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ABB ACS880-14 Hardware Manual
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ABB ACS880-14 Hardware Manual

Drive modules (132…400 kw, 200…400 hp)
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ABB INDUSTRIAL DRIVES
ACS880-14 drive modules (132...400 kW,
200...400 hp)
Hardware manual

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Summary of Contents for ABB ACS880-14

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-14 drive modules (132…400 kW, 200…400 hp) Hardware manual...
  • Page 3 ACS880-14 drive modules (132…400 kW, 200…400 hp) Hardware manual Table of contents 1. Safety instructions 6. Mechanical installation 8. Electrical installation 13. Start-up 3AXD50000035160 Rev D Original instructions EFFECTIVE: 2021-01-13...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ................Use of warnings and notes ............... General safety in installation, start-up and maintenance ........Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ..............Additional instructions and notes .............
  • Page 6 Required free space ................Free space at the top of the drive module ..........Free space around the drive module ............ABB air inlet and outlet kits ............... 6 Mechanical installation Contents of this chapter ................Examining the installation site ..............

  • Page 7: Table Of Contents

    Availability of du/dt filter and common mode filter by drive type ..... Additional requirements for explosion-safe (EX) motors ......Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ..................Additional requirements for the regenerative and low harmonics drives ...
  • Page 8 8 Table of contents Continuous motor cable shield/conduit or enclosure for equipment on the motor cable ....................Separate control cable ducts ..............Implementing motor and motor cable short-circuit and thermal overload protection ..Protecting the motor and motor cable in short-circuits ........Protecting the motor cables against thermal overload ........

  • Page 9: Table Of Contents

    Table of contents 9 Attaching the external control unit vertically on a DIN rail ........ Attaching the external control unit horizontally on a DIN rail ......Connecting the control cables to the terminals of the external control unit ....Connecting a control panel ............... Panel bus (Control of several units from one control panel) .........
  • Page 10 Power cable connection procedure ............Installing the drive module into the enclosure ..........Installation procedure ................Assembly drawing of connecting the drive module to the cabling panels ..Installing air baffles (non-ABB parts) ............Miscellaneous ..................Installing the rubber grommet ..............12 Installation checklist Contents of this chapter ................
  • Page 11 Table of contents 11 Replacing the memory unit of the line-side converter control unit (ZCU-12) ..Functional safety components ..............16 Ordering information Contents of this chapter ................ACS-AP-W and ACS-AP-I control panel ............Control panel mounting platforms ............... Output (du/dt) filters ................Sine filters ...................
  • Page 12 12 Table of contents EMC compliance (IEC/EN 61800-3:2004) ............. Definitions ..................Category C2 ..................Category C3 ..................Category C4 ..................UL and CSA checklist ................EU Declaration of Conformity (Machinery Directive) ......... Disclaimers ..................Generic disclaimer ................Cybersecurity disclaimer ..............18 Dimension drawings Contents of this chapter ................
  • Page 13 Description, installation and technical data of the FOCH filters ......Sine filters ................... When is a sine filter necessary? ............. Selection table .................. ABB ordering codes ................Derating ..................Description, installation and technical data of the sine filters ......22 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure Handling the drive module, power cable connection diagram .......

  • Page 15: Safety Instructions

    Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

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

    16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
  • Page 17 Safety instructions 17 • Make sure that the module does not topple over when you move it on the floor: To open the support legs, press each leg a little down and turn it aside (1, 2). Whenever possible attach the module also with chains. Do not tilt the drive module. It is heavy and its center of gravity is high.

  • Page 18: Electrical Safety In Installation, Start-Up And Maintenance

    18 Safety instructions • Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors, and brake resistors, remain hot for a while after disconnection of the electrical supply. • Vacuum clean the area around the drive before the start-up to prevent the drive cooling fan from drawing the dust inside the drive.
  • Page 19 Safety instructions 19 WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Go through these steps before you begin any installation or maintenance work. 1.

  • Page 20: Additional Instructions And Notes

    20 Safety instructions 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 electrical professional, do not do installation or maintenance work. •...

  • Page 21: Grounding

    Safety instructions 21 Grounding ￭ These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase. If you are not a qualified electrical professional, do not do grounding work.

  • Page 22: General Safety In Operation

    22 Safety instructions General safety in operation These instructions are for all personnel that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Keep the cabinet doors closed when the drive is powered. With the doors open, a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists.

  • Page 23: Safety In Operation

    Safety instructions 23 Before installation, start-up and maintenance work on the drive: • Stop the drive. • Disconnect the motor from the drive with a safety switch or by other means. • If you cannot disconnect the motor, make sure that the motor cannot rotate 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.

  • Page 25: Introduction To The Manual

    The flowchart refers to chapters/sections in this manual and other manuals. Applicability This manual applies to ACS880-14 drive modules intended for user-defined cabinet installations. Target audience This manual is intended for people who plan the installation, install, start up and do maintenance work on the drive, or create instructions for the end user of the drive concerning the installation and maintenance of the drive.

  • Page 26: Quick Installation, Commissioning And Operating Flowchart

    26 Introduction to the manual The instructions and technical data which concern only certain optional selections are marked with option codes, eg, +E208. The options included in the drive can be identified from the option codes visible on the type designation label. The option selections are listed in section Type designation key (page 41).

  • Page 27: Terms And Abbreviations

    Introduction to the manual 27 Task See chapter/section Drive modules with optional cabling panels (+H381) Installing the mechanical accessories into a enclos- ure (page 141) •Install the cabling panels into the enclosure. •Install the additional components into the enclosure: Connecting the power cables (page 143) for example, main disconnector, main contactor, main Installing the drive module into the enclosure (page 146) AC, fuses, etc.

  • Page 28: Related Documents

    28 Introduction to the manual Term Description FCAN Optional CANopen® adapter module FCNA-01 Optional ControlNet™ adapter module FDCO-01 DDCS communication module with two pairs of 10 Mbit/s DDCS channels FDCO-02 DDCS communication module with one pair of 10 Mbit/s and one pair of 5 Mbit/s DDCS channels FDIO-01 Optional digital I/O extension module...
  • Page 29 Introduction to the manual 29 Name Code (English/Multi- Code (Translation) lingual) ACS880-14 drive modules (132 to 400 kW, 200 to 450 hp) hard- 3AXD50000035160 ware manual ACS880-14 drive modules (132 to 400 kW, 200 to 450 hp) quick 3AXD50000212446 installation guide...

  • Page 31: Operation Principle And Hardware Description

    This chapter describes the operating principle and construction of the drive module. Operation principle The ACS880-14 is a regenerative drive module for controlling asynchronous AC induction motors, permanent magnet motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors).

  • Page 32: Block Diagram Of The Main Circuit Of The Drive Module

    ￭ L1/U1 T1/U2 L2/V1 T2/V2 L3/W1 T3/W2 UDC- UDC+ ACS880-14 drive module Charging circuit contactor Charging circuit Line contactor LCL filter Line-side converter DC link. DC circuit between the line-side converter and motor-side converter. Motor-side converter Common mode filter (+E208) Line-side converter ￭...

  • Page 33: Ac Voltage And Current Waveforms

    Operation principle and hardware description 33 The following figure shows the simplified main circuit diagram of the line-side converter. LCL filter contactor LCL filter Line-side converter DC capacitors DC link AC voltage and current waveforms The AC current is sinusoidal at a unity power factor. The LCL filter suppresses the AC voltage distortion and current harmonics.

  • Page 34: Layout

    34 Operation principle and hardware description Layout Standard drive module configuration ￭ Drive module. Contains line-side converter and Lower front cover motor side converter. LCL filter module Cooling fan cassette LCL filter module connected to the drive module Support legs Clear plastic shrouds attached Pedestal Circuit board compartment...

  • Page 35: Drive Module

    Operation principle and hardware description 35 Drive module ￭ +H370 Clear plastic shroud to be attached onto the drive Pedestal guide plate for the drive module module input power cabling (1a). Entry shroud for side cabling (1b). Clear plastic shrouds to be attached onto the drive Telescopic extraction/installation ramp module output power cabling Clear plastic shroud to be attached on top of the...

