Page 1 — ABB INDUSTRIAL DRIVES ACS880-01 drives Hardware manual...
Page 3 ACS880-01 drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation – Global (IEC) 7. Electrical installation – North America (NEC) 10. Start-up 3AUA0000078093 Rev T Original instructions EFFECTIVE: 2024-07-02...
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 Examining the compatibility of the motor and drive ........Protecting the motor insulation and bearings ........... Requirements tables ..................Requirements for ABB motors, P < 100 kW (134 hp) ....Requirements for ABB motors, P > 100 kW (134 hp) ....
Page 7 Availability of d u /d t 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 braking applications ......
Page 8 8 Table of contents Protecting the motor against thermal overload ........Protecting the motor against overload without thermal model or temperature sensors ..................Protecting the drive against ground faults ............Residual current device compatibility ............Connecting drives to a common DC system ............Implementing the emergency stop function ............
Page 9 Table of contents 9 Panel bus (control of several units from one control panel) ......Installing option modules ..................Fieldbus cabling ....................Installing FSO-xx safety functions modules ..........Installation procedure ................7 Electrical installation – North America (NEC) Contents of this chapter ..................Safety ..........................
Page 10 10 Table of contents 10 Start-up Contents of this chapter ..................Reforming the capacitors ..................Start-up procedure ....................11 Fault tracing Contents of this chapter ..................LEDs ..........................Warning and fault messages ................12 Maintenance Contents of this chapter ..................Maintenance intervals .....................
Page 11: Table Of Contents
Calculating the short-circuit current of the installation ......Calculation example ................Fuses (UL) ........................Circuit breakers (IEC) ....................ABB miniature and molded case circuit breakers ........Circuit breakers (UL) ....................ABB inverse time circuit breakers ..............230 V circuit breakers ................
Page 12 12 Table of contents Package materials for small wall-mounted drives and converter modules ....................... Package materials for large wall-mounted drives and converter modules ....................... Package materials for options, accessories and spare parts ....Materials of manuals ..................Disposal ........................Applicable standards ....................Markings ........................
Page 13 Table of contents 13 15 Resistor braking Contents of this chapter ..................Operation principle and hardware description ..........Planning the braking system ................. Selecting the brake circuit components ............Selecting a custom resistor ................Selecting and routing the brake resistor cables ......... Minimizing electromagnetic interference ........
Page 14 14 Table of contents External power supply ................. Operation principle ....................Start-up including validation test ................. Competence ....................... Validation test reports ..................Validation test procedure ................Use ..........................Maintenance ......................Competence ....................... Perfect proof test procedure ................Simplified proof test procedure ..............Fault tracing ......................
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 persons 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 • Before you adjust the drive operation limits, make sure that the motor and all driven equipment can operate throughout the set operation limits. • Before you activate the automatic fault reset or automatic restart functions of the drive control program, make sure that no dangerous situations can occur.
Page 18: Electrical Safety In Installation, Start-Up And Maintenance
18 Safety instructions Electrical safety in installation, start-up and maintenance ￭ Electrical safety precautions These electrical safety precautions are for all persons who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 19: Additional Instructions And Notes
Safety instructions 19 motor circuit. This voltage can remain charged for a long time after the drive power-off. The measurement discharges the voltage. • Make sure that the voltage between the drive DC terminals (UDC+ and UDC-) and the grounding (PE) terminal is zero. Note: If cables are not connected to the drive DC terminals, measuring the voltage from the DC terminal screws can give incorrect results.
Page 20: Printed Circuit Boards
20 Safety instructions Printed circuit boards WARNING! Use ESD wristband when you handle printed circuit boards. Do not touch the boards unnecessarily. The boards are sensitive to electrostatic discharge. ￭ Grounding These instructions are for all persons who are responsible for the grounding of the drive.
Page 21: General Safety In Operation
Safety instructions 21 General safety in operation These instructions are for all persons that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you have a cardiac pacemaker or other electronic medical device, do not go near the area near motor, drive, and the drive power cabling when the drive is in operation.
Page 22: Safety In Operation
22 Safety instructions • Do not do work on the drive when a rotating permanent magnet motor is connected to it. A rotating permanent magnet motor energizes the drive including its input and output power terminals. Before installation, start-up and maintenance work on the drive: •...
Page 23: Introduction To The Manual
Introduction to the manual 23 Introduction to the manual Contents of this chapter This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in examining the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.
Page 24: Quick Installation, Commissioning And Operation Flowchart
24 Introduction to the manual Quick installation, commissioning and operation flowchart Task Identify the frame of your drive: R1…R9. Type designation key (page 37) Plan the electrical installation and acquire the accessor- Guidelines for planning the electric- ies needed (cables, fuses, etc.). al installation (page 67) Check the ratings, required cooling air flow, input Technical data (page 195)
Page 25: Terms And Abbreviations
Introduction to the manual 25 Task Start the drive up. Start-up (page 171) Quick start-up guide, firmware Operate the drive: start, stop, speed control etc. manual Terms and abbreviations Term Description DC link DC circuit between rectifier and inverter DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage DPMP-01 Mounting platform for control panel (flush mounting)
Page 26 26 Introduction to the manual Term Description FSO-21 Safety functions module which supports the FSE-31 module and the use of safety encoders FSO-12 Safety functions module which does not support the use of encoders FSPS-21 Optional functional safety module IGBT Insulated gate bipolar transistor Inverter Converts direct current and voltage to alternating current and...
Page 27: Related Documents
Introduction to the manual 27 Related documents You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. ACS880-01 manuals...
Page 29: Operation Principle And Hardware Description
Contents of this chapter This chapter briefly describes the operation principle and construction of the drive. Product overview The ACS880-01 is a drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors).
Page 30: Main Circuit
30 Operation principle and hardware description ￭ Main circuit The main circuit of the drive is shown below. ACS880-01 T1/U T2/V T3/W R- UDC+ UDC- Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter.
Page 31: Layout
Operation principle and hardware description 31 ￭ Layout IP21, UL Type 1 The components of the drive are shown below (view of frame R5). Control panel Front cover Cable entry box Four attaching points at the back of the unit Heatsink Lifting eyes...
Page 32: Ip55 (Option +B056)
32 Operation principle and hardware description IP55 (option +B056) The components of the IP55 drive (option +B056) are shown below (view of frame R4). Control panel behind the control panel cover Front cover Four fastening points at the back of the drive Heatsink Lifting eyes...
Page 33: Ul Type 12 (Option +B056)
Operation principle and hardware description 33 UL Type 12 (option +B056) The components of the UL Type 12 drive (option +B056) are shown below (view of frame R6). Control panel behind the control panel cover Front cover Four attaching points at the back of the unit Llifting eyes Heatsink...
Page 34: Overview Of Power And Control Connections
34 Operation principle and hardware description ￭ Overview of power and control connections This diagram shows the power connections and control interfaces of the drive. Slot 1 X208 Slot 2 Slot 3 U/T1 V/T2 W/T3 UDC+ UDC- Analog and digital I/O extension modules, feedback interface modules and fieldbus communication modules can be inserted into slots 1, 2 and 3.
Page 35: Control Panel
Note: The cover is not included with options +0J400+P940 and +0J400+P944. Control panel door mounting kits 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...
Page 36: Type Designation Label
36 Operation principle and hardware description Manual Code (English) DPMP-01 mounting platform for control panels installation guide 3AUA0000100140 DPMP-02/03 mounting platform for control panels installation guide 3AUA0000136205 DPMP-04 and DPMP-05 mounting platform for control panels installation 3AXD50000308484 guide DPMP-06 / 07 mounting platform for control panels installation guide 3AXD50000289561 Type designation label Type designation, see section...
Page 37: Type Designation Key
Operation principle and hardware description 37 Link to product information Typical drive losses when it operates at 90% of the motor nominal frequency and 100% of the drive nominal output current Type designation key The type designation contains information on the specifications and configuration of the drive.
