop for ACS880-07 (45…250 kW, 60…300 hp) drives 3AUA0000119908 +Q964 Category 1 emergency stop for ACS880-07 (45…250 kW, 60…300 hp) drives...

  • Page 81: Declaration Of Conformity

    Guidelines for planning the electrical installation 81 For wiring instructions, safety data and more information on the functions provided by the options, see FSO-11 user’s manual (3AUA0000097054 [English]). Declaration of Conformity  See page 197. Implementing the Power-loss ride-through function Implement the power-loss ride-through function as follows: Check that the power-loss ride-through function of the drive is enabled with parameter 30.31 Undervoltage control in the ACS880 primary control program.

  • Page 82: Implementing A Safety Switch Between The Drive And The Motor

    82 Guidelines for planning the electrical installation If there are power factor compensation capacitors in parallel with the three phase input of the drive: 1. Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may trip or even damage the drive.

  • Page 83: Implementing A Bypass Connection

    Guidelines for planning the electrical installation 83 Implementing a bypass connection If bypassing is required, employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line. Make sure with interlocking that the contactors cannot be closed simultaneously. WARNING! Never connect the drive output to the electrical power network.

  • Page 84: Switching The Motor Power Supply From Drive To Direct-On-Line

    84 Guidelines for planning the electrical installation Switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in local control mode) or with the external stop signal (drive in remote control mode). 2.

  • Page 85: Connecting A Motor Temperature Sensor To The Drive I/O

    Guidelines for planning the electrical installation 85 230 V AC 230 V AC + 24 V DC 1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode Connecting a motor temperature sensor to the drive I/O WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non- conductive or conductive but not connected to the protective earth.
  • Page 86 86 Guidelines for planning the electrical installation...

  • Page 87: Electrical Installation

    Electrical installation 87 Electrical installation Contents of this chapter This chapter gives instructions on the wiring the drive. Warnings WARNING! If you ar not a qualified electrician do not do the installation work described in this chapter. Obey the instructions in chapter Safety instructions.

  • Page 88: Motor And Motor Cable

    Earth conductor using 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, consult the manufacturer’s instructions. Note: Moisture inside the motor casing will reduce the insulation resistance.

  • Page 89: Connecting The Power Cables

    Electrical installation 89 Connecting the power cables Connection diagram  ACS880-07 UDC+ T1/ T2/ T3/ R+ UDC- UDC- UDC+ (PE) (PE) 3 ~ M Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor (see page 72).

  • Page 90: Layout Of The Power Cable Connection Terminals And Lead-Throughs

    90 Electrical installation Note: If there is a symmetrically constructed grounding conductor on the motor cable in addition to the conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor ends. Do not use an asymmetrically constructed motor cable. Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.

  • Page 91: (Frames R6 To R8 With Option +C129)

    Electrical installation 91 Layout of the power cable connection terminals and lead-throughs  (frames R6 to R8 with option +C129) Power cable lead-throughs Strain relief Ground bar Input cable power connection terminals L1, L2 and L3 Motor cable connection terminals U2, V2, W2...

  • Page 92: (Frames R6 To R8 With Options +C129+F289)

    92 Electrical installation Layout of the power cable connection terminals and lead-throughs  (frames R6 to R8 with options +C129+F289) Input power cable lead-through Motor cable lead-through Control cable lead-through Ground bar for motor cables Ground bar for input power cables Motor cable connection terminals U2, V2, Strain relief Input cable power connection terminals...

  • Page 93: Layout Of The Input And Motor Cable Connection Terminals (Frame R9)

    Electrical installation 93 Layout of the input and motor cable connection terminals (frame  Strain relief L1, L2, L3 Input power cable terminals U2, V2, W2 Motor cable terminals Main switch-disconnector Cable routing from below is shown with the arrows.

  • Page 94: Layout Of The Power Cable Connection Terminals And Lead-Throughs (Frame R9 With Option +C129)

    94 Electrical installation Layout of the power cable connection terminals and lead-throughs  (frame R9 with option +C129) Power cable lead-through Strain relief Ground bar Input cable power connection terminals L1, L2 and L3 Motor cable connection terminals U2, V2,...

  • Page 95: Layout Of The Input And Motor Cable Connection Terminals (Frames R10 And R11)

    Electrical installation 95 Layout of the input and motor cable connection terminals (frames  R10 and R11) Strain relief L1, L2, L3 Input power cable terminals U2, V2, W2 Motor cable terminals PE terminal...