  • Page 36: Lcl Filter Module

    36 Operation principle and hardware description Output power cable connection terminals Cover for the busbar connection Grounding terminal for output power cable shields Auxiliary cooling fan Metallic shroud. With option +H370, the shroud Handle includes a ground bar. Fiber optic cables for connecting the control unit Cover.

  • Page 37: Drive Module With Full Power Cabling Panels (Option +H381)

    Operation principle and hardware description 37 Drive module with full power cabling panels (option +H381) ￭ Accessories Assembled drive module Input power cabling panel Rubber grommet Side guides Input power cabling panel to be attached to the drive cabinet Output power cabling panel Output power cabling panel to be attached to the drive cabinet Top guide plate...

  • Page 38: Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) And Ip20 Shrouds (Option +0B051) And With Common Mode Filter (Option +E208)

    38 Operation principle and hardware description Drive module without full-size output cable connection terminals ￭ (option +0H371) and IP20 shrouds (option +0B051) and with common mode filter (option +E208) Lifting lugs Auxiliary cooling fan Input cable connection busbars (L1/U1, L2/V1, PE busbar L3/W1) and DC+ and DC- busbars (UDC+, UDC-) Circuit board compartment...

  • Page 39: Control Panel

    Operation principle and hardware description 39 Control panel ￭ In the standard drive module configuration, the control panel is located in the control panel holder of the external control unit. One control panel can also be used to control several drives through a panel link; see section Panel bus (Control of several units from one control panel) (page 113).

  • Page 40: Overview Of Power And Control Connections

    1 2 3 Slots 1, 2 and 3 X205 ..V1, V2, V20, V21 ACS880-14 V2, V7, V8, V13 M 3 ~ UDC- UDC+ External control unit (motor-side converter control unit) Line-side converter control unit Analog and digital I/O extension modules, feedback interface modules and fieldbus communication modules can be inserted into slots 1, 2 and 3.

  • Page 41: Type Designation Label

    Operation principle and hardware description 41 Type designation label The type designation label includes a rating, markings, a type designation and a serial number, which allow individual recognition of each drive module. The type designation label is located on the front cover. An example label is shown below. Type designation, see section Type designation key Name and address of the manufacturer...

  • Page 42: Option Codes

    ￭ Code Description 0B051 No IP20 shrouds for cabling area (Not to be used with option +H381) EMC filter for 1st environment TN (grounded) system, category C2. Available for ACS880-14-xxxx- E202 3 and -5 types only. E208 Common mode filter...
  • Page 43 Operation principle and hardware description 43 Code Description K492 FPNO-21 PROFINET IO adapter module L500 FIO-11 analog I/O extension module (1, 2 or 3 pcs) L501 FIO-01 digital I/O extension module L502 FEN-31 HTL incremental encoder interface module L503 FDCO-01 optical DDCS communication adapter module L508 FDCO-02 optical DDCS communication adapter module L515...
  • Page 44 44 Operation principle and hardware description Code Description R706 Finnish R707 French R708 Spanish R709 Portuguese R711 Russian R712 Chinese R713 Polish R714 Turkish...

  • Page 45: Generic Cabinet Planning Instructions

    The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 46: Grounding Of Mounting Structures

    Shrouds ￭ The installation of shrouds (touch protection) to fulfill applicable safety regulations is the responsibility of the drive system builder. Ready-made shrouding parts are available from ABB for some cabinet designs, see the ordering information. Tightening torques ￭ Unless a tightening torque is specified in the text, the following torques can be used.

  • Page 47: Insulation Supports

    Generic cabinet planning instructions 47 Insulation supports Size Max. torque Strength class 5 N·m (44 lbf·in) 9 N·m (6.6 lbf·ft) 18 N·m (13.3 lbf·ft) 31 N·m (23 lbf·ft) Cable lugs Size Max. torque Strength class 15 N·m (11 lbf·ft) 32 N·m (23.5 lbf·ft) 50 N·m (37 lbf·ft) Cooling and degrees of protection Planning the cooling...
  • Page 48 48 Generic cabinet planning instructions Note: Use an extra exhaust fan if the air outlet is on the cabinet door. Air inlet Air outlet Arrange the cooling air flow through the components according to the technical data. See the specifications for: •...

  • Page 49: Preventing The Recirculation Of Hot Air

    Generic cabinet planning instructions 49 Preventing the recirculation of hot air ￭ Prevent hot air circulation outside the cabinet by leading the outgoing hot air away from the area where the inlet air to the cabinet is taken. Possible solutions are listed below: •...
  • Page 50 • The best galvanic connection between the steel panels is achieved by welding them together as no holes are necessary. If welding is not possible, ABB recommends to leave the seams between the panels unpainted and equipped with special conductive EMC strips to provide adequate galvanic connection.

  • Page 51: Attaching The Cabinet

    Strain relief Grommet Entry plate Attaching the cabinet WARNING! Do not attach the cabinet by electric welding. ABB does not assume any liability for damages caused by electric welding as the welding circuit can damage electronic circuits in the cabinet.

  • Page 52: Cabinet Placement On A Cable Channel

    52 Generic cabinet planning instructions Cabinet placement on a cable channel Note the following when you plan to place the cabinet on a cable channel: • The cabinet structure must be sturdy enough. If the whole cabinet base is not supported from below, the cabinet weight will lie on the sections that the floor carries.

  • Page 53: Mounting The Control Panel On The Cabinet Door

    Mounting the control panel on the cabinet door You can use a mounting platform to mount the control panel on the cabinet door. Mounting platforms for control panels are available as options from ABB. For more information, see Manual Code (English)

  • Page 55: Guidelines For Planning The Mechanical Installation

    Guidelines for planning the mechanical installation 55 Guidelines for planning the mechanical installation Contents of this chapter This chapter guides in planning drive cabinets and installing the drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirements around the module for cooling.

  • Page 56: Layout Example, Door Closed

    56 Guidelines for planning the mechanical installation Layout example, door closed This diagram shows a cabinet layout example with the input power cable entry from top and the motor cable entry from bottom. Air inlet for the drive module Operating handle of the disconnector An extra fan is not necessary if an extra air baffle Rubber grommets for degree of protection is used on the cabinet roof (see the following...

  • Page 57: Layout Example, Door Open (Standard Drive Module Configuration)

    Guidelines for planning the mechanical installation 57 Layout example, door open (standard drive module configuration) L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A B– B Supporting frame of the cabinet LCL filter module Motor cable including the protective ground con- Vertical (2a) and horizontal (2b) air baffles that ductor of the drive module separate the cool and hot areas (leakproof...

  • Page 58: Layout Example, Door Open (Option +0B051)

    58 Guidelines for planning the mechanical installation Layout example, door open (option +0B051) This diagram shows a layout example for drive modules with no IP20 shrouds (option +0B051) or no cabling panels (option +H381 not included). L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A –...

  • Page 59: Cooling Solutions

    Guidelines for planning the mechanical installation 59 Note: The power cable shields can also be grounded to the drive module grounding terminals. Note: See also section Required free space (page 62). Cooling solutions The drawing below shows typical cabinet cooling solutions. The air inlet is at the bottom of the cabinet, while the outlet is on the roof or on the upper part of the door.

  • Page 60: Preventing The Recirculation Of Hot Air

    60 Guidelines for planning the mechanical installation Preventing the recirculation of hot air Bookshelf mounting (standard drive module configuration) ￭ This diagram shows the air baffle position inside an example cabinet. For dimensions of the baffle, see the dimension drawings. L1/U1 L2/V1 L3/W1...

  • Page 61: Bookshelf Mounting (Option +0B051)

    Guidelines for planning the mechanical installation 61 Bookshelf mounting (option +0B051) ￭ This diagram shows air baffle positions inside an example cabinet. For the descriptions, see the next page. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 C – C A - A B - B D –...