Page 38: Option Codes
38 Operation principle and hardware description ￭ Option codes Code Description B056 IP55 (UL Type 12) C131 Vibration dampers C132 Marine type approval C135 Flange mounting C205 Marine product certification issued by DNV GL C206 Marine product certification issued by the American Bureau of Shipping (ABS) C207 Marine product certification issued by Lloyd's Register (LR) C208...
Page 39 Operation principle and hardware description 39 Code Description K451 FDNA-01 DeviceNet™ adapter module K454 FPBA-01 PROFIBUS DP adapter module K457 FCAN-01 CANopen adapter module K458 FSCA-01 RS-485 (Modbus/RTU) adapter module K462 FCNA-01 ControlNet™ adapter module K469 FECA-01 EtherCat adapter module K470 FEPL-02 EtherPOWERLINK adapter module FENA-21 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET...
Page 40 40 Operation principle and hardware description Code Description N5000 Winder control program N5050 Crane control program N5100 Winch control program N5150 Centrifuge control program N5200 PCP (Progressive Cavity Pump) control program N5250 Rod pump control program N5300 Test bench control program N5350 Cooling tower control program N5450...
Page 41 Operation principle and hardware description 41 Code Description Version for cabinet mounting (Drive without front cover and cable box. Includes panel holder, cable between P940 panel holder and control unit, I/O clamp kit in frames R1…R5, main cable clamp kit in frames R1…R5, power cable shield grounding shelf in frames R6…R9. Cannot be selected with P944.) Version for cabinet mounting (drive module with front covers but without cable P944...
Page 42 42 Operation principle and hardware description Code Description R712 Printed manuals in Chinese R713 Printed manuals in Polish R714 Printed manuals in Turkish V997 ZCU-12 control unit 1) Manuals in English may be included if a translation in the specified language is not available. Note: Option codes R700…R714 denote full set of printed manuals in the selected language.
Page 43: Mechanical Installation
Mechanical installation 43 Mechanical installation Contents of this chapter This chapter tells you how to examine the installation site, examine the delivery, and mechanically install the drive. Safety WARNING! For frame sizes R4 to R9: Use the lifting eyes of the drive when you lift the drive.
Page 44: Mounting Positions
44 Mechanical installation Mounting positions There are three alternative ways to install the drive: • vertically alone. Do not install the drive upside down. • vertically side by side. UL Type 12 frames R4 to R9 need 100 mm (4 in) between the hoods.
Page 45: Necessary Tools
Mechanical installation 45 The operation conditions of the drive agree with the specifications in section Ambient conditions (page 268). The wall is vertical, not flammable and strong enough to hold the weight of the drive. The material below the installation is not flammable. There is enough free space above the drive (200 mm [7.87 in]) and below the drive (300 mm [11.81 in]) when measured from the drive base without the cable box) for cooling air flow, service and maintenance.
Page 46: Package Of Frames R1 To R4
46 Mechanical installation ￭ Package of frames R1 to R4 IP21 (UL Type 1) Drive with factory installed options. 6…9 Cushions Control cable grounding shelf. Romex Mounting template on top of 6 and 7. connectors in IP21 frames R1 to R3 in a plastic bag inside the cable box.
Page 47 Mechanical installation 47 IP55 (UL Type 12) 3AXD50000003341 Printed quick installation and start- 7…11 Cushions and cardboard support up guide and manuals, multilingual Mounting template on top of 7. residual voltage warning sticker Straps Cardboard tray + top cardboard Hood included in frame R4. The cover hood is required only in UL Type 12 installations.
Page 48: Package Of Frames R5 And R6
48 Mechanical installation ￭ Package of frames R5 and R6 IP21 (UL Type 1) 3AXD50000889723 Drive with factory installed options Pallet tray Cable box. Power and control cable Screw (4 pcs) grounding shelves in a plastic bag, assembly drawing. IP21 (UL Type 1) frame R5: Vibration damper package (option +C131) inside the cable box.
Page 49 Mechanical installation 49 IP55 (UL Type 12) 3AXD50000889723 Drive with factory installed options Cardboard cover Hood (required only in UL Type 12 in- Pallet tray stallation) Option box Screw (4 pcs) Packing bracket (4 pcs) Straps VCI bag Mounting template To unpack: •...
Page 50: Frame R5 Cable Box (Ip21, Ul Type 1)
50 Mechanical installation Frame R5 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame. 3aua0000118007...
Page 51: Frame R6 Cable Box (Ip21, Ul Type 1)
Mechanical installation 51 Frame R6 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame. 3aua0000112044...
Page 52: Package Of Frame R7
52 Mechanical installation ￭ Package of frame R7 IP21 (UL Type 1) 3AXD50000012445 Drive with factory installed options, VCI bag mounting template Cable box. Power and control cable Straps grounding shelves in a plastic bag, assembly drawing. Note: The cable entry box is mounted to the IP55 drive module frame at the factory Cardboard cover...
Page 53 Mechanical installation 53 IP55 (UL Type 12) 3AXD50000012445 Drive with factory installed options, Straps mounting template Cardboard cover Hood (required only in UL Type 12 in- stallation) Packing bracket Printed quick installation and start-up guide and manuals, multilingual resid- ual voltage warning sticker Pallet tray Screws VCI bag...
Page 54: Frame R7 Cable Box (Ip21, Ul Type 1)
54 Mechanical installation Frame R7 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame. 3aua0000111117...
Page 55: Package Of Frames R8 And R9
Mechanical installation 55 ￭ Package of frames R8 and R9 IP21 (UL Type 1) 3AXD50000006554 Drive with factory installed options, Plywood support (only in frame R8) mounting template Cable box. Power and control cable Straps grounding shelves in a plastic bag, assembly drawing.
Page 56 56 Mechanical installation IP55 (UL Type 12) 3AXD50000006554 Drive with factory installed options, Straps mounting template Cardboard cover Hood (required only in UL Type 12 in- stallation) Plywood support (only in frame R8) Printed quick installation and start-up guide and manuals, multilingual resid- ual voltage warning sticker Pallet tray Packing bracket...
Page 57: Frame R8 Cable Box (Ip21, Ul Type 1)
Mechanical installation 57 Frame R8 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. There is also an assembly drawing which shows how to install the cable entry box to the drive module frame. 3aua0000112174...
Page 58: Frame R9 Cable Box (Ip21, Ul Type 1)
58 Mechanical installation Frame R9 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame. 3aua0000112356...
Page 59: Installing The Drive Vertically
R4 to R9 in wall installations. See Vibration dampers for ACS880-01 drives (frames R4 and R5, option +C131) installation guide (3AXD50000010497 [English]) Vibration dampers for ACS880-01 drives (frames R6 to R9, option +C131) installation guide (3AXD50000013389 [English]). The guide is included in the vibration damper package.
Page 60: Frames R1 To R4 (Ip21, Ul Type 1)
60 Mechanical installation ￭ Frames R1 to R4 (IP21, UL Type 1) See the dimensions in chapter Dimension drawings. Mark the locations for the four mounting holes. You can use the mounting template included in the drive package. 2. Drill the mounting holes. 3.
Page 61: Frames R5 To R9 (Ip21, Ul Type 1)
Mechanical installation 61 ￭ Frames R5 to R9 (IP21, UL Type 1) See the dimensions in chapter Dimension drawings. Mark the locations for the four or six mounting holes. You can use the mounting template included in the drive package. Note: The lowest holes/mounting screws or bolts are not necessarily needed.
Page 62 62 Mechanical installation...
Page 63: Frames R1 To R9 (Ip55, Ul Type 12)
Mechanical installation 63 ￭ Frames R1 to R9 (IP55, UL Type 12) Note: Do not open or remove the cable box for easier installation. The gaskets do not fulfill the degree of protection if the box is opened. See the dimensions in chapter Dimension drawings.
Page 64 64 Mechanical installation...