  • Page 96: Lead-Through Of External Resistor And Dc Cables

    12. Fasten the conductive sleeves to the cable shields with cable ties. 13. Seal the slot between the cable and mineral wool sheet (if used) with sealing compound (eg, CSD-F, ABB brand name DXXT-11, code 35080082). 14. Tie up the unused conductive sleeves with cable ties.
  • Page 97 Electrical installation 97...

  • Page 98: Connection Procedure (Us)

    98 Electrical installation Connection procedure (US)  1. Do the steps in section Precautions before electrical work on page before you start the work. 2. Open the cabinet door. 3. Open the swing-out frame (if installed). 4. Plan cable access and mark the conduit plate accordingly for the input and output power and control cables.

  • Page 99: Dc Connection (Option +H356)

    The UDC+ and UDC- terminals are intended for common DC configurations of a number of drives, allowing regenerative energy from one drive to be utilized by the other drives in motoring mode. Contact your local ABB representative for further instructions. Connecting the control cables...

  • Page 100: Grounding The Outer Shields Of The Control Cables At The Cabinet Lead-Through

    100 Electrical installation Grounding the outer shields of the control cables at the cabinet lead-through Applicability This section applies to drives without solid cable conduit plate (no options +C129, +H351, +H353, +H358). Procedure Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions as follows: 1.
  • Page 101 Electrical installation 101 Stripped cable Conductive surface of the shield exposed Stripped part covered with copper foil Cable shield Copper foil Shielded twisted pair Grounding wire Note for top entry of cables: When each cable has its own rubber grommet, sufficient IP and EMC protection can be achieved.

  • Page 102: Routing The Control Cables Inside The Cabinet (Frames R6 To R8)

    102 Electrical installation Routing the control cables inside the cabinet (frames R6 to R8) +H351, +C129 +C129+F289...

  • Page 103: Routing The Control Cables Inside The Cabinet (Frame R9)

    Electrical installation 103 Routing the control cables inside the cabinet (frame R9) +H351, +C129, +C129+F289...

  • Page 104: Routing The Control Cables Inside The Cabinet (Frames R10 And R11)

    104 Electrical installation Routing the control cables inside the cabinet (frames R10 and R11) Note: Leave some slack in the control wiring to allow the removing of the control unit assembly plate when the drive module is replaced.

  • Page 105: Connecting The Control Unit Cables

    Electrical installation 105 Connecting the control unit cables Units without additional I/O terminal block (option L504): Ground the pair-cable shields and all grounding wires to the clamp below the control unit as shown below. Units with additional I/O terminal block (option L504): Ground the pair-cable shields and all grounding wires to the grounding clamp below the terminal block as shown below.

  • Page 106: Connecting The External 230 V Uninteruptible Control Voltage (Ups, Option +G307)

    106 Electrical installation Leave the other ends of the control cable shields unconnected or 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.

  • Page 107: Wiring The Thermistor Relay(S) (Options +L505 And +2L505)

    Electrical installation 107 Wiring the thermistor relay(s) (options +L505 and +2L505) The external wiring of option +2L505 (two thermistor relays) is shown below. For example, one relay can be used to monitor the motor windings, the other to monitor the bearings. The maximum contact load capacity is 250 V AC 10 A.

  • Page 108: Wiring The Pt100 Relays (Options +2L506, +3L506, +5L506 And +8L506)

    108 Electrical installation Wiring the Pt100 relays (options +2L506, +3L506, +5L506 and +8L506) External wiring of eight Pt100 sensor modules is shown below. Contact load capacity 250 V AC 10 A. For the actual wiring, see the circuit diagram delivered with the drive. X506 1 ×...

  • Page 109: Connecting The External Power Supply Cables For The Cabinet Heater And Lighting And Motor Heater (Options +G300, +G301 And +G313)

    Electrical installation 109 Connecting the external power supply cables for the cabinet heater and lighting and motor heater (options +G300, +G301 and +G313) See the circuit diagrams delivered with drive. Connect the external power supply wires for the cabinet heater and lighting to terminal block X300 at the back of the mounting plate.

  • Page 110: Wiring Ground Fault Monitoring For It Ungrounded Systems (Option +Q954)

    110 Electrical installation Wiring ground fault monitoring for IT ungrounded systems (option +Q954) We recommend to connect Alarm 1 for drive tripping and Alarm 2 for alarm signals in order to avoid unnecessary trippings due to the ground fault monitor self testing with Alarm 2. X954 Internal wiring: Ground fault alarm 1.