  • Page 62: Bookshelf Mounting (Option +H381)

    62 Guidelines for planning the mechanical installation Air flow to the drive modules, max. 40 °C (104 °F) LCL filter module Vertical air baffle that separates the cool and hot Disconnector and fuses areas in the cabinet Vertical air baffle Contactor Upper horizontal air baffle Drive control unit...

  • Page 63: Free Space Around The Drive Module

    The module can be installed in a cabinet with the following dimensions: • width 800 mm (31.50 in) • depth 600 mm (23.62 in) • height 2000 mm (78.74 in). ABB air inlet and outlet kits See chapter Ordering information (page 173).

  • Page 65: Mechanical Installation

    Mechanical installation 65 Mechanical installation Contents of this chapter This chapter describes alternatives of the mechanical installation of the drive module. It refers to the installation example chapters which contain instructions that depend on the selected drive configuration. Examining the installation site The material below the drive must be non-flammable and strong enough to carry the weight of the drive.

  • Page 66: Package Drawings

    66 Mechanical installation Package drawings ￭ Drive module package without option +E202 3AXD50000174287_091117 Transport package contents Finger guard Pedestal guide plate for the LCL filter module Pedestal guide plate for the drive module Accessories box See the box contents on the following pages. Center of gravity symbol Package for LCL filter fan Package for LCL filter pedestal...

  • Page 67: Package With Option +E202

    Mechanical installation 67 14–16 Cardboard support Pallet Strap VCI film or bag Drive module with factory installed options and multilingual residual voltage warning sticker, fastening screws in a plastic bag, control panel and cable or control panel with door mounting kit (option +J410), delivery documents, printed multilingual installation and start-up quick guides.

  • Page 68: Boxes

    68 Mechanical installation Telescopic extraction and insertion ramp Package for option H370: Full-size input power cable connection terminals and PE busbar. Plywood support With standard drive module configuration: Clear plastic shrouds box and output cable connection terminals box. With option +H370: Also Input cable connection terminals box. See below for the box contents.
  • Page 69 Mechanical installation 69 Option +H381 box: Input power cabling panel parts Screw package Paper fill Code label Output power cabling panel Input power cabling panel Grounding busbar to be connected to the input power cabling panel and the drive module Cardboard box bottom Cardboard box cover Rubber grommet...
  • Page 70 70 Mechanical installation Option +H370: input cable connection terminals box Metallic shroud with ground bar Paper fill Input cable connection terminal L3/W1 Input cable connection terminal L2/V1 Input cable connection terminal L1/U1 Cardboard box Screws and insulators in a plastic bag 3AXD5000009522 Ramp box Cardboard box...

  • Page 71: Lcl Filter Module Package

    Mechanical installation 71 Accessories box Screw package Busbar for main contactor - LCL con- nection (3 pcs) Busbar for IGBT - LCL connection (3 pcs) Cardboard box Installation bracket (2 pcs) Feed through (2 pcs) 3AXD50000477104 LCL filter module package 3AXD50000113651 VCI bag Plywood support...

  • Page 72: Examining The Delivery

    72 Mechanical installation Examining the delivery Make sure that all items listed in Moving and unpacking (page 65) are present. Make sure that there are no signs of damage. Before attempting installation and operation, examine the information on the type designation label of the drive to verify that the unit is of the correct type.

  • Page 73: Attaching The Drive Module To The Lcl Filter Module

    Mechanical installation 73 Attaching the drive module to the LCL filter module Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure (page 233). Attaching the drive module and the LCL filter module to the enclosure base Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure (page...

  • Page 74: Optional Input Power Cable Connection Terminals And Ground Busbar Assembly (+H370)

    74 Mechanical installation Optional input power cable connection terminals and ground busbar assembly (+H370) Install the metallic shroud with ground bar as shown below. Combi screw M4×8 Torx T20 2 N·m Connect the input power cable connection terminals as shown in Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure (page...

  • Page 75: Guidelines For Planning The Electrical Installation

    The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 76: North America

    Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.

  • Page 77: Requirements Table

    Guidelines for planning the electrical installation 77 time. The pulse voltage can almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals. This 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 that flow through the motor bearings.
  • Page 78 78 Guidelines for planning the electrical installation This table shows the requirements when an ABB motor is in use. Motor type Nominal AC line Requirement for voltage Motor insula- ABB du/dt and common mode filters, insulated tion system N-end motor bearings <...
  • Page 79 Guidelines for planning the electrical installation 79 This table shows the requirements when a non-ABB motor is in use. Motor type Nominal AC line Requirement for voltage Motor insula- ABB du/dt and common mode filters, insulated tion system N-end motor bearings <...

  • Page 80: Availability Of Du/Dt Filter And Common Mode Filter By Drive Type

    The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: •...

  • Page 81: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    Guidelines for planning the electrical installation 81 Nominal AC supply Requirement for voltage Motor insulation system ABB du/dt and common mode filters, insulated N- end motor bearings < 100 kW or frame size 100 kW < P < 350 kW or <...

  • Page 82: Additional Note For Sine Filters

    82 Guidelines for planning the electrical installation Û du/dt -------------(1/ µs) Û - - - - (1/ µs) -- - - -- - l (m) l (m) Drive with du/dt filter Drive without du/dt filter Motor cable length Û Relative peak line-to-line voltage (du/dt)/U Relative du/dt value Note: Û...

  • Page 83: Typical Power Cable Sizes

    Guidelines for planning the electrical installation 83 required in 411.3.2. of IEC 60364-4-41:2005 and be capable of withstanding the prospective fault current during the disconnection time of the protective device. The cross-sectional area of the protective conductor can either be selected from the table below or calculated according to 543.1 of IEC 60364-5-54.

  • Page 84: Alternate Power Cable Types

    84 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or armored) cable with three phase conductors and symmetrically constructed PE conductor and a shield (or armor) Symmetrical shielded (or armored) cable with three phase conductors and a shield (or armor), and separ- ate PE conductor/cable...

  • Page 85: Not Allowed Power Cable Types

    Additional guidelines, North America ￭ ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor(s). Due to the variety of application needs, metallic and non-metallic conduit can be used. ABB recommends the use of metallic conduit.

  • Page 86: Metal Conduit

    86 Guidelines for planning the electrical installation Wiring method Notes 1) 2) Conduit - Metallic Electrical metallic tubing: Type EMT Prefer symmetrical shielded VFD cable. Use separate conduit run for each motor. Rigid metal conduit: Type RMC Do not run input power wiring and motor wiring in the Liquid-tight flexible metal electrical conduit: Type LFMC same conduit.

  • Page 87: Selecting The Control Cables

    Relay cable ￭ The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel to drive cable ￭ Use EIA-485 with male RJ-45 connector, cable type Cat 5e or better. The maximum permitted...

  • Page 88: Pc Tool Cable

    88 Guidelines for planning the electrical installation PC tool cable ￭ Connect the Drive composer PC tool to the drive through the USB port of the control panel. Use a USB Type A (PC) - Type Mini-B (control panel) cable. The maximum length of the cable is 3 m (9.8 ft).

  • Page 89: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable

    Guidelines for planning the electrical installation 89 The following figure illustrates the cable routing guidelines with an example drive. Input power cabling Motor cabling Conduit Continuous motor cable shield/conduit or enclosure for equipment ￭ on the 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: •...

  • Page 90: Implementing Motor And Motor Cable Short-Circuit And Thermal Overload Protection

    90 Guidelines for planning the electrical installation Implementing motor and motor cable short-circuit and thermal overload protection Protecting the motor and motor cable in short-circuits ￭ The drive protects the motor cable and motor in a short-circuit situation when the motor cable is sized according to the nominal output current of the drive.

  • Page 91: Protecting The Drive And The Input Power Cable In Short-Circuits

    Guidelines for planning the electrical installation 91 For more information, see drive firmware manual. Protecting the drive and the input power cable in short-circuits Protect the drive (1) with fuses (a) and the input cable with fuses (b) or a circuit breaker. Size the fuses or the circuit breaker according to local regulations for the input cable protection.