Page 65: Installing The Drive Horizontally
Mechanical installation 65 Installing the drive horizontally The drive can be installed with either the left or right side up. Follow the steps in section Installing the drive vertically (page 59). For free space requirements, see section Free space requirements (page 252).
Page 67: 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 68: Selecting The Main Contactor
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 69: Requirements Tables
Guidelines for planning the electrical installation 69 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 70: Requirements For Abb Motors, P
Nominal AC line Requirement for voltage Motor insu- ABB d u /d t and common mode filters, in- lation sys- sulated N-end motor bearings P n < 100 kW and frame size < IEC 315 P n < 134 hp and frame size < NEMA 500 Random-wound U n ≤...
Page 71: Requirements For Abb Motors, P
Motor type Nominal AC line Requirement for voltage Motor insu- ABB d u /d t and common mode filters, in- lation sys- sulated N-end motor bearings 100 kW ≤ P n < 350 P n ≥ 350 kW frame size ≥...
Page 72: Requirements For Non-Abb Motors, P < 100 Kw (134 Hp)
Nominal AC line Requirement for voltage Motor insu- ABB d u /d t and common mode filters, in- lation sys- sulated N-end motor bearings P n < 100 kW and frame size < IEC 315 P n < 134 hp and frame size < NEMA 500 Random-wound U n ≤...
Page 73 Motor type Nominal AC line Requirement for voltage Motor insu- ABB d u /d t and common mode filters, in- lation sys- sulated N-end motor bearings 100 kW ≤ P n < 350 P n ≥ 350 kW frame size ≥...
Page 74: Abbreviations
If you use an explosion-safe (EX) motor, obey the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ Use the selection criteria given for non-ABB motors.
Page 75: 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). 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 76: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
76 Guidelines for planning the electrical installation Nominal AC supply Requirement for voltage ABB d u /d t and common mode filters, insu- Motor insulation sys- lated N-end motor bearings P n < 100 kW or frame 100 kW < P n < 350 kW size <...
Page 77: Additional Note For Sine Filters
Guidelines for planning the electrical installation 77 Û du/dt -------------(1/ µs) Û -- - - -- - - - - - (1/ µs) l (m) l (m) Drive with d u /d t filter Drive without d u /d t filter Motor cable length Û...
Page 78: Selecting The Power Cables
78 Guidelines for planning the electrical installation Selecting the power cables ￭ General guidelines Select the input power and motor cables according to local regulations. • Current: Select a cable capable of carrying the maximum load current and suitable for the prospective short-circuit current provided by the supply network.
Page 79: Power Cable Types
Guidelines for planning the electrical installation 79 ￭ Power cable types Preferred power cable types This section shows the preferred cable types. Make sure that the selected cable type also complies with local/state/country electrical codes. Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar-...
Page 80: Alternate Power Cable Types
80 Guidelines for planning the electrical installation Alternate power cable types Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Yes with phase conductor Yes with phase conductor smaller than 10 mm 2 (8 AWG) smaller than 10 mm 2 (8 AWG) Cu, or motors up to 30 kW (40 hp).
Page 81: Not Allowed Power Cable Types
￭ Additional guidelines – North America ABB recommends the use of metallic conduit for power wiring. ABB also recommends the use of symmetrical shielded VFD cable between drive and motor(s). This table shows examples of methods for wiring the drive. Refer to NFPA 70 (NEC) along with state and local codes for the appropriate methods for your application.
Page 82: Metal Conduit
82 Guidelines for planning the electrical installation Wiring method Notes Free air Prefer symmetrical shielded VFD cable. Enclosures, air handlers, etc. Allowed internally in enclosures when in ac- cordance with UL. 1) Metallic conduit may be used as an additional ground path, provided this path is a solid path capable of handling ground currents.
Page 83: Grounding Requirements
Guidelines for planning the electrical installation 83 Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient.
Page 84: Additional Grounding Requirements - Iec
84 Guidelines for planning the electrical installation earth conductor must be determined in a manner which produces a conductance equivalent to that which results from the application of this table. Cross-sectional area of the phase conduct- Minimum cross-sectional area of the corres- ponding protective earth conductor S (mm 2 ) S p (mm 2 )
Page 85: Additional Grounding Requirements - Ul (Nec)
Shielding Only use shielded control cables. Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable also for the pulse encoder signals. Use one individually shielded pair for each signal. Do not use common return for different analog signals.
Page 86: Relay Cable
￭ 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, Cat 5e (or better) cable with male RJ45 connectors. The maximum length of the cable is 100 m (328 ft).
Page 87: General Guidelines - North America
Guidelines for planning the electrical installation 87 The following figure illustrates the cable routing guidelines with an example drive. min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min.
Page 88: Continuous Motor Cable Shield/Conduit And Metal Enclosure For Equipment On The Motor Cable
88 Guidelines for planning the electrical installation Input power cabling Motor cabling Conduit ￭ Continuous motor cable shield/conduit and metal 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 89: Separate Control Cable Ducts
Guidelines for planning the electrical installation 89 ￭ Separate control cable ducts Put 24 V DC and 230 V AC (120 V AC) control cables in separate ducts, unless the 24 V DC cable is insulated for 230 V AC (120 V AC) or insulated with an insulation sleeving for 230 V AC (120 V AC).
Page 90: Protecting The Motor And Motor Cable In Short-Circuits
90 Guidelines for planning the electrical installation WARNING! Due to the inherent operating principle and construction of circuit breakers, independent of the manufacturer, hot ionized gases can escape from the breaker enclosure in case of a short-circuit. To make sure of safe use, pay special attention to the installation and placement of the breakers.
Page 91: Protecting The Motor Against Thermal Overload
Guidelines for planning the electrical installation 91 WARNING! If the drive is connected to multiple motors, use a separate overload protection for each motor cable and motor. The drive overload protection is tuned for the total motor load. It may not detect an overload in one motor circuit only.
Page 92: Protecting The Drive Against Ground Faults
These capacitors and long motor cables increase the ground leakage current and may cause nuisance faults in residual current devices. Connecting drives to a common DC system Common DC systems with ACS880-01, -04, -11, -14, -31 and -34 drives application guide (3AUA0000127818 [English]).
Page 93: Implementing An Atex-Certified Motor Thermal Protection
Guidelines for planning the electrical installation 93 The FSO module reserves the standard Safe torque off (STO) connection of the drive control unit. STO can still be utilized by other safety circuits through the FSO module. See the appropriate manual for more information. Name Code FSO-12 safety functions module user's manual...
Page 94: Using Power Factor Compensation Capacitors With The Drive
94 Guidelines for planning the electrical installation Note: If the power loss lasts so long that the drive trips on undervoltage, a fault reset and a fresh start command is required to continue operation. Implement the power-loss ride-through function as follows: Enable the power-loss ride-through function of the drive (parameter 30.31).
Page 95: Controlling A Contactor Between Drive And Motor
Guidelines for planning the electrical installation 95 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. If you have the DTC motor control mode and the motor ramp stop mode selected, use this operation sequence to open the contactor: Give a stop command to the drive.
Page 96 96 Guidelines for planning the electrical installation Drive main switch Drive main contactor on/off control Bypass circuit breaker S 4 0 Motor power supply selection (drive or direct-on-line) Drive main contactor Start when motor is connected direct- on-line Bypass contactor S 4 2 Stop when motor is connected direct- on-line...
Page 97: Switching The Motor Power Supply From Drive To Direct-On-Line
Guidelines for planning the electrical installation 97 Drive output contactor Switching the motor power supply from drive to direct-on-line 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 98: Implementing A Motor Temperature Sensor Connection
98 Guidelines for planning the electrical installation 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode Implementing a motor temperature sensor connection WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: •...
Page 99: Connecting A Motor Temperature Sensor To The Drive Through An Option Module
Guidelines for planning the electrical installation 99 module (page 99). Make sure that the voltage does not exceed the maximum allowed voltage over the sensor. 3. If there is basic insulation between the sensor and the live parts of the motor, or if the insulation type is not known: You can connect a sensor to a digital input of the drive via an external relay.