  • Page 111: Connecting A Pc

    Electrical installation 111 Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. Connect a PC to the drive with an USB data cable (USB Type A <-> USB Type Mini-B) as follows: 1.

  • Page 112: Controlling Several Drives From One Control Panel Through Panel Bus

    112 Electrical installation Controlling several drives from one control panel through panel bus One control panel (or PC) can be used to control several drives by constructing a panel bus. 1. Connect the panel to one drive using an Ethernet (eg. CAT5E) cable. •...

  • Page 113: Installing Option Modules

    Electrical installation 113 Installing option modules Mechanical installation of I/O extension, fieldbus adapter and pulse  encoder interface modules See page for the available slots for each module. Install the option modules as follows: WARNING! Obey the instructions in chapter Safety instructions.

  • Page 114: Installation Of Safety Functions Modules (Frames R6 To R9)

    114 Electrical installation Installation of safety functions modules (frames R6 to R9)  Mount the safety functions module next to the control unit as described below. WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 115: Installation Of Safety Functions Modules (Frames R10 And R11)

    Electrical installation 115 installation of safety functions modules (frames R10 and R11)  Install the safety functions module next to the control unit as described below. Change the mounting plate of the module as shown in FSO-11 user’s manual (3AUA0000097054 [English]).
  • Page 116 116 Electrical installation...

  • Page 117: Case 2: Fso-Xx Safety Functions Module Above The Control Unit

    Electrical installation 117 Case 2: FSO-xx safety functions module above the control unit Install the safety functions module next to the control unit as described below. Change the original mounting plate of the module to the alternative plate included in the module package.
  • Page 118 118 Electrical installation...

  • Page 119: Control Unit Of Frames R6 To R9

    Control unit of frames R6 to R9 119 Control unit of frames R6 to R9 Contents of this chapter This chapter contains the default I/O connection diagram, descriptions of the terminals and technical data for the control unit (ZCU-12) of drive frames R6 to R9.

  • Page 120: Layout

    120 Control unit of frames R6 to R9 Layout The layout of external control connection terminals of the control unit is shown below. Description XPOW External power input Analog inputs X202 Analog outputs X208 XD2D Drive-to-drive link XRO1 Relay output 1 X205 XRO2 Relay output 2...

  • Page 121: Default I/O Connection Diagram Of Frames R6 To R9

    Control unit of frames R6 to R9 121 Default I/O connection diagram of frames R6 to R9 XPOW External power input +24VI 24 V DC, 2 A Reference voltage and analog inputs +VREF 10 V DC, R 1…10 kohm -VREF -10 V DC, R 1…10 kohm AGND Ground AI1+...

  • Page 122: Notes

    122 Control unit of frames R6 to R9 Notes: Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R > 200 kohm] input selected with jumper J1. Change of setting requires reboot of control unit. Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R >...

  • Page 123: Ai1 And Ai2 As Pt100 And Kty84 Sensor Inputs (Xai, Xao)

    Control unit of frames R6 to R9 123 AI1 and AI2 as Pt100 and KTY84 sensor inputs (XAI, XAO)  Three Pt100 sensors or one KTY84 sensor for motor temperature measurement can be connected between an analog input and output as shown below. (Alternatively, you can connect the KTY to FEN-11 analog /I/O extension module or FEN-xx encoder interface module.) Do not connect both ends of the cable shields directly to ground.

  • Page 124: Di6 (Xdi:6) As Ptc Sensor Input

    124 Control unit of frames R6 to R9 DI6 (XDI:6) as PTC sensor input  PTC sensors can be connected to this input for motor temperature measurement as follows. The sum of the sensor resistances must not exceed the threshold resistance of the digital input at the motor normal operating temperature.

  • Page 125: Safe Torque Off (Xsto)

    Control unit of frames R6 to R9 125 This diagram shows the wiring of the drive-to-drive link for frames R6 to R9... . . 3.3 nF > 630 V AC Safe torque off (XSTO) ...
  • Page 126 126 Control unit of frames R6 to R9 Digital inputs/outputs DIO1 Connector pitch 5 mm (0.2 in), wire size 2.5 mm (14 AWG) and DIO2 As inputs: (XDIO:1 and XDIO:2) 24 V logic levels: “0” < 5 V, “1” > 15 V : 2.0 kohm Input/output mode selection Filtering: 0.25 ms...
  • Page 127 Control unit of frames R6 to R9 127 Ground isolation diagram XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- channels +30 V AI2+ AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND Switch J6 settings: XDIO All digital inputs and outputs share a common...
  • Page 128 128 Control unit of frames R6 to R9...