  • Page 92: Connecting Motor Temperature Sensor To The Drive Via An Option Module

    92 Guidelines for planning the electrical installation 1. If there is double or reinforced insulation between the sensor and the live parts of the motor: You can connect the sensor directly to the analog/digital input(s) of the drive. See the control cable connection instructions. Make sure that the voltage does not exceed the maximum allowed voltage over the sensor.

  • Page 93: Protecting The Drive Against Ground Faults

    Guidelines for planning the electrical installation 93 Option module Temperature sensor Temperature sensor insulation type requirement Type Insulation/Isolation Pt100, Pt1000 FIO-11 Galvanic isolation between sensor Reinforced insulation connector and other connectors (in- cluding drive control unit connector) FEN-xx Galvanic isolation between sensor Reinforced insulation connector and other connectors (in- cluding drive control unit connector)

  • Page 94: Implementing The Functions Provided By The Fso-Xx Safety Functions Module

    94 Guidelines for planning the electrical installation Implementing the functions provided by the FSO-xx safety functions module You can order a safety function module from ABB. The cabinet builder can use the module for implementing various safety functions. Using power factor compensation capacitors with the drive Power factor compensation is not needed with AC drives.

  • Page 95: Controlling A Contactor Between Drive And Motor

    Guidelines for planning the electrical installation 95 FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option +L537+Q971) 3AXD50000027782 for ACS880 drives user's manual Controlling a contactor between drive and motor The control of the output contactor depends on how you use the drive, that is, which motor control mode and which motor stop mode you select.

  • Page 96: Example Bypass Connection

    96 Guidelines for planning the electrical installation Example bypass connection ￭ An example bypass connection is shown below. Drive main switch Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor Drive main contactor on/off control Motor power supply selection (drive or direct-on-line) Start when motor is connected direct-on-line Stop when motor is connected direct-on-line Switching the motor power supply from drive to direct-on-line...

  • Page 97: Switching The Motor Power Supply From Direct-On-Line To Drive

    Guidelines for planning the electrical installation 97 Switching the motor power supply from direct-on-line to drive 1. Stop the motor with S42. 2. Switch 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 to position 1).

  • Page 99: Electrical Installation

    Electrical installation 99 Electrical installation Contents of this chapter This chapter gives instructions on the wiring of the drive. Safety WARNING! If you are not a qualified electrical professional, do not do installation or maintenance work. Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 100: Measuring The Insulation

    Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 C [77°F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.

  • Page 101: Installing The Emc Filter (Option +E202)

    Electrical installation 101 WARNING! Do not install the drive with EMC filter option +E202 connected to a system that the filter is not suitable for. This can cause danger, or damage the drive. Note: When EMC filter +E202 is disconnected, the drive EMC compatibility is considerably reduced.

  • Page 102: Power Cable Connection Diagram

    50% of the conductivity of the phase conductor, use a separate PE cable (2a) or a cable with a grounding conductor (2b) ABB recommends 360-degree grounding at the cabinet entry if a shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board.
  • Page 103 Electrical installation 103 Use a separate grounding cable if the conductivity of the cable shield is < 50% of the conductivity of the phase conductor and there is no symmetrically constructed grounding conductor in the cable (see Guidelines for planning the electrical installation (page 75)) Common mode filter (option) du/dt filter (option)

  • Page 104: Preparing The Cable Ends And Making 360-Degree Grounding At The Cable Entry

    104 Electrical installation Preparing the cable ends and making 360-degree grounding at the ￭ cable entry 1. Peel off 3…5 cm (1 1/4 … 2 in) of the outer insulation of the cables at the cable entries with the conductive sleeves for the 360° high-frequency grounding. 2.

  • Page 105: Power Cable Connection Procedure

    Electrical installation 105 5. Remove rubber grommets from the entry plate for the cables to be connected. Cut adequate holes into the rubber grommets. Slide the grommets onto the cables. Slide the cables through the entry plate and attach the grommets to the holes. 6.

  • Page 106: Removing The Control Panel Holder From The External Control Unit

    106 Electrical installation 6. Twist the cable shields of the input cables into bundles and connect them and any separate ground conductors or cables to the drive module ground terminal or to the cabinet PE busbar. 7. Connect the phase conductors of the input cables to terminals L1/U1, L2/V1 and L3/W1 of the drive module.

  • Page 107: Connecting The External Control Unit To The Drive Module

    Electrical installation 107 0.7 N·m (6.2 lbf·in) Connecting the external control unit to the drive module External control unit connection cables ￭ The cables that are delivered with the drive module for connecting the drive module and control panel to the external control unit are shown below. ZBIB INU STO STO1 X7...

  • Page 108: Routing The External Control Unit Cables Into The Drive Module

    108 Electrical installation WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. Routing the external control unit cables into the drive module ￭...

  • Page 109: Attaching The External Control Unit

    Electrical installation 109 QOIA ZBIB X7 (STO1) INU STO X8 (STO2) INU ZBIB ISU ZBIB V20 V21 Attaching the external control unit The drive control unit can be attached on a mounting plate or onto a DIN rail.

  • Page 110: Attaching The External Control Unit To A Mounting Plate Or Wall

    110 Electrical installation Attaching the external control unit to a mounting plate or wall ￭ 1. Attach the mounting screws in the wall. 2. Lift the control unit onto the screws and tighten the screws. 3AUA0000130997 Attaching the external control unit vertically on a DIN rail ￭...

  • Page 111: Attaching The External Control Unit Horizontally On A Din Rail

    Electrical installation 111 Attaching the external control unit horizontally on a DIN rail ￭ 1. Attach the latches (A) to the back of the control unit with three screws. 2. Click the control unit to the rail as shown below (B). 3AUA0000130997...

  • Page 112: Connecting The Control Cables To The Terminals Of The External Control Unit

    112 Electrical installation Connecting the control cables to the terminals of the external control unit 1. Route the cables to the control unit as shown below. 2. Ground the shields of the control cables at the clamp plate. Use torque 1.5 N·m (13 lbf·in). The shields should be continuous as close to the terminals of the control unit as possible.

  • Page 113: Panel Bus (Control Of Several Units From One Control Panel)

    Electrical installation 113 Note: When a PC is connected to the control panel, the control panel keypad is disabled. In this case, the control panel acts as a USB-RS485 adapter. Panel bus (Control of several units from one control panel) One control panel (or PC) can be used to control several drives (or inverter units, supply units etc.) by constructing a panel bus.
  • Page 114 114 Electrical installation With twin connectors in the control panel holder:...
  • Page 115 Electrical installation 115 With FDPI-02 modules:...

  • Page 116: Panel Bus Wiring With Fdpi-02 - Single Drive

    116 Electrical installation With FDPI-02 module ACS880-14 and ACS880-34: Panel bus wiring with FDPI-02 – single drive ￭ FDPI-02 X202 X204 X203 ZDPI-01 X1-1 FDPI-02 diagnostics and panel interface installed onto the motor-side converter control unit X2-X204 X2: Daisy chain bus terminal 1, RJ-45 shielded female connector for connecting a control panel...

  • Page 117: Panel Bus Wiring With Fdpi-02 And Zdpi-01 - Several Drives

    Electrical installation 117 Panel bus wiring with FDPI-02 and ZDPI-01 – several drives ￭ FDPI-02 X202 X204 X203 X202 X204 X203 X202 X204 X203 X202 X204 X203 ZDPI-01 ZDPI-01 ZDPI-01 ZDPI-01 X1-1 FDPI-02 diagnostics and panel interface installed onto the motor-side converter control unit X2-X204 X2: Daisy chain bus terminal 1, RJ-45 shielded female connector for connecting a control panel X3-2...

  • Page 118: Connecting A Pc

    118 Electrical installation X1-1 FDPI-02 diagnostics and panel interface installed onto the motor-side converter control unit X2-X204 X2: Daisy chain bus terminal 1, RJ-45 shielded female connector for connecting a control panel X3-2 X3: Daisy chain bus terminal 2, RJ-45 shielded female connector for connecting to the line-side converter control unit RJ-45 connector (X13, CONTROL PANEL) Drive 2 Drive 3...