Page 100 100 Guidelines for planning the electrical installation Option module Temperature sensor Temperature sensor type insulation require- ment Type Insulation/Isolation Pt100, Pt1000 FEN-11 Galvanic isolation between Reinforced insulation sensor connector and drive control unit connector. No isol- ation between sensor connector and TTL encoder emulation output.
Page 101: Electrical Installation - Global (Iec)
Electrical installation – Global (IEC) 101 Electrical installation – Global (IEC) Contents of this chapter This chapter gives instructions on wiring 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 102: Grounding The Motor Cable Shield At The Motor End
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...
Page 103: Grounding System Compatibility Check
Electrical installation – Global (IEC) 103 Note: Moisture inside the motor reduces the insulation resistance. If you think that there is moisture in the motor, dry the motor and do the measurement again. U1-PE, V1-PE, W1-PE 1000 V DC, > 100 Mohm Grounding system compatibility check The standard drive can be installed to a symmetrically grounded TN-S system.
Page 104: Connecting The Power Cables
104 Electrical installation – Global (IEC) Connecting the power cables ￭ Connection diagram UDC+ UDC- R- R+ T1/U T2/V T3/W (PE) (PE) Drive For alternatives, see section Selecting the main supply disconnecting device (page 67). Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity of the shield does not meet the requirements for the PE conductor.
Page 105: Connection Procedure For Frames R1 To R3
Electrical installation – Global (IEC) 105 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 for motors above 30 kW. Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.
Page 106 106 Electrical installation – Global (IEC) 3. Attach the residual voltage warning sticker in the local language to the control panel mounting platform. 4. Remove the rubber grommets from the entry plate for the cables to be connected. 5. IP21 drives: Attach the Romex clamps (included in the delivery in a plastic bag) to the cable entry plate holes.
Page 107 Electrical installation – Global (IEC) 107 R1…R3 L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/UDC+, UDC (N·m) (N·m) R1, R2: 1.5 N m (13.3 lbf · · R3: 2 N m (17 lbf · · 1.5 N m (13.3 lbf ·...
Page 108: Connection Procedure For Frames R4 And R5
108 Electrical installation – Global (IEC) 11. Install the control cable grounding shelf in the cable entry box. M4×8 Torx T20 1.5 N·m 12. Attach the cables outside the drive mechanically. ￭ Connection procedure for frames R4 and R5 Remove the front cover. IP21 drives: Release the retaining clip with a screwdriver (a) and lift the cover from the bottom outwards (b).
Page 109 Electrical installation – Global (IEC) 109 10. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals and the phase conductors of the motor cable to the T1/U, T2/V and T3/W terminals. Tighten the screws to the torque given in the figure below. Note: For cable lug installation (frame R5): Detach the connector and install a cable lug to the terminal post as follows: •...
Page 110 110 Electrical installation – Global (IEC) R4, R5 IP55 IP21...
Page 111 Electrical installation – Global (IEC) 111 R4, R5...
Page 112 112 Electrical installation – Global (IEC) R4, R5 M4x30 Torx T20 1.2 N m (10.6 lbf · · L1, L2, L3, T1/U, R-, R+/UDC+, T2/V, T3/W UDC- (N·m) (N·m) (N·m)
Page 113: Connection Procedure For Frames R6 To R9
T1/U, T2/V and T3/W terminals. Tighten the screws to the torque given in the figure. Note: Frames R8 and R9: If you put only one conductor to the connector, ABB recommends that you put it under the upper pressure plate.
Page 114 114 Electrical installation – Global (IEC) 12. Drives with option +D150: Connect the brake resistor cable conductors to the R+ and R- terminals. 13. If parallel cables are installed (frames R8 and R9), install the grounding shelves for them. Repeat steps 8 to 12. 14.
Page 115 Electrical installation – Global (IEC) 115 R6 … R9 IP55 IP21...
Page 116 116 Electrical installation – Global (IEC) R6 … R9 R8, R9...
Page 117 Electrical installation – Global (IEC) 117 R6 … R9 R6: M5×25 Torx T20; M4×20 Torx T20 R7: M5×35 Torx T20 R8,R9: M5×25 Torx T20 · Frame L1, L2, L3, T1/U, R-, R+/UDC+, T2/V, T3/W UDC- T (Wire screw) T (Wire screw) M…...
Page 118 118 Electrical installation – Global (IEC) R6 … R9 R8, R9 M5×25 Torx T20 m (17 lbf · · M5×12 Torx T20 m (17 lbf · · M4×20 Torx T20 m (17 lbf · · M4×8 Torx T20 R9: M4x12 Torx T20 m (17 lbf ·...
Page 119: Detaching Connectors (Frames R8 And R9)
Electrical installation – Global (IEC) 119 ￭ Detaching connectors (frames R8 and R9) ABB does not recommend that you detach the connectors. If you do, detach and reinstall the connector as follows: L1, L2 and L3 connectors R8: Loosen the nut that attaches the connector to its terminal post.
Page 120: Cable Lug Installation (Frames R6 To R9)
120 Electrical installation – Global (IEC) ￭ Cable lug installation (frames R6 to R9) The power cable connectors are connected to the drive with a nut to its terminal post or with a combi screw to busbar as follows: Terminal Nut / Screw size L1, L2, L3 M8×25 combi...
Page 121: Connecting The Control Cables
Electrical installation – Global (IEC) 121 Connecting the control cables See section Control unit (page 155) for the default I/O connections of the Factory macro of ACS880 primary control program. For other macros and control programs, see the firmware manual. ￭...
Page 122 122 Electrical installation – Global (IEC) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Repeat the steps described in Electrical safety precautions (page 18). 2. Remove the front cover(s). See section Connecting the power cables (page 104).
Page 123: Connecting A Pc
Electrical installation – Global (IEC) 123 Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit. It can cause damage. A PC (with, for example, the Drive Composer PC tool) can be connected as follows: To connect a control panel to the unit, either •...
Page 124 124 Electrical installation – Global (IEC) • Use parameter 49.01* to assign the drive with a unique node ID number • Set other parameters in group 49* if necessary • Use parameter 49.06* to validate any changes. *The parameter group is 149 with supply (line-side), brake or DC/DC converter units.
Page 125 Electrical installation – Global (IEC) 125 With FDPI-02 modules:...
Page 126: Installing Option Modules
126 Electrical installation – Global (IEC) ACS880-01 IP55 (UL Type 12): Installing option modules In frames R1 and R2, 90° connector cannot be used in Slot 1. In other frames, there is 50…55 mm free space for the connector and its cable available on Slots 1, 2 and For frames R1…R3: Pull the control panel mounting platform upwards to gain...
Page 127 Electrical installation – Global (IEC) 127 WARNING! Use ESD wristband when you handle printed circuit boards. Do not touch the boards unnecessarily. The boards are sensitive to electrostatic discharge. Pay attention to the free space required by the cabling or terminals coming to the option modules.
Page 128: Fieldbus Cabling
128 Electrical installation – Global (IEC) ￭ Fieldbus cabling Install the additional grounding shelf. 2. Ground the outer shields of the cables 360° at a grounding clamp. 3. Knock out holes in the cable entry box cover for the cables to be installed. Install the cable entry box cover.
Page 129 Electrical installation – Global (IEC) 129 R4, R5 M4×16 Torx T20 2 N·m M4×16 Torx T20 1.5 N·m K40×12 tapping screw 1.5 N·m M4×10 Torx T20 2 N·m...
Page 130 130 Electrical installation – Global (IEC) R6…R9 M4×8 Torx T20 2 N·m M4×16 Torx T20 1.5 N·m M4×12 Torx T20 2 N·m...