  • Page 129: Control Unit Of Frames R10 And R11

    Control unit of frames R10 and R11 129 Control unit of frames R10 and Contents of this chapter This chapter contains the default I/O connection diagram, descriptions of the terminals and technical data for the control unit (ZCU-14) of drive frames R10 and R11.

  • Page 130: Layout

    130 Control unit of frames R10 and R11 Layout The layout of the external control connection terminals of the control unit is shown below. Description XPOW External power input XRO1 Analog inputs Analog outputs XRO2 XD2D Drive to drive link XRO1 Relay output RO1 XRO3...

  • Page 131: Default I/O Connection Diagram Of Frames R10 And R11

    Control unit of frames R10 and R11 131 Default I/O connection diagram of frames R10 and R11 Relay outputs XRO1…XRO3 Ready 250 V AC / 30 V DC Running 250 V AC / 30 V DC Faulted(-1) 250 V AC / 30 V DC Fault External power input XPOW...

  • Page 132: Notes

    132 Control unit of frames R10 and R11 Notes: Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R > 200 kohm] input selected with jumper J1. Change of setting requires reboot of control unit. Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R >...

  • Page 133: Ground Isolation Diagram

    Control unit of frames R10 and R11 133 Ground isolation diagram XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- channels +30 V AI2+ AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND Jumper J6 determines whether DICOM is XDIO separated from DIOGND (ie.
  • Page 134 134 Control unit of frames R10 and R11...

  • Page 135: Installation Checklist

    Installation checklist 135 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before you start up the drive. Warnings WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Checklist Do the steps in section Precautions before electrical work...
  • Page 136 136 Installation checklist Check that … There is an adequately sized protective earth (ground) conductor between the drive and the switchboard, and the conductor has been connected to appropriate terminal. Proper grounding has also been measured according to the regulations. There is an adequately sized protective earth (ground) conductor between the motor and the drive, and the conductor has been connected to appropriate terminal.

  • Page 137: Start-Up

    Start-up 137 Start-up Contents of this chapter This chapter contains the start-up procedure of the drive. The default device designations (if any) are given in brackets after the name, for example “main switch-disconnector (Q1)”. The same device designations are also used in the circuit diagrams, typically. Start-up procedure Action Safety...

  • Page 138: Powering Up The Drive

    138 Start-up Action Powering up the drive Close the cabinet doors. Make sure that it is safe to connect voltage. Ensure that: • cabinet doors are closed • nobody is working on the drive or circuits that have been wired from outside into the drive cabinet •...

  • Page 139: Fault Tracing

    Fault tracing 139 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs Where Color When the LED is lit Control POWER Green Control unit is powered and +15 V is supplied to the control panel panel.
  • Page 140 140 Fault tracing...

  • Page 141: Maintenance

    ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to www.abb.com/searchchannels.See the maintenance instructions in this chapter.
  • Page 142 Battery for control panel and ZCU control unit To maintain optimal performance and reliability of the drive, contact ABB at least once in three years for possible replacements of aging components such as circuit boards, electrolytic capacitors and flat ribbon cables.

  • Page 143: Cleaning The Interior Of The Cabinet

    Maintenance 143 Cleaning the interior of the cabinet WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use a vacuum cleaner with an antistatic hose and nozzle. Using a normal vacuum cleaner creates static discharges which can damage circuit boards.

  • Page 144: Replacing The Air Filters (Ip54 / Ul Type 12)

    144 Maintenance Replacing the air filters (IP54 / UL Type 12) Check the air filters and replace if necessary (see page for the correct filter types). Inlet (door) filters (IP54 / UL Type 12)  1. Remove the fasteners at the top of the grating. 2.

  • Page 145: Heatsink

    See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after a fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

  • Page 146: Replacing The Cabinet "Door" Fans

    146 Maintenance Replacing the cabinet “door” fans  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 147: Replacing The Cabinet Fans (Frames R6 To R9)

    Maintenance 147 Replacing the cabinet fans (frames R6 to R9)  1. For removing the fan mounting plate, see section Replacing the drive module (frames R6 to R8) on page (steps 1 to 3 and 13) or section Replacing the drive module (frame R9) on page (steps 1, 9 and 10).