  • Page 119: Installing I/O Extension, Fieldbus Adapter And Pulse Encoder Interface Modules

    Electrical installation 119 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. If the bottom plate of the FSO-xx module looks different from that in the drawing below, remove the bottom plate and attach the alternative bottom plate from the FSO package to module.

  • Page 120: Wiring The Option Modules

    120 Electrical installation WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start work.

  • Page 121: External Control Unit

    External control unit 121 External control unit Contents of this chapter This chapter • describes the connections of the control unit(s) used in the drive, • contains the specifications of the inputs and outputs of the control unit(s).

  • Page 122: Zcu-14 Layout

    122 External control unit ZCU-14 layout Description XPOW External power input Analog inputs XRO1 Analog outputs XD2D Drive-to-drive link XRO1 Relay output RO1 XRO2 XRO2 Relay output RO2 XRO3 Relay output RO3 XRO3 XD24 Digital input interlock (DIIL) and +24 V output XDIO Digital input/outputs XPOW...

  • Page 123: Default I/O Diagram Of The Drive Control Unit (Zcu-1X)

    External control unit 123 Default I/O diagram of the drive control unit (ZCU-1x) Connection Term Description XPOW External power input +24VI 24 V DC, 2 A min. (without optional modules) J1, J2, XAI Reference voltage and analog inputs +VREF 10 V DC, R 1…10 kohm +VREF -VREF...
  • Page 124 124 External control unit Connection Term Description XD24 Auxiliary voltage output, digital interlock DIIL Run enable DIIL +24VD +24VD +24 V DC 200 mA DICOM DICOM Digital input ground +24VD +24VD DIOGND +24 V DC 200 mA DIOGND Digital input/output ground XDIO Digital input/outputs DIO1 Output: Ready run...

  • Page 125: Additional Information On The Connections

    External control unit 125 Additional information on the connections External power supply for the control unit (XPOW) ￭ The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW. Using an external supply is recommended if •...

  • Page 126: Diil Input

    (nominal impedance 100 to 165 ohm, for example Belden 9842) for the wiring. For best immunity, ABB recommends high quality cable. Keep the cable as short as possible. Avoid unnecessary loops and parallel runs near power cables such as motor cables.

  • Page 127: Safe Torque Off (Xsto)

    External control unit 127 ZCU-14 Termination ON Termination OFF Termination ON Safe torque off (XSTO) ￭ See chapter The Safe torque off function (page 215). Note: The XSTO input only acts as a true Safe torque off input on the inverter control unit. De-energizing the IN1 and/or IN2 terminals of other units (supply, DC/DC converter, or brake unit) will stop the unit but not constitute a true safety function.

  • Page 128: Connector Data

    128 External control unit Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 2.5 mm 24 V (±10%) DC, 2 A External power input. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3) 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 mm...
  • Page 129 External control unit 129 Analog outputs AO1 and AO2 (XAO) Connector pitch 5 mm, wire size 2.5 mm 0…20 mA, R < 500 ohm load Frequency range: 0…300 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range XD2D connector Connector pitch 5 mm, wire size 2.5 mm Physical layer: RS-485...

  • Page 130: Zcu-1X Ground Isolation Diagram

    130 External control unit ZCU-1x 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 XDIO DIO1 DIO2 XSTO OUT1...

  • Page 131: Installation Example Of The Standard Drive Module Configuration In Rittal Vx25

    In this chapter, the drive module is installed in a 800 mm wide Rittal VX25 enclosure in a bookshelf way of mounting. The module is placed in an upright position on the cabinet bottom with its front facing the cabinet door. Available alternative ABB parts are also given. For control cable installation, see chapter Electrical installation (page 99).

  • Page 132: Required Parts

    8806.000 Enclosure without bottom plates and side panels. Includes supports for installing air baffles. 7967.000 Spacers for roof plates / ABB roof (one set = four pieces) 8100.743 Punched section with mounting flange, inner mounting level for 800 mm horizontal Contact ABB for the suitable filter Air filter.

  • Page 133: Installing The Drive Module And Lcl Filter Module Into An Enclosure

    Installation example of the standard drive module configuration in Rittal VX25 enclosure 133 Step Task For instructions, see Connect the power cables and clear plastic Connecting the motor cables and installing the shrouds to the drive module. shrouds (page 134) Connect the power supply cable to the LCL filter Connecting the input cables and installing the cooling fan.

  • Page 134: Connecting The Motor Cables And Installing The Shrouds

    134 Installation example of the standard drive module configuration in Rittal VX25 enclosure Push the LCL filter module carefully into the enclosure along the extraction/installation ramp. Work preferably with help from another person as shown below. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back.

  • Page 135: Connecting The Input Cables And Installing The Shrouds

    Installation example of the standard drive module configuration in Rittal VX25 enclosure 135 Connect the twisted shields of the motor cables to the grounding terminal. Screw in and tighten the insulators to the drive module by hand. Install the T3/W2 connection ter- minal to the insulators.

  • Page 136: Installing The Air Baffles

    136 Installation example of the standard drive module configuration in Rittal VX25 enclosure Install the L2/V1 connection terminal to the insulators. See the warning in step 5. Connect the L2/V1 conductors to the L2/V1 connection terminal. Install the L3/W1 connection terminal to the insulators. See the warning in step 5. Connect the L3/W1 conductors to the L3/W1 connection terminal.

  • Page 137: Installing The Roof And Door (Rittal Parts)

    Installation example of the standard drive module configuration in Rittal VX25 enclosure 137 Installing the roof and door (Rittal parts) This drawing shows a layout tested by ABB. Door Install these gratings as close to each other as possible. Remove the filter mats.

  • Page 138: Removing The Protective Covering From The Drive Module And Lcl Filter Module Air Outlet

    138 Installation example of the standard drive module configuration in Rittal VX25 enclosure Removing the protective covering from the drive module and LCL filter module air outlet WARNING! Remove the protective covering from the top of the drive module after the installation.

  • Page 139: Installation Example With Full Cabling Panels (Option +H381)

    The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 140: Required Parts

    Enclosure frame: Frame, rear door, roof plate, plinth. VX 8106.245 Side panels for the enclosure SZ/DK 7967.000 Spacers for roof plate. Alternative ABB roof (3AUA0000125203 [IP20], AUA0000114968 [IP42]), see Air outlet kits (page 176). (one set = four pieces) + additional spacers VX 8617.140...

  • Page 141: Overall Flowchart Of The Installation Process

    Installation example with full cabling panels (option +H381) 141 Overall flowchart of the installation process Step Task For instructions, see Install the Rittal parts and drive module mechan- Installing the mechanical accessories into a en- ical accessories into the enclosure closure (page 141) Connect the power cables to the cabling panels Connecting the power cables (page 143)
  • Page 142 142 Installation example with full cabling panels (option +H381)

  • Page 143: Connecting The Power Cables

    PE cable (2a) or a cable with a grounding conductor (2b). ABB recommends 360-degree grounding at the enclosure entry if a shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board.

  • Page 144: Power Cable Connection Procedure

    144 Installation example with full cabling panels (option +H381) Input and output power cabling panels (option +H381) ABB recommends 360-degree grounding at the enclosure entry Use a separate grounding cable if the conductivity of the cable shield is < 50% of the conductivity of the...
  • Page 145 Installation example with full cabling panels (option +H381) 145 An example installation is shown below. L1/U1, L2/V1, L3/W1 102 mm (4 in) T1/U2, T2/V2, T3/W2 View without enclosure side plate in place. 360-degree grounding at the entry plate for the input power cables Grounding busbar of the input power cabling panel 360-degree grounding at the entry plate for the output power cables Grounding busbar of the output power cabling panel...

  • Page 146: Installing The Drive Module Into The Enclosure

    146 Installation example with full cabling panels (option +H381) Installing the drive module into the enclosure WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work: Open the support legs by pressing each leg a little down and turning it aside (1, 2).

  • Page 147: Installation Procedure

    Installation example with full cabling panels (option +H381) 147 Installation procedure ￭ 1. Install the drive module and the LCL filter module into the Rittal enclosure as shown in Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure (page 233).