Page 131: Installing Fso-Xx Safety Functions Modules
Electrical installation – Global (IEC) 131 ￭ Installing FSO-xx safety functions modules The safety functions module can be mounted onto Slot 2 on the control unit or, in frames R6…R9, also next to the control unit. Installation procedure WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 132 132 Electrical installation – Global (IEC) Installation on Slot 2 Installation next to the control unit (possible for frames R6…R9)
Page 133: Electrical Installation - North America (Nec)
Electrical installation – North America (NEC) 133 Electrical installation – North America (NEC) Contents of this chapter This chapter gives instructions on wiring the drive. Safety WARNING! If you are not a qualified electrical professional, do not do installation or maintenance work.
Page 134: Grounding System Compatibility Check
134 Electrical installation – North America (NEC) Grounding system compatibility check See section Grounding system compatibility check (page 103). Connecting the power cables ￭ Connection diagram Note: NEC installation can include separate insulated conductors inside a conduit, shielded VFD cable in conduit, or shielded VFD cable without conduit. The normal dashed symbol (c) in this diagram represents the shield of shielded VFD cable.
Page 135 301). If necessary, install an external filter (du/dt, common mode, or sine filter). Filters are available from ABB. Note: Do not use an asymmetrically constructed motor cable for motors above 30 kW. Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.
Page 136: Connection Procedure For Frames R1 To R3
136 Electrical installation – North America (NEC) ￭ Connection procedure for frames R1 to R3 Use symmetrical shielded VFD cable for the motor cabling. Undo the mounting screws at the sides of the front cover. 2. Remove the cover by sliding it forward. 3.
Page 137 Electrical installation – North America (NEC) 137 8. If brake chopper is in use: Connect the brake resistor conductors to the R+ and R- terminals. 9. Install the control cable grounding shelf in the cable entry box. 10. Connect the motor cable at the motor end. IP55 (UL Type 12) IP21 (UL Type 1) M4x16 Torx T20...
Page 138 138 Electrical installation – North America (NEC) L1, L2, L3, T1/U, T2/V, Ground Clamp T3W, r-, R+/UDC+, UDC- lbf·ft lbf·ft lbf·in 13.3 13.3...
Page 139: Connection Procedure For Frames R4 And R5
Electrical installation – North America (NEC) 139 M4×8 Torx T20 13.3 lbf·in ￭ Connection procedure for frames R4 and R5 In this connection procedure, the cables are connected to the power cable connectors. Use symmetrical shielded VFD cable for the motor cabling. Remove the front cover.
Page 140 140 Electrical installation – North America (NEC) 6. Connect the conductors of the input and motor cables. Tighten the screws. 7. Install the EMC shroud separating the input and output cabling if not installed yet. 8. If brake chopper is in use: Connect the conductors of the brake resistor conductors to the R+ and R- terminals.
Page 141 Electrical installation – North America (NEC) 141...
Page 142 142 Electrical installation – North America (NEC) L1, L2, L3, T1/U, T2/V, Ground Clamp T3W, R-, R+/UDC+, UDC- lbf·ft lbf·ft lbf·in 10.6 10.6...
Page 143 Electrical installation – North America (NEC) 143 R4: M4×8 Torx T20 (2 pcs), M4×10 Torx T20 (1 pcs), 1.5 lbf·ft R5: M4×8 Torx T20, 1.5 lbf·ft...
Page 144: Connection Procedure For Frames R6 To R9
144 Electrical installation – North America (NEC) ￭ Connection procedure for frames R6 to R9 In this connection procedure, the cables are connected to the power cable connectors. Use symmetrical shielded VFD cable for the motor cabling. Remove the front cover: UL Type 1 drives: Release the retaining clip with a screwdriver (a) and pull the cover by the bottom outwards (b).
Page 145 Electrical installation – North America (NEC) 145 9. Connect the conductors of the input and motor cables. Tighten the screws. 10. Drives with option +D150: Connect the conductors of the brake resistor conductors to the R+ and R- terminals. 11. Reinstall the shroud on the power terminals. 12.
Page 146 146 Electrical installation – North America (NEC)
Page 147: Connecting The Control Cables
Electrical installation – North America (NEC) 147 L1, L2, L3, R-, R+/ T1/U, T2/V, UDC+, T3/W UDC- lbf·ft lbf·ft lbf·ft 22.1 14.8 29.5 14.8 29.5 29.5 51.6 51.6 2 N•m (17 lbf•in) Connecting the control cables See section Control unit (page 155) for the default I/O connections of the Factory macro of ACS880 primary control program.
Page 148 148 Electrical installation – North America (NEC) 4. Ground the pair-cable shields to the grounding clamp (in frames R4 and R5 below the control unit). Leave the other end of the shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg, 3.3 nF / 630 V.
Page 149 Electrical installation – North America (NEC) 149 Frames R1…R3 5 lbf·in 13 lbf·in M4×20 Torx T20 Note: Use an unused ground clamp screw. If none available ground as shown.
Page 150 150 Electrical installation – North America (NEC) Frames R4 and R5 5 lbf·in M4×16 Torx T20 13 lbf·in Note: Use an unused ground clamp screw. If none available ground as shown.
Page 151 Electrical installation – North America (NEC) 151 Frames R6…R9 Install the control cable grounding shelf. R6, R7: M4×20 Torx T20 R8, R9: M4×20 Torx T20 17 lbf·in M4×8 Torx T20 R9: M4×12 Torx T20 17 lbf·in...
Page 152: Connecting A Pc
152 Electrical installation – North America (NEC) Frames R6…R9 5 lbf·in 13 lbf·in M4×20 Torx T20 13 lbf·in M4×20 Torx T20 Note: Use an unused ground clamp screw. If none available ground as shown. Connecting a PC See section Connecting a PC (page 123).
Page 153: Panel Bus (Control Of Several Units From One Control Panel)
Electrical installation – North America (NEC) 153 Panel bus (control of several units from one control panel) See section Panel bus (control of several units from one control panel) (page 123). Installing option modules See section Installing option modules (page 126).
Page 155: Control Unit
Control unit 155 Control unit Contents of this chapter This chapter • gives information on the connections of the control unit, and • has the specifications of the inputs and outputs of the control unit.
Page 156: Zcu-12 Layout
156 Control unit ZCU-12 layout Description Analog inputs X202 Analog outputs X208 X210 Digital inputs XDIO Digital input/outputs X205 XD24 Digital input interlock (DIIL) and +24 V output XD2D Drive-to-drive link X203 XPOW External power input XRO1 Relay output RO1 XRO2 Relay output RO2 XRO3...
Page 157: Default I/O Diagram Of The Drive Control Unit (Zcu)
Control unit 157 Default I/O diagram of the drive control unit (ZCU) Connection Term Description XPOW External power input +24VI 24 V DC, 2 A min. (without optional mod- +24VI ules) XAI Reference voltage and analog inputs 10 V DC, R L 1…10 kohm +VREF +VREF -VREF...
Page 158 158 Control unit Connection Term Description XRO1, XRO2, XRO3 Relay outputs Ready run 250 V AC / 30 V DC Running 250 V AC / 30 V DC Fault Fault (-1) +24VD DIOGND 250 V AC / 30 V DC XD24 Auxiliary voltage output, digital interlock DIIL Run enable...
Page 159 Control unit 159 Connection Term Description OUT1 Safe torque off circuits must be closed for OUT1 the drive to start. SGND SGND Safety options connection Control panel connection X205 Memory unit connection 1) Current [0(4)…20 mA, R in = 100 ohm] or voltage [0(2)…10 V, R in > 200 kohm] input selected by jumper. Change of setting requires reboot of control unit.
Page 160: Additional Information On The Connections
Use a shielded twisted-pair cable for data, and another pair or a wire for signal ground (nominal impedance 100…165 ohm, for example Belden 9842). For the 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 161: Safe Torque Off (Xsto)
Control unit 161 The diagram that follows shows the wiring of the drive-to-drive link. The diagram is applicable to ZCU-12 control units. ￭ Safe torque off (XSTO) The XSTO input only acts as a true Safe torque off input on the inverter control unit.
Page 162: Connector Data
162 Control unit Connector data The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (22…12 AWG). Connector pitch is 5 mm. The maximum tightening torque for screw terminals is 0.5 N·m (5 lbf·in). Power supply (XPOW) 24 V DC (±10%), 2 A External power input.