  • Page 148: Replacing The Drive Module Main Fans (Frames R6 To R8)

    148 Maintenance Replacing the drive module main fans (frames R6 to R8)  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 149: Replacing The Auxiliary Cooling Fan Of The Drive Module (Frames R6 To R9)

    Maintenance 149 Replacing the auxiliary cooling fan of the drive module (frames R6  to R9) WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 150: Replacing The Drive Module Main Fans (Frame R9)

    150 Maintenance Replacing the drive module main fans (frame R9)  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 151: Replacing The Drive Module Main Fans (Frames R10 And R11)

    Maintenance 151 Replacing the drive module main fans (frames R10 and R11)  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 152: Replacing The Circuit Board Compartment Cooling Fan (Frames R10 And R11)

    152 Maintenance Replacing the circuit board compartment cooling fan (frames R10  and R11) WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 153: Replacing The Ip54 (Ul Type 12) Roof Fan Of Frames R6 To R8

    Maintenance 153 Replacing the IP54 (UL type 12) roof fan of frames R6 to R8  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 154: Replacing The Ip54 (Ul Type 12) Roof Fan Of Frame R9

    154 Maintenance Replacing the IP54 (UL type 12) roof fan of frame R9  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 155: Replacing The Ip54 (Ul Type 12) Roof Fan Of Frames R10 And R11

    Maintenance 155 Replacing the IP54 (UL type 12) roof fan of frames R10 and R11  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 156: Replacing The Drive Module (Frames R6 To R8)

    Required in this replacing procedure: two persons, lifting chains, lifting device, a set of screw drivers and torque wrench with extension bar. A lifting device for ACS880-07 drive modules is available from ABB. For its installation and use, see ACS880-07 lifting device user’s manual (3AUA0000131337 [English]).
  • Page 157 Maintenance 157 16. Undo the upper mounting nuts of the drive module. 17. Undo the lower mounting nuts of the drive module. 18. Slide the drive module towards the end of the sliding bars. 19. Secure the drive module with chains from the lifting eyes. 20.
  • Page 158 158 Maintenance R6 to R8...
  • Page 159 Maintenance 159 R6 to R8 +D150, +D151 +H356 UDC- UDC+...
  • Page 160 160 Maintenance R6 to R9...

  • Page 161: Replacing The Drive Module (Frame R9)

    Required in the replacing procedure: two persons, lifting chains, lifting device, a set of screw drivers and torque wrench with extension bar. A lifting device for ACS880-07 drive modules is available from ABB. For its installation and use, see ACS880-07 lifting device user’s manual (3AUA0000131337 [English]).

  • Page 162: 18. Lift The Module Out Of The Cabinet With The Lifting Device

    162 Maintenance 16. Slide the drive module towards the end of the sliding bars. 17. Secure the drive module with chains from the lifting eyes. 18. Lift the module out of the cabinet with the lifting device. 19. Install the new module in reverse order.
  • Page 163 Maintenance 163...
  • Page 164 164 Maintenance...
  • Page 165 Maintenance 165...

  • Page 166: Replacing The Drive Module (Frames R10 And R11)

    166 Maintenance Replacing the drive module (frames R10 and R11) This replacing procedure requires: two persons, installation ramp, a set of screw drivers and a torque wrench with an extension bar. The drawings show frame R11. The details in frame R10 are slightly different. WARNING! Obey the instructions in chapter Safety instructions.
  • Page 167 Maintenance 167 11. Fasten the extraction ramp to the cabinet base with two screws. 12. Attach the drive module lifting lugs to the cabinet lifting lug with chains. 13. Pull the drive module carefully out of the cabinet preferably with help from another person.
  • Page 168 168 Maintenance R10 and R11...
  • Page 169 Maintenance 169 R10 and R11...
  • Page 170 170 Maintenance R10 and R11...
  • Page 171 Maintenance 171 R10 and R11...

  • Page 172: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts.

  • Page 173: Replacing The Control Panel Battery

    Maintenance 173 Replacing the control panel battery The battery is housed on the rear of the control panel. Replace with a new CR 2032 battery. Dispose the old battery according to local disposal rules or applicable laws. Replacing the control unit battery 1.