  • Page 148: Assembly Drawing Of Connecting The Drive Module To The Cabling Panels

    148 Installation example with full cabling panels (option +H381) Assembly drawing of connecting the drive module to the cabling panels 3AXD50000248919 Combi screw M12×25 hex (delta) or equal (9 pcs) Extraction/insertion ramp (3AXD50000476374)

  • Page 149: Installing Air Baffles (Non-Abb Parts)

    Installation example with full cabling panels (option +H381) 149 Installing air baffles (non-ABB parts) See dimension drawings for the air baffle measurements. Left Front Right Rear Miscellaneous Installing the rubber grommet ￭ To get IP20 degree of protection for the drive module, install the input power cables through the rubber grommet.
  • Page 150 150 Installation example with full cabling panels (option +H381)

  • Page 151: Installation Checklist

    Installation checklist 151 Installation checklist Contents of this chapter This chapter contains a checklist of the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 152 152 Installation checklist Make sure that … The cooling air flows freely in and out of the drive. Air recirculation inside the cabinet is not possible (air baffle plates are on place, or there is another air guiding solution). If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground- to-phase varistor).

  • Page 153: Start-Up

    ACx-AP-x Assistant control panels user's manual (3AUA0000085685 [English]). • For drives with ABB du/dt filter: Check that bit 13 of parameter 95.20 HW options word 1 is switched on. • For drives with ABB sine filter: Check that parameter 95.15 Special HW settings is set to ABB sine filter.
  • Page 154 154 Start-up 6. For drive modules in which the Safe torque off function is in use: Test and validate the operation of the Safe torque off function. See Validation test procedure (page 223). 7. For drive modules with an FSO-xx safety functions module (options +Q972 and Q973): Test and validate the operation of the safety functions.

  • Page 155: Fault Tracing

    Fault tracing 155 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs The table below describes the LEDs of the drive module with option +J410. Where Color When the LED is lit Control panel POWER Green...

  • Page 157: Maintenance

    For more information, consult your local ABB Service representative (www.abb.com/searchchannels). The maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance.

  • Page 158: Recommended Maintenance Intervals After Start-Up

    158 Maintenance Recommended annual actions by the user Annually Connections and environment Quality of supply voltage Spare parts Spare parts DC circuit capacitors reforming, spare modules and spare capacitors Inspections by the user Tightness of terminals Dustiness, corrosion and temperature Heat sink cleaning Recommended maintenance intervals after start-up ￭...

  • Page 159: Cleaning The Interior Of The Heatsink

    Maintenance 159 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Open the cabinet door. 3. Clean the interior of the cabinet. Use a vacuum cleaner and a soft brush. 4.

  • Page 160: Cleaning The Interior Of The Lcl Filter

    Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the auxiliary cooling fans of the drive module ￭...

  • Page 161: Replacing The Drive Module Main Cooling Fans

    Maintenance 161 Fan at the bottom of the circuit board compartment: 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Undo the mounting screw of the fan cassette. 3.

  • Page 162: Replacing The Lcl Filter Module Cooling Fan

    162 Maintenance 3. Undo the mounting screws of the fan cassette. 4. Pull the fan cassette out. 5. Undo the mounting screws of the fan(s). Note: 690 V drive modules have only one fan in the cassette. 6. Install the new fans in reverse order. For 690 V drive modules, connect the fan power supply to connector FAN1:PWR1.

  • Page 163: Replacing The Standard Drive Module

    Maintenance 163 5. Undo the mounting screws of the fan. The finger guard of the fan is attached by the same screws and is removed at the same time. Keep the finger guard for reuse 6. Install the new fan in reverse order. Make sure that the arrow in the fan points up. Replacing the standard drive module WARNING! Obey the safety instructions of the drive.
  • Page 164 164 Maintenance 3AUA0000086323 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Remove the clear plastic shrouds on the power cables and parts in front of the drive module (if present).
  • Page 165 Maintenance 165 10. Adjust the extraction/installation ramp to the correct height and attach it to the cabinet base with the two mounting screws.

  • Page 166: Replacing The Lcl Filter Module

    166 Maintenance 11. Pull the drive module carefully out of the cabinet preferably with help from another person. 12. Install the new module in reverse order. Replacing the LCL filter module Replace the LCL filter module in the same way as the drive module. Replacing the drive module with option +H381 WARNING! Obey the safety instructions of the drive.
  • Page 167 Maintenance 167 • Make sure that the module does not topple over when you move it on the floor: To open the support legs, press each leg a little down and turn it aside (1, 2). Whenever possible secure the module also with chains. •...

  • Page 168: Replacing The Lcl Filter Module With Option +H381

    168 Maintenance Replacing the LCL filter module with option +H381 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure (page 233): 1. Disconnect the LCL filter module from the drive module. 2. Undo the screws that attach the LCL filter module to the enclosure frame. 3.

  • Page 169: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. Reforming the capacitors ￭...

  • Page 170: Replacing The Zcu-14 Control Unit Battery

    170 Maintenance Replacing the ZCU-14 control unit battery WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. 1.

  • Page 171: Replacing The Zcu-12 Control Unit Battery

    Maintenance 171 Replacing the ZCU-12 control unit battery Contact ABB service center for instructions on how to replace the control unit battery. Memory unit When a drive module is replaced, the parameter settings can be retained by transferring the memory unit from the defective drive module to the new module. One memory unit is...

  • Page 172: Functional Safety Components

    Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information.

  • Page 173: Ordering Information

    This chapter gives ordering information on additional components available from ABB for the drive module installation. Note: This chapter only lists the installation accessories available from ABB. All other parts must be sourced from a third party by the system integrator.

  • Page 174: Output (Du/Dt) Filters

    174 Ordering information Type Description Ordering code Illustration Door mounting kit for flush mounting. Includes a control DPMP-01 panel mounting platform, an IP54 3AUA0000108878 cover and a 3- meter panel con- nection cable. DPMP-04 Cotrol panel mounting platform 3AXD50000217717 Output (du/dt) filters See section du/dt filters (page 231).
  • Page 175 Ordering information 175 Enclosure width / Kit code Ordering code Illustration Degree of protection 800 mm / IP42 A-8-X-026 3AUA0000117009 Instruction code: 3AUA0000116875 800 mm / IP54 A-8-X-029 3AXD50000009186 Instruction code: 3AXD50000010001...

  • Page 176: Air Outlet Kits

    176 Ordering information Air outlet kits ￭ Enclosure width / Kit code Ordering code Illustration Degree of protection 800 mm / IP20 A-4-X-062 3AUA0000125201 Instruction code: 3AXD50000001982 Note: Fan to be ordered separately 800 mm / IP42 A-4-X-060 3AUA0000114967 Instruction code: 3AUA0000115290 Note: Fan to be ordered separately 800 mm / IP54 (IEC) A-4-X-064...

  • Page 177: Cooling Fans

    Ordering information 177 Enclosure width / Kit code Ordering code Illustration Degree of protection 800 mm / IP54 (UL) A-4-X-067 3AXD50000010362 Instruction code: 3AXD50000010284 Note: Fan to be ordered separately Cooling fans Two cooling fans must be installed inside the air outlet compartment to ensure sufficient cooling of the cabinet.

  • Page 178: Fso Accessories Kit

    178 Ordering information FSO accessories kit Kit code Ordering code Illustration A-X-X-279 3AXD50000025495 Instruction code: 3AXD50000025583 Control panel mounting platforms Ordering code DPMP-04 control panel mounting platform 3AXD50000217717 Retrofit accessory kits Option code Ordering code Common mode filter kit +E208 3AXD50000026145 Full size cable connection terminals for input power cables +H370...