Page 163 Control unit 163 Analog inputs AI1 and AI2 Current input: -20…20 mA, R in = 100 ohm (XAI:4 … XAI:7). Voltage input: -10…10 V, R in > 200 kohm Current/voltage input mode Differential inputs, common mode range ±30 V selection by jumpers Sampling interval per channel: 0.25 ms Hardware filtering: 0.25 ms Resolution: 11 bit + sign bit...
Page 164 164 Control unit Control panel connection (X13) Connector: RJ-45 Cable length < 100 m (328 ft) The terminals of the control unit fulfill the Protective Extra Low Voltage (PELV) requirements. The PELV requirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output.
Page 165: Zcu Ground Isolation Diagram
Control unit 165 ￭ ZCU ground isolation diagram XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- AI2+ channels ±30 V AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 XSTO OUT1 * Ground selector (J6) settings...
Page 166 166 Control unit Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from DIO signal ground (DIOGND). Isolation voltage 50 V.
Page 167: Installation Checklist
Installation checklist 167 Installation checklist Contents of this chapter This chapter contains a checklist for 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 168 168 Installation checklist Make sure that … The insulation resistance of the input power cable, motor cable and motor is meas- ured according to local regulations and the manuals of the drive. The drive is attached securely on an even, vertical and non-flammable wall. The cooling air can flow freely in and out of the drive.
Page 169 Installation checklist 169 Make sure that … The control cables are connected to the correct terminals, and the terminals are tightened to the correct torque. If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive output contactor are either mechanically and/or electrically interlocked, that is, they cannot be closed at the same time.
Page 171: Start-Up
For drives with resistor braking (option +D150): see also section Start-up in chapter Resistor braking. • For drives with ABB sine filter, check that parameter 95.15 Special HW settings is set to ABB sine filter. For other sine filters, see Sine filter hardware manual (3AXD50000016814 [English]).
Page 172 172 Start-up 3. Validate the safety functions (option +Q973 or +Q972) as described in FSO-12 safety functions module user’s manual (3AXD50000015612 [English]) or in FSO-21 safety functions module user’s manual (3AXD50000015614 [English]).
Page 173: Fault Tracing
Fault tracing 173 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 panel mount- POWER Green Control unit is ing platform powered and +15 V is supplied to the con- trol panel.
Page 175: Maintenance
Maintenance intervals The tables show the maintenance tasks that can be done by the end user. For the ABB Service offering, contact your local ABB Service representative (new.abb.com/contact-centers). ￭ Description of symbols...
Page 176: Recommended Maintenance Intervals After Start-Up
176 Maintenance ￭ Recommended maintenance intervals after start-up Annual ac- Target tion Quality of supply voltage Spare parts DC circuit capacitor reforming, spare modules and spare capacitors Tightness of terminals Dustiness, corrosion or temperature Heat sink cleaning Component Years from start-up Cooling Main cooling fan Auxiliary cooling fan for circuit boards (frames R1 to...
Page 177: Cleaning The Exterior Of The Drive
• The maintenance and component replacement intervals are based on the assumption that the equipment operates within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long-term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.
Page 178: Fans
Reset the running time signal after a fan replacement. Also, reset the maintenance counter, if used. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.
Page 179: Replacing The Main Cooling Fan Of Frames R1 To R3
Maintenance 179 ￭ Replacing the main cooling fan of frames R1 to R3 Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Release the retaining clip by pushing with a flat screwdriver and turning to the right.
Page 180: Replacing The Auxiliary Cooling Fan Of Ip55 Frames R1 To R3
180 Maintenance ￭ Replacing the auxiliary cooling fan of IP55 frames R1 to R3 Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Remove the front cover by undoing the mounting screws at the sides. 3.
Page 181: Replacing The Main Cooling Fan Of Frames R4 And R5
Maintenance 181 ￭ Replacing the main cooling fan of frames R4 and R5 Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Lift the fan mounting plate up from the front edge. 3.
Page 182: Replacing The Auxiliary Cooling Fan Of Frames R4 And R5
182 Maintenance ￭ Replacing the auxiliary cooling fan of frames R4 and R5 This fan is included in R5 types ACS880-01-xxxx-7 and with option +B056+C135. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work.
Page 183: Replacing The Main Cooling Fan Of Frames R6 To R8
Maintenance 183 ￭ Replacing the main cooling fan of frames R6 to R8 Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Undo the mounting screws of the fan mounting plate (view from bottom below).
Page 184: Replacing The Auxiliary Cooling Fan Of Frames R6 To R9 (Ip21, Ul Type 1)
184 Maintenance ￭ Replacing the auxiliary cooling fan of frames R6 to R9 (IP21, UL Type Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Remove the lower front cover. 3.
Page 185: Replacing The Second Auxiliary Cooling Fan Of Frame R9 (Ip55, Ul Type 12)
Maintenance 185 ￭ Replacing the second auxiliary cooling fan of frame R9 (IP55, UL Type Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Remove the IP55 front cover. Disconnect the power supply wire of the auxiliary cooling fan in the cover (see section Replacing the auxiliary cooling fan in the IP55 (UL Type 12) cover, frames R8 and R9 (page...
Page 186: Replacing The Auxiliary Cooling Fan In The Ip55 (Ul Type 12) Cover, Frames R8 And R9
186 Maintenance ￭ Replacing the auxiliary cooling fan in the IP55 (UL Type 12) cover, frames R8 and R9 Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Remove the lower front cover from the cover. 3.
Page 187 Maintenance 187...
Page 188: Replacing The Main Cooling Fans Of Frame R9
188 Maintenance ￭ Replacing the main cooling fans of frame R9 Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Undo the two mounting screws of the fan mounting plate (view from drive bottom below).
Page 189: Replacing The Drive (Ip21, Ul Type 1, Frames R1 To R9)
Maintenance 189 Replacing the drive (IP21, UL Type 1, frames R1 to R9) This section gives instructions for replacing the drive module without the cable entry box. This allows you to leave the cables installed (except from disconnecting the conductors). Note: IP55 (UL Type 12) drives: It is not allowed to remove the cable entry box.
Page 190: Capacitors
Capacitor life can be extended by decreasing the surrounding air temperature. Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB.
Page 191: Reforming The Capacitors
Maintenance 191 ￭ Reforming the capacitors The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more. The manufacturing date is on the type designation label. For information on reforming the capacitors, refer to Capacitor reforming instructions (3BFE64059629 [English]).
Page 192: Replacing The Zcu-12 Control Unit Battery
192 Maintenance ￭ Replacing the ZCU-12 control unit battery The control unit battery can be changed with the help of the battery ejector (a in the drawing below). The ejector is included on the battery slot. The battery is of type CR2032.
Page 193: Replacing Safety Functions Modules (Fso-12, Option +Q973 And Fso-21, Option +Q972)
Maintenance 193 Replacing safety functions modules (FSO-12, option +Q973 and FSO-21, option +Q972) Do not repair safety functions modules. Replace a faulty module with a new one as described in section Installing FSO-xx safety functions modules (page 131).
Page 194: 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 195: Technical Data
ACS880-34… +C132 marine type-approved drives supplement (3AXD50000010521 [English]) for the ratings, marine-specific data and reference to valid marine type approvals. Drives for SynRM motors Refer to ACS880-01 drives for SynRM motors supplement (3AXD50000029482 [English]) for the ratings, fuses and other technical data.
Page 196: Electrical Ratings
Electrical ratings The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the tables. ABB recommends the DriveSize dimensioning tool for selecting the drive, motor and gear combination. IEC RATINGS...
Page 197 Technical data 197 IEC RATINGS ACS880- Frame Input Output ratings 01-… size rating Nominal use Light-duty use Heavy-duty I max I Ld P Ld I Hd P Hd 09A4-3 10.0 12.2 10.0 12A6-3 12.9 16.0 12.9 12.0 10.0 017A-3 12.6 025A-3 032A-3 038A-3...