  • Page 174: Transferring The Memory Unit

    174 Maintenance Transferring the memory unit  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 175: Technical Data

    The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table. IEC RATINGS Drive type Frame Input Output ratings size rating ACS880-07- No-overload use Light-overload Heavy-duty use = 400 V 0105A-3 0145A-3 0169A-3 0206A-3...
  • Page 176 176 Technical data IEC RATINGS Drive type Frame Input Output ratings size rating ACS880-07- No-overload use Light-overload Heavy-duty use 0650A-3 0725A-3 1020 0820A-3 1020 0880A-3 1100 725 *** = 500 V 0096A-5 0124A-5 0156A-5 0180A-5 0240A-5 0260A-5 240* 0361A-5 0414A-5...

  • Page 177: Definitions

    Technical data 177 NEMA RATINGS Drive type Frame Input Max. Output ratings size rating current ACS880-07- Light-overload use Heavy-duty use = 460 V 0096A-5 0124A-5 0156A-5 0180A-5 0240A-5 0302A-5 0361A-5 0414A-5 361 ** 0503A-5 0583A-5 0635A-5 0715A-5 0820A-5 1020 = 600 V...

  • Page 178: Derating

    Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.
  • Page 179 Technical data 179 Fuses (IEC) The drive is equipped with aR fuses listed below. Drive type Input Ultrarapid (aR) fuses (one fuse per phase) ACS880-07- current Manufacturer Type Type with Size option +F289 = 400 V 0105A-3 8250 Bussmann 170M3814D...

  • Page 180: Fuses (Ul)

    180 Technical data Drive type Input Ultrarapid (aR) fuses (one fuse per phase) ACS880-07- current Manufacturer Type Type with Size option +F289 0425A-7 300000 Bussmann 170M6411 170M6411 0470A-7 465000 Bussmann 170M6412 170M6412 0522A-7 465000 Bussmann 170M6412 170M6412 0590A-7 670000 Bussmann...

  • Page 181: Dimensions And Weights

    Technical data 181 Drive type Input Fuse (one fuse per phase) current ACS880-07- Manufacture Type Type with UL class option +F289 / Size 0142A-7 Bussmann DFJ-250 170M3416 0174A-7 Bussmann DFJ-300 170M4410 0210A-7 Bussmann 170M4410 170M4410 0271A-7 Bussmann 170M5410 170M5410 0330A-7...

  • Page 182: Free Space Requirements

    182 Technical data Free space requirements Front Side Above 5.91 15.75 measured from the base plate of the cabinet top. Note: 320 mm (12.28 in.) is required for fan replacement of IP54 cabinets. 320 mm (12.28 in.) > 400 mm (15.75 in.) IP22/42 IP54...

  • Page 183: Losses, Cooling Data And Noise

    Technical data 183 Losses, cooling data and noise Drive type Frame Air flow Heat dissipation Noise dB(A) /min = 400 V ACS880-07-0105A-3 1750 1130 1795 ACS880-07-0145A-3 1750 1130 1940 ACS880-07-0169A-3 1750 1130 2440 ACS880-07-0206A-3 1750 1130 2810 ACS880-07-0246A-3 1750 1130...

  • Page 184: Terminal And Lead-Through Data For The Power Cables

    184 Technical data Drive type Frame Air flow Heat dissipation Noise dB(A) /min ACS880-07-0425A-7 2950 1837 6909 ACS880-07-0470A-7 2950 1837 8622 ACS880-07-0522A-7 2950 1837 9264 ACS880-07-0590A-7 2950 1837 10362 ACS880-07-0650A-7 3170 1978 11078 Terminal and lead-through data for the power cables ...
  • Page 185 Technical data 185 Input and motor cable terminal dimensions of frames R6 to R7 Bottom entry and exit: Top entry and exit: Input and motor cable terminal dimensions of frame R8 Bottom entry and exit: Top entry and exit: Resistor and DC cable terminal dimensions of frames R6 to R8...
  • Page 186 186 Technical data Motor cable terminal dimensions of frame R9 – Units with optional du/dt filter (+E205): Motor cable terminal dimensions of frame R9 – Units without optional du/dt filter (+E205): Input cable terminal dimensions of frame R9: Resistor and DC cable terminal dimensions of frames R9...
  • Page 187 Technical data 187 Input and motor cable terminal dimensions of frame R10 Bottom entry and exit:...
  • Page 188 188 Technical data Input and motor cable terminal dimensions of frame R10 Top entry and exit:...
  • Page 189 Technical data 189 Input and motor cable terminal dimensions of frame R11 Bottom entry and exit:...