  • Page 179: Technical Data

    Technical data 179 Technical data Contents of this chapter This chapter contains the technical specifications of the drive, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Ratings The nominal rating for the drive modules with 50 Hz and 60 Hz supply are given below. IEC RATINGS ACS880- Frame...
  • Page 180 180 Technical data IEC RATINGS ACS880- Frame Input Output ratings 14-… size current Nominal use Light-duty use Heavy-duty use 361A-5 414A-5 460A-5 503A-5 = 690 V 142A-7 174A-7 210A-7 271A-7 330A-7 370A-7 430A-7 3AXD00000588487 UL (NEC) RATINGS ACS880- Frame size Input Max.

  • Page 181: When Is Derating Necessary

    The power ratings apply to most IEC 34 motors at the nominal voltage of the drive. ABB recommends to select the drive, motor and gear combination for the required motion profile with the DriveSize dimensioning tool available from ABB.

  • Page 182: Altitude Derating

    • drive is used with an ABB motor for explosive atmospheres (Ex) and EX motor in parameter 95.15 Special HW settings is enabled • sine filter given in the selection table (see section Sine filters) is used and ABB sine filter in parameter 95.15 Special HW settings is enabled...
  • Page 183 With other than recommended sine filters (see section Sine filters (page 232)) and non-ABB Ex motors, contact ABB. ACS880- Output ratings for special settings 14-… Ex motor (ABB Ex motor) ABB sine filter Low noise mode Nominal use Light- Heavy- Nominal use...

  • Page 184: High Speed Mode

    High speed mode The selection High speed mode of parameter 95.15 Special HW settings improves control performance at high output frequencies. ABB recommends it to be selected with output frequency of 120 Hz and above. This table gives the drive module ratings for 120 Hz output frequency and the maximum output frequency for the drive ratings when High speed mode in parameter 95.15 Special...

  • Page 185: Derating For Output Voltage Boosting

    0.875 Example 1: P for ACS880-14-650A-3 is 355 kW. The input voltage (U) is 350 V. -> U/U = 350 V / 400 V = 0.875. -> P/P = 0.975 -> The derated power P = 0.975 × 355 kW = 346 kW.
  • Page 186 0.96 Example 1: P for ACS880-14-430A-7 is 400 kW. The input voltage (U) is 660 V. -> U/U 660 V / 690 V = 0.96 -> P/P = 0.96 -> The derated power P = 0.96 × 400 kW = 384 kW.

  • Page 187: Fuses (Iec)

    Technical data 187 Fuses (IEC) aR fuses by Cooper Bussmann for protection against short-circuit in the input power cable of drive are listed below. Ultrarapid (aR) fuses per drive module Input Fuse ACS880- current 14-… Type Flush End Size = 400 V 246A-3 74000 170M5408...

  • Page 188: Fuses (Ul)

    188 Technical data Fuses (UL) UL fuses by Cooper Bussman for branch circuit protection per NEC per drive module are listed below. Obey local regulations. Fuse ACS880- Input cur- 14-… rent (A) Type DIN 43653 Type US Style Type French Style Size = 500 V 240A-5...

  • Page 189: Circuit Breakers (Ul)

    Technical data 189 Circuit breakers (UL) Note: Circuit breakers must not be used without fuses. For suitable circuit breakers, contact your local ABB representative. Dimensions, weights and free space requirements Standard drive module configuration drive module + LCL filter module)

  • Page 190: Losses, Cooling Data And Noise

    This table shows typical heat loss values, required air flow and noise at the nominal ratings of the drive. The heat loss values can vary depending on voltage, cable conditions, motor efficiency and power factor. To obtain more accurate values for given conditions, use ABB DriveSize tool (http://new.abb.com/drives/software-tools/drivesize).

  • Page 191: Terminal And Entry Data For The Power Cables

    Technical data 191 ACS880- Cu cable type Al cable type Cu cable type Al cable type 14-… AWG/kcmil AWG/kcmil = 400 V 246A-3 2 × (3 × 50) 2 × (3 × 95) 250 MCM or 2 × 1 350 MCM or 2 × 2/0 293A-3 2 ×...

  • Page 192: Units With Optional Cabling Panels (+H381)

    ACS880-14-xxxx-3 drive modules: 380…415 VAC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage level 3~400 V AC. ACS880-14-xxxx-5 drive modules: 380…500 V AC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage levels 3~400/480/500 V AC.

  • Page 193: Motor Connection Data

    Motor connection data Motor types Asynchronous AC induction motors, permanent magnet motors, AC induction ser- vomotors and ABB synchronous reluctance motors (SynRM motors) Voltage (U 0 to U , 3-phase symmetrical. This is indicated in the type designation label as typical output voltage level as 3 0…U...

  • Page 194: Dc Connection Data

    Longer motor cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and characteristics. Contact ABB for more information. Note that a sine filter (optional) at the drive output also causes a voltage decrease.

  • Page 195: Efficiency

    Technical data 195 Efficiency Approximately 96.5% at nominal power level. Protection classes for module Degrees of protection IP20 (standard) (IEC/EN 60529) IP00 (option +0B051) Enclosure types UL Type Open (UL 61800-5-1) Overvoltage category (IEC/EN 60664-1) Protective class (IEC/EN 61800-5-1) Ambient conditions The table shows environmental limits for the drive.

  • Page 196: Materials

    IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must...

  • Page 197: Applicable Standards

    Technical data 197 Applicable standards The drive complies with the following standards. European electrical safety requirements product standards IEC/EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety requirements – electrical, thermal and energy IEC 60204-1:2016 Safety of machinery. Electrical equipment of machines. Part 1: General require- ments.

  • Page 198: Emc Compliance (Iec/En 61800-3:2004)

    198 Technical data RCM mark Product complies with Australian and New Zealand requirements specific to EMC, telecommunica- tions and electrical safety. For fulfilling the EMC requirements, see the additional information con- cerning the drive EMC compliance (IEC/EN 61800-3). KC mark Product complies with Korea’s product safety requirements for electrical and electronic equipment and components that utilize power from 50…1000 V AC.

  • Page 199: Category C3

    Technical data 199 WARNING! The drive may cause radio interference if used in a residential or domestic environment. The user is required to take measures to prevent interference, in addition to the requirements for CE compliance listed above, if necessary. WARNING! Do not install a drive equipped with EMC filter +E202 grounding wire connected on IT (ungrounded) systems.

  • Page 200: Category C4

    200 Technical data Category C4 ￭ The drive complies with the C4 category with these provisions: 1. It is ensured that no excessive emission is propagated to neighboring low-voltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply transformer with static screening between the primary and secondary windings can be used.

  • Page 201: Eu Declaration Of Conformity (Machinery Directive)

    • The drive provides motor overload protection. This feature is not enabled when the drives leaves the ABB factory. For enabling this motor overload protection, see the firmware manual. • The drive overvoltage category according to IEC 60664-1 is III...

  • Page 202: Cybersecurity Disclaimer

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized...

  • Page 203: Dimension Drawings

    Dimension drawings 203 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules with optional parts for Rittal VX25 enclosure.

  • Page 204: Standard Configuration

    204 Dimension drawings Standard configuration...

  • Page 205: Location Of Power Cable Connection Terminals With Options +H370, +H356

    Dimension drawings 205 Location of power cable connection terminals with options +H370, +H356...

  • Page 206: Drive Module With Options +0B051+H356+0H371

    206 Dimension drawings Drive module with options +0B051+H356+0H371...

  • Page 207: Configuration With Option +H381

    Dimension drawings 207 Configuration with option +H381...

  • Page 208: Lcl Filter Module

    208 Dimension drawings LCL filter module...

  • Page 209: Bottom Plate

    Dimension drawings 209 Bottom plate This drawing shows the dimensions of the bottom plate for 800 mm Rittal VX25 enclosure. It is not an ABB product.

  • Page 210: Air Baffles

    210 Dimension drawings Air baffles This drawing shows the dimensions of the air baffles around the standard drive module for 800 mm Rittal VX25 enclosure. These are not ABB products. LEFT RIGHT REAR FRONT 3AXD50000453931 Material of the air baffles ￭...