Page 198 198 Technical data IEC RATINGS ACS880- Frame Input Output ratings 01-… size rating Nominal use Light-duty use Heavy-duty I max I Ld P Ld I Hd P Hd 11A0-5 11.0 16.0 11.0 10.4 014A-5 021A-5 027A-5 11.0 11.0 034A-5 15.0 15.0 040A-5 18.5...
Page 199 Technical data 199 IEC RATINGS ACS880- Frame Input Output ratings 01-… size rating Nominal use Light-duty use Heavy-duty I max I Ld P Ld I Hd P Hd 014A-5 021A-5 027A-5 034A-5 18.5 18.5 040A-5 052A-5 065A-5 077A-5 096A-5 124A-5 156A-5 180A-5 240A-5...
Page 200 061A-7 084A-7 098A-7 119A-7 142A-7 174A-7 210A-7 271A-7 1) IP55 (+B056), marine type-approved (+C132) and high-speed (+N7500) drives not available at the time of publication. For availability, contact ABB. UL (NEC) RATINGS ACS880- Frame Input Output ratings 01-… size rating Max.
Page 201 Technical data 201 UL (NEC) RATINGS ACS880- Frame Input Output ratings 01-… size rating Max. App. Light-duty use Heavy-duty use cur- power rent I max I Ld P Ld I Hd P Hd 061A-2 11.0 075A-2 18.5 087A-2 18.5 115A-2 145A-2 170A-2 206A-2...
Page 202 202 Technical data UL (NEC) RATINGS ACS880- Frame Input Output ratings 01-… size rating Max. App. Light-duty use Heavy-duty use cur- power rent I max I Ld P Ld I Hd P Hd 156A-5 180A-5 240A-5 260A-5 240* 302A-5 361A-5 414A-5 414* 361**...
Page 203 I max I Ld P Ld I Hd P Hd 210A-7 271A-7 242* (See Note 5 below) 1) IP55 (+B056), marine type-approved (+C132) and high-speed (+N7500) drives not available at the time of publication. For availability, contact ABB.
Page 204: Definitions
Note 4 – ACS880-01-174A-7 amp rating: The drive can deliver 192 A continuously with no overload. Note 5 – ACS880-01-271A-7 power rating: The power rating is as per NEC Table 42.1. How- ever, the drive can be used for a typical 4-pole motor rated to 300 hp meeting NEMA MG 1 Table 12-11 minimum efficiency standard (EPAct efficiency electrical motors) if motor full load current is not more than 271 A.
Page 205: Deratings
Technical data 205 ￭ Deratings Surrounding air temperature derating IP21 (UL Type 1) drives and IP55 (UL Type 12) frames R1…R7 and R9. In the temperature range +40…55 °C (+104…131 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). To calculate the output current, multiply the current in the ratings table by the derating factor (k): 1.00...
Page 206: Altitude Derating
206 Technical data ACS880- Derated output current ( I Ld ) 01-… 35 °C 40 °C 45 °C 50 °C 55 °C Frame (95 °F) (104 °F) (113 °F) (122 °F) (131 °F) U n = 230 V 274A-2 Derated output current ( I Hd ) ACS880- 01-…...
Page 207: Deratings For Special Settings In The Drive Control Program
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 in chapter Filters is used and "ABB Sine filter" in parameter 95.15 Special HW settings is enabled •...
Page 208 Note: If Ex motors are used together with sine filters, "EX motor " in parameter 95.15 Special HW settings is disabled and "ABB Sine filter" in parameter 95.15 Special HW settings is enabled. Obey the instructions of the motor manufacturer.
Page 209 Technical data 209 ACS880- Setting of parameter 95.15: Ex motor Setting of parameter 95.15: ABB sine 01-… enabled filter enabled Drive output ratings Drive output ratings Nominal use Light- Heavy- Nominal use Light- Heavy- duty duty use duty duty use...
Page 210 210 Technical data ACS880- Setting of parameter 95.15: Ex motor Setting of parameter 95.15: ABB sine 01-… enabled filter enabled Drive output ratings Drive output ratings Nominal use Light- Heavy- Nominal use Light- Heavy- duty duty use duty duty use...
Page 211 Technical data 211 ACS880- Setting of parameter 95.15: Ex motor Setting of parameter 95.15: ABB sine 01-… enabled filter enabled Drive output ratings Drive output ratings Nominal use Light- Heavy- Nominal use Light- Heavy- duty duty use duty duty use...
Page 212 212 Technical data The ratings apply at an ambient temperature of 40 °C (104 °F). ACS880-01-… Output ratings when selection "Low noise optimization" in parameter 97.09 Switching freq mode is enabled Nominal use Light-duty use Heavy-duty use I Ld I Hd...
Page 213 Technical data 213 ACS880-01-… Output ratings when selection "Low noise optimization" in parameter 97.09 Switching freq mode is enabled Nominal use Light-duty use Heavy-duty use I Ld I Hd 025A-3 20.9 15.0 032A-3 038A-3 045A-3 061A-3 072A-3 087A-3 105A-3 145A-3...
Page 214 214 Technical data ACS880-01-… Output ratings when selection "Low noise optimization" in parameter 97.09 Switching freq mode is enabled Nominal use Light-duty use Heavy-duty use I Ld I Hd 034A-5 040A-5 052A-5 065A-5 077A-5 096A-5 124A-5 156A-5 180A-5 240A-5 260A-5...
Page 215 High speed mode 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 ratings for the maximum output frequency when "High speed mode"...
Page 216 216 Technical data At the 120 Hz output frequency: no derating. ACS880-01-… Output ratings with selection High speed mode of parameter 95.15 Special HW settings Maximum output frequency f max Nominal use Light-duty use Heavy-duty use I Ld I Hd...
Page 217 Technical data 217 ACS880-01-… Output ratings with selection High speed mode of parameter 95.15 Special HW settings Maximum output frequency f max Nominal use Light-duty use Heavy-duty use I Ld I Hd 017A-3 14.3 11.3 025A-3 20.9 15.0 032A-3 038A-3...
Page 218 218 Technical data ACS880-01-… Output ratings with selection High speed mode of parameter 95.15 Special HW settings Maximum output frequency f max Nominal use Light-duty use Heavy-duty use I Ld I Hd 021A-5 18.0 17.1 12.0 027A-5 23.0 21.9 18.0...
Page 219: Fuses (Iec)
The operating time depends on the supply network impedance and the cross-sectional area and length of the supply cable. For frames R7 to R9 ABB recommends ultra-rapid (aR) fuses, refer to Quick guide for selecting between gG and aR fuses (page...
Page 220: Ar Fuses Din 43653 Stud-Mount (Frames R1 To R9)
￭ aR fuses DIN 43653 stud-mount (frames R1 to R9) ABB recommends stud-mount fuses for better cooling but blade style fuses can be used as well. Ultrarapid (aR) fuses stud-mount (one fuse per phase) ACS880-01-…...
Page 221 Technical data 221 Ultrarapid (aR) fuses stud-mount (one fuse per phase) ACS880-01-… Input Fuse Min. short- circuit cur- current A 2 s Bussmann Type rent type DIN 43653 03A3-3 170M1311 04A0-3 170M1311 05A6-3 170M1311 07A2-3 170M1311 09A4-3 10.0 170M1311 12A6-3 12.9...
Page 222 222 Technical data Ultrarapid (aR) fuses stud-mount (one fuse per phase) ACS880-01-… Input Fuse Min. short- circuit cur- current A 2 s Bussmann Type rent type DIN 43653 05A2-5 170M1308 07A6-5 170M1308 11A0-5 11.0 170M1308 014A-5 170M1313 021A-5 170M1313 027A-5...
Page 223: Ar Fuses Din 43620 Blade Style (Frames R1 To R9)
Technical data 223 Ultrarapid (aR) fuses stud-mount (one fuse per phase) ACS880-01-… Input Fuse Min. short- circuit cur- current A 2 s Bussmann Type rent type DIN 43653 035A-7 1450 170M1315 042A-7 2550 170M1316 049A-7 2550 170M1316 061A-7 8500 170M1318...