  • Page 190: Terminal Data For The Control Cables

    190 Technical data Input and motor cable terminal dimensions of frame R11 Top entry and exit: Terminal data for the control cables See chapter Control unit of frames R6 to R9 on page Control unit of frames R10 and R11 on page 129.

  • Page 191: Electrical Power Network Specification

    0.98 (at nominal load) factor (cos phi Motor connection data Motor types Asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors) Voltage (U 0 to U , 3-phase symmetrical, U at the field weakening point Frequency 0…500 Hz...

  • Page 192: Ambient Conditions

    192 Technical data Overvoltage category (IEC 60664-1) Protective class (IEC/EN 61800-5-1) Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. Operation Storage Transportation installed for stationary in the protective package in the protective package Installation site altitude 0 to 4000 m (13123 ft)

  • Page 193: Applicable Standards

    288 mm x 521 mm (ABB code: 64640194) 688 mm x 521 mm (ABB code 64748017) Outlet (roof): airTex G150 2 pcs: 398 mm x 312 mm (ABB code: 64722166) Fire safety of materials Insulating materials and non-metallic items mostly self-extinctive...

  • Page 194: Ce Marking

    194 Technical data EN 61800-3:2004 Adjustible speed electrical power drive systems. Part 3: EMC requirements and specific test methods UL 501:2007 Enclosures for Electrical Equipment, Non-Environmental Considerations UL 508C:2002 UL Standard for Safety, Power Conversion Equipment, third edition UL 508A: 2001 UL Standard for Industrial Control Panels, first edition CSA C22.2 No.

  • Page 195: Declaration Of Conformity (Safe Torque Off)

    Technical data 195 Declaration of Conformity (Safe torque off) See also chapter Safe torque off function on page 213.
  • Page 196 196 Technical data...

  • Page 197: Declaration Of Conformity (Option +Q973)

    Technical data 197 Declaration of Conformity (option +Q973) See also section Implementing the functions provided with the safety functions module FSO-11 (option +Q973) on page 80.
  • Page 198 198 Technical data...

  • Page 199: Compliance With The En 61800-3:2004

    Technical data 199 Compliance with the EN 61800-3:2004 Definitions  EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality.

  • Page 200: Category C3

    Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in the hardware manual. 4. The drive is installed according to the instructions given in the hardware manual.

  • Page 201: Ul Checklist

    The input cable must be protected with fuses. Circuit breakers must not be used without fuses in the USA. For suitable circuit breakers, contact your local ABB representative. Suitable IEC (class aR) fuses for drive protection are listed on page and UL fuses on page 180.

  • Page 202: Disclaimer

    202 Technical data Disclaimer The manufacturer shall have no obligation hereunder with respect to any product which (i) has been improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident; (iii) has been used in a manner contrary to the Manufacturer's instructions; or (iv) has failed as a result of ordinary wear and tear..

  • Page 203: Dimension Drawings

    Dimension drawings 203 Dimension drawings Example dimension drawings with dimensions in millimeters and [inches] are shown below.

  • Page 204: Frame Sizes R6 To R8 (Ip22, Ip42)

    204 Dimension drawings Frame sizes R6 to R8 (IP22, IP42)

  • Page 205: Frame Sizes R6 To R8 (Ip54, Option +B055)

    Dimension drawings 205 Frame sizes R6 to R8 (IP54, option +B055)
  • Page 206 206 Dimension drawings Frame size R9 (IP22, IP42)
  • Page 207 Dimension drawings 207 Frame size R9 (IP54, option +B055)
  • Page 208 208 Dimension drawings Frame size R9 (marine unit, option +C121)
  • Page 209 Dimension drawings 209 Frame sizes R6 to R8 with option +F289 (UL Type 1)
  • Page 210 210 Dimension drawings Frame sizes R6 to R8 with option +F289 (UL Type 12)
  • Page 211 Dimension drawings 211 Frame size R10 and R11 (IP22, IP42)
  • Page 212 212 Dimension drawings Frame size R10 and R11 (IP54, UL Type 12)

  • Page 213: Safe Torque Off Function

    Safe torque off function 213 Safe torque off function Contents of this chapter This chapter describes the Safe torque off function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, to construct safety or supervision circuits that stop the drive in case of danger (such as an emergency stop circuit).

  • Page 214: Compliance With The European Machinery Directive

    214 Safe torque off function Standard Name 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 –...

  • Page 215: Grounding Of Protective Shields

    Ground the shield in the cabling between the activation switch and the control unit at the control unit. • Ground the shield in the cabling between two control units at one control unit only. Single drive (internal power supply)  ACS880-07 OUT1 +24 V SGND Control logic UDC+ T1/U, T2/V, T3/W UDC–...