  • Page 211: Air Baffles For Option +H381 In 800 Mm Wide Rittal Vx25 Enclosure

    Air baffles for option +H381 in 800 mm wide Rittal VX25 enclosure This drawing shows the dimensions of the air baffles for the full cabling panels option (+H381) in 800 mm Rittal VX25 enclosure. These are not ABB products. LEFT RIGHT...

  • Page 212: External Control Unit

    212 Dimension drawings External control unit 3AXD50000011687...

  • Page 213: Example Circuit Diagrams

    Example circuit diagrams 213 Example circuit diagrams Contents of this chapter This chapter shows an example circuit diagram for a cabinet-installed drive module. Example circuit diagram This diagram is an example for the main wiring of a drive cabinet. Note that the diagram includes components which are not included in a basic delivery (* plus code options, ** other options, *** to be acquired by the customer).
  • Page 214 214 Example circuit diagrams X7 X8 V2 V1 V21 V20 ZBIB V13 V8 V7 V2 QOIA Cabinet *ACS-AP-W control panel ZCU control unit ***Main contactor **Motor temperature supervision ***Switch fuse disconnector *Common mode filter **du/dt filter or sine filter Drive module Input and output signals Alarm Supply...

  • Page 215: The Safe Torque Off Function

    The Safe torque off function 215 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description WARNING! In case of parallel-connected drives or dual-winding motors, the STO must be activated on each drive to remove the torque from the motor.

  • Page 216: Compliance With The European Machinery Directive

    216 The Safe torque off function Standard Name IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards – Im- munity requirements for equipment intended to perform functions in a safety-related system (functional safety) in industrial locations IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC requirements –...

  • Page 217: Wiring

    The Safe torque off function 217 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. Activation switch ￭ In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC.

  • Page 218: Single Drive (Internal Power Supply)

    218 The Safe torque off function Single drive (internal power supply) ￭ Dual-channel connection +24 V SGND UDC+ UDC– Drive Control unit Control logic To motor Activation switch...

  • Page 219: Single-Channel Connection

    The Safe torque off function 219 Single-channel connection +24 V SGND Note: •Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL classification is given. •Pay special attention to avoiding any potential failure modes for the wiring. For example, use shielded cable. For measures for fault exclusion of wiring, see eg.

  • Page 220: Multiple Drives

    220 The Safe torque off function Multiple drives ￭ Internal power supply XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * Terminal designation may vary depending on drive type...

  • Page 221: External Power Supply

    The Safe torque off function 221 External power supply 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * Terminal designation may vary depending on drive type...

  • Page 222: Operation Principle

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

  • Page 223: Start-Up Including Validation Test

    The Safe torque off function 223 Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed •...
  • Page 224 224 The Safe torque off function Action Test the operation of the STO function when the motor is running. •Start the drive and make sure the motor is running. •Open the STO circuit. The motor should stop. The drive generates an indication if one is defined for the 'running' state in parameter 31.22 (see the firmware manual).

  • Page 225: Use

    The Safe torque off function 225 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs.

  • Page 226: Maintenance

    If any wiring or component change is needed after start up, or the parameters are restored, do the test given in section Validation test procedure (page 223). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...

  • Page 227: Fault Tracing

    See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.

  • Page 228: Safety Data

    228 The Safe torque off function Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. MTTF SIL/ Frame size...

  • Page 229: Tüv Certificate

    Mission time: the period of time covering the intended use of the safety function/device. After the mission time elapses, the safety device must be replaced. Note that any T values given cannot be regarded as a guarantee or warranty. TÜV certificate ￭ The TÜV certificate is available on the Internet at www.abb.com/drives/documents.

  • Page 230: Declaration Of Conformity

    230 The Safe torque off function Declaration of conformity ￭...

  • Page 231: Filters

    FOCH0320-5x 361A-5 FOCH0320-5x 271A-7 FOCH0260-7x 505A-3 FOCH0610-7x 414A-5 FOCH0320-5x 330A-7 FOCH0610-7x 585A-3 FOCH0610-7x 460A-5 FOCH0320-5x 370A-7 FOCH0610-7x 650A-3 FOCH0610-7x 503A-5 FOCH0610-7x 430A-7 FOCH0610-7x Ordering codes ￭ Filter type Degree of protection ABB ordering code FOCH0320-50 IP00 68612209 FOCH0320-52 IP22 3AXD50000030047...

  • Page 232: Description, Installation And Technical Data Of The Foch Filters

    232 Filters Filter type Degree of protection ABB ordering code FOCH0260-70 IP00 68490308 FOCH0260-72 IP22 3AXD50000030048 FOCH0610-70 IP00 68550505 Description, installation and technical data of the FOCH filters ￭ See FOCH du/dt filters hardware manual (3AFE68577519 [English]). Sine filters When is a sine filter necessary? ￭...

  • Page 233: Step-By-Step Drawings For An Installation Example Of Standard Drive Configuration In Rittal Vx25 800 Mm Wide Enclosure

    22. Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure See: • Handling the drive module, power cable connection diagram (page 233) • Installing the drive module and LCL filter module into a Rittal VX25 enclosure (page 235) •...
  • Page 234 Handling the drive module, power cable connection diagram ACS880-14 UDC- UDC+ INPUT OUTPUT WARNING! The UDC+ and UDC- terminals of the drive module must not be used for any other than optional external brake chopper connection.

  • Page 235: Installing The Drive Module And Lcl Filter Module Into A Rittal Vx25 Enclosure

    Installing the drive module and LCL filter module into a Rittal VX25 enclosure See instructions in section Installing the drive module and LCL filter module into an enclosure (page 133). Rittal 8806.000 non-ABB part (see dimension drawings) Rittal 8617.140 80.5 (3.17) 280.5 (11.04)
  • Page 236 Tapping screw M6×12 Torx T30 (Hex) 8 N·m (71 lbf·in) Combi screw M8×30 Hex 20 N·m (14.75 lbf·ft)
  • Page 237 Combi screw M4×8 Torx T20 2 N·m (18 lbf·in) Combi screw M4×8 Torx T20 2 N·m (18 lbf·in) Combi screw M4×8 Torx T20 2 N·m (18 lbf·in)
  • Page 238 M6 Serpress 8 N·m (71 lbf·in) M6 Serpress 8 N ·m (71 lbf·in) Screw M10x30 and washer Combi screw M8 Combi screw M8 24 N·m (17.70 lbf·ft) 24 N·m (17.70 lbf·ft)
  • Page 239 M10×30 Combi screw M4×8 Torx T20 2 N·m (18 lbf·in) Combi screw M12×25 70 N·m (52 lbf·ft) Combi screw M4×8 Torx T20 2 N·m (18 lbf·in)

  • Page 240: Connecting The Motor Cables And Installing The Shrouds

    Connecting the motor cables and installing the shrouds See instructions in section Connecting the motor cables and installing the shrouds (page 134).
  • Page 242 Combi screw M4×10 Torx T20 2 N·m (18 lbf·in) Combi screw M6×20 Torx T25 2 N·m (18 lbf·in) Combi screw M6×20 Torx T25 2 N·m (18 lbf·in)

  • Page 243: Connecting The Input Power Cables And Installing The Shrouds

    Connecting the input power cables and installing the shrouds See instructions in section Connecting the input cables and installing the shrouds (page 135) UDC+ UDC+ UDC+ UDC- UDC- UDC- L1/U1 L1/U1 L3/W1 L2/V1 L1/U1 L3/W1 Hex screw M12×35 L2/V1 L2/V1 full thread L3/W1 70 N·m (52 lbf·ft)

  • Page 244: Installing The Air Baffles And Removing The Cardboard Covers

    UDC+ UDC- L3/W1 L2/V1 L1/U1 Combi screw M4×10 Torx T20 2 N·m (18 lbf·in) Combi screw M4×10 Torx T20 2 N·m (18 lbf·in) Combi screw M6×20 Torx T25 2 N·m (18 lbf·in)
  • Page 245 Installing the air baffles and removing the cardboard covers See instructions in section Installing the air baffles (page 136)

  • Page 247: 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 248 3AXD50000035160D © Copyright 2021 ABB. All rights reserved. Specifications subject to change without notice.

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