Page 224 224 Technical data Ultrarapid (aR) fuses blade style (one fuse per phase) ACS880-01-… Input Fuse Min. short- circuit cur- current A 2 s Bussmann Type DIN rent type 43620 075A-2 15000 170M3815 087A-2 1100 28500 170M3816 115A-2 1500 46500 170M3817...
Page 225 Technical data 225 Ultrarapid (aR) fuses blade style (one fuse per phase) ACS880-01-… Input Fuse Min. short- circuit cur- current A 2 s Bussmann Type DIN rent type 43620 293A-3 4600 490000 170M6812D 363A-3 6500 1000 985000 170M6814D 430A-3 9800...
Page 226 226 Technical data Ultrarapid (aR) fuses blade style (one fuse per phase) ACS880-01-… Input Fuse Min. short- circuit cur- current A 2 s Bussmann Type DIN rent type 43620 414A-5 9800 1250 2150000 170M8554D 477A-5 9800 1250 2150000 170M8554D U n = 690 V...
Page 227: Gg Fuses Din 43620 Blade Style (Frames R1 To R9)
DIN 43620 blade style (frames R1 to R9) Check on the fuse time-current curve to ensure the operating time of the fuse is below 0.5 seconds. Obey the local regulations. gG fuses (one fuse per phase) ACS880-01-… Input Fuse Min. short-...
Page 228 228 Technical data gG fuses (one fuse per phase) ACS880-01-… Input Fuse Min. short- current circuit cur- rent A 2 s ABB type DIN size 017A-3 2500 OFAF000H25 025A-3 4500 OFAF000H32 032A-3 7700 OFAF000H40 038A-3 15400 OFAF000H50 045A-3 21300 OFAF000H63...
Page 229 Technical data 229 gG fuses (one fuse per phase) ACS880-01-… Input Fuse Min. short- current circuit cur- rent A 2 s ABB type DIN size 034A-5 15400 OFAF000H50 040A-5 21300 OFAF000H63 052A-5 37000 OFAF000H80 065A-5 1000 63600 OFAF000H100 077A-5 1000...
Page 230 230 Technical data gG fuses (one fuse per phase) ACS880-01-… Input Fuse Min. short- current circuit cur- rent A 2 s ABB type DIN size 119A-7 2200 350000 OFAA1GG200 142A-7 3200 700000 OFAA1GG250 174A-7 5500 850000 OFAA2GG315 210A-7 7000 1300000...
Page 231: Quick Guide For Selecting Between Gg And Ar Fuses
Technical data 231 ￭ Quick guide for selecting between gG and aR fuses The combinations (cable size, cable length, transformer size and fuse type) in this table fulfill the minimum requirements for the proper operation of the fuse. Use this table to select between gG and aR fuses or to calculate the short-circuit current of the installation as described in Calculating the short-circuit current of the installation (page...
Page 232 232 Technical data ACS880- Cable type Supply transformer minimum apparent power S N (kVA) 01-… Copper Alumin- Maximum cable length with Maximum cable length with gG fuses aR fuses mm 2 mm 2 10 m 50 m 100 m 10 m 100 m 200 m 09A4-3...
Page 233 Technical data 233 ACS880- Cable type Supply transformer minimum apparent power S N (kVA) 01-… Copper Alumin- Maximum cable length with Maximum cable length with gG fuses aR fuses mm 2 mm 2 10 m 50 m 100 m 10 m 100 m 200 m 027A-5...
Page 234: Calculating The Short-Circuit Current Of The Installation
Z k = z k · U n 2 / S n = transformer impedance (ohm) Transformer impedance (%) Transformer rated voltage (V) Nominal apparent power of the transformer (kVA) Cable reactance (ohm) Calculation example Drive: • ACS880-01-145A-3 • Supply voltage = 410 V Transformer: • rated power S = 600 kVA...
Page 235 + (22.19 mohm + 13.94 mohm) The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF00H160 (1700 A). -> The 500 V gG fuse (ABB Control OFAF00H160) can be used.
Page 236: Fuses (Ul)
100 kA symmetrical amperes (rms) at 240 V, 480 V, and 600 V maximum when protected by the fuses given below. ABB recommends Class T fuses listed below. Also allowed are UL Listed 248-8 Class J fast acting, time delay, and high speed fuses, 248-4 Class CC fast acting fuses and 248-17 Class CF fast acting and time delay fuses of the same nominal voltage and current rating.
Page 237 Technical data 237 ACS880-01-… Input current UL (one fuse per phase) Bussmann UL class type U n = 400 V 02A4-3 JJS-15 03A3-3 JJS-15 04A0-3 JJS-15 05A6-3 JJS-15 07A2-3 JJS-15 09A4-3 10.0 JJS-15 12A6-3 12.9 JJS-20 017A-3 JJS-25 025A-3 JJS-35...
Page 238 238 Technical data ACS880-01-… Input current UL (one fuse per phase) Bussmann UL class type 05A2-5 JJS-15 07A6-5 JJS-15 11A0-5 JJS-20 014A-5 JJS-25 021A-5 JJS-35 027A-5 JJS-40 034A-5 JJS-50 040A-5 JJS-60 052A-5 JJS-80 065A-5 JJS-90 077A-5 JJS-110 096A-5 JJS-150 124A-5...
Page 239 Technical data 239 ACS880-01-… Input current UL (one fuse per phase) Bussmann UL class type 049A-7 JJS-80 061A-7 JJS-110 084A-7 JJS-150 098A-7 JJS-150 119A-7 JJS-200 142A-7 JJS-250 174A-7 JJS-300 210A-7 JJS-400 271A-7 JJS-400 Semiconductor fuses for frame R9 with base part numbers are listed below.
Page 240: Circuit Breakers (Iec)
240 Technical data 3. The UL listed fuses recommended by ABB are the required branch circuit protection per NEC. Circuit breakers listed in section Circuit breakers (UL) are also acceptable as branch circuit protection. 4. The recommended size or smaller UL listed 248 fast acting, time delay, or high speed fuses must be used to maintain the UL listing of the drive.
Page 241 Technical data 241 ACS880- Frame ABB miniature circuit ABB moulded case circuit breaker (Tmax) 01-… breaker Type Type 24A3-2 S 203 M/P-B/C 32 031A-2 S 203 M/P-B/C 046A-2 S 803 S-B/C 75 061A-2 S 803 S-B/C 80 075A-2 S 803 S-B/C 125...
Page 242 242 Technical data ACS880- Frame ABB miniature circuit ABB moulded case circuit breaker (Tmax) 01-… breaker Type Type 105A-3 XT4 L 250 Ekip LS/I In=250 3p F F 145A-3 XT4 L 250 Ekip LS/I In=250 3p F F 169A-3 XT4 L 250 Ekip LS/I In=250 3p F F...
Page 243 Technical data 243 ACS880- Frame ABB miniature circuit ABB moulded case circuit breaker (Tmax) 01-… breaker Type Type 260A-5 T5 L 630 PR221DS-LS/I In=630 3p F F 302A-5 T5 L 630 PR221DS-LS/I In=630 3p F F 361A-5 T5 L 630 PR221DS-LS/I In=630 3p F F...
Page 244: Circuit Breakers (Ul)
ABB does not assume any liability whatsoever for the correct function and protection with circuit breakers not listed. Furthermore, if the recommendations given by ABB are not obeyed, the drive can experience problems that warranty does not cover.
Page 245: 480 V Circuit Breakers
Technical data 245 ACS880- Frame Input Circuit Circuit Enclos- Drive Circuit breaker (ABB) 01-… current breaker breaker ure min- volume maxim- voltage imum um cur- volume rent in 3 in 3 65 kA @ 240 V 087A-2 ‡ 2030 XT4Nαβ150#******** 115A-2 ‡...
Page 