  • Page 216: Multiple Drives (Internal Power Supply)

    216 Safe torque off function Multiple drives (internal power supply)  ACS880-07 OUT1 +24 V SGND ACS880-07 OUT1 SGND ACS880-07 OUT1 SGND...

  • Page 217: Multiple Drives (External Power Supply)

    Safe torque off function 217 Multiple drives (external power supply)  24 V DC ACS880-07 – OUT1 +24 V SGND ACS880-07 OUT1 SGND ACS880-07 OUT1 SGND...

  • Page 218: Operation Principle

    218 Safe torque off function Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. STO inputs on the drive control unit de-energize. 3. The control unit cuts off the control voltage from the drive IGBTs. 4.

  • Page 219: Use

    Safe torque off function 219 Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...

  • Page 220: Maintenance

    Any failures of the Safe torque off function must be reported to ABB. Safety data (SIL, PL) The safety data for the Safe torque off function is given below.
  • Page 221 Safe torque off function 221 Frame IEC 61508 Lifetime (Years) (T1 = 2 a) (1/h) = 525…690 V R6 to R9 3.84E-09 (3.84 FIT) 95.04 1.56E-4 R10, R11 3.91E-09 (3.91 FIT) 99.63 3.43E-5 Frame EN/ISO 13849-1 IEC 62061 IEC 61511 MTTF Cat.

  • Page 222: Safety Data (Sil, Pl)

    222 Safe torque off function Safety data (SIL, PL)  Abbr. Reference Description EN ISO 13849-1 Common cause failure (%) EN ISO 13849-1 Diagnostic coverage IEC 61508 Failure in time: 1E-9 hours IEC 61508 Hardware fault tolerance MTTF EN ISO 13849-1 Mean time to dangerous failure: (The total number of life units) / (the number of dangerous, undetected failures) during a particular measurement interval under stated conditions...

  • Page 223: Resistor Braking

    Resistor braking 223 Resistor braking Contents of this chapter This chapter tells how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. Operation principle and hardware description The drive can be equipped with optional built-in brake chopper (+D150). Brake resistors are available as add-on kits or factory installed (+D151).

  • Page 224: Selecting And Routing The External Brake Resistor Cables

    224 Resistor braking Note: A custom resistor can be selected within the limits imposed by the internal brake chopper of the drive: • The resistance value of the custom resistor is at least R . The braking power capacity of the resistor can be calculated from the following equation: <...

  • Page 225: Emc Compliance Of The Complete Installation

    Resistor braking 225 EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user- defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.

  • Page 226: Electrical Installation

    226 Resistor braking Electrical installation Checking the insulation of the assembly  Follow the instructions given under Brake resistor assembly on page 88. Connection diagram  See section Connection diagram on page 89. Connection procedure  • Connect the resistor cables to the R+ and R- terminals in the same way as the other power cables.

  • Page 227: Technical Data

    Resistor braking 227 Technical data Ratings  Drive type Internal brake Example brake resistor(s) chopper Type brcont Rcont = 400 V ACS880-07-0105A-3 SAFUR80F500 2400 ACS880-07-0145A-3 SAFUR80F500 2400 ACS880-07-0169A-3 SAFUR125F500 3600 ACS880-07-0206A-3 SAFUR125F500 3600 ACS880-07-0246A-3 SAFUR200F500 5400 13.5 ACS880-07-0293A-3 SAFUR200F500 5400 13.5...

  • Page 228: Degree Of Protection Of Safur Resistors

    228 Resistor braking Drive type Internal brake Example brake resistor(s) chopper Type brcont Rcont = 690 V ACS880-07-0061A-7 SACE15RE13 ACS880-07-0084A-7 SACE15RE13 ACS880-07-0098A-7 SAFUR90F575 1800 ACS880-07-0119A-7 SAFUR90F575 1800 ACS880-07-0142A-7 SAFUR80F500 2400 ACS880-07-0174A-7 SAFUR80F500 2400 ACS880-07-0210A-7 SAFUR125F500 3600 ACS880-07-0271A-7 SAFUR125F500 3600 3AXD00000588487 The internal brake chopper will withstand this continuous braking power.

  • Page 229: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 230 Contact us www.abb.com/drives www.abb.com/drivespartners 3AUA0000105718 Rev D (EN) 2014-01-21...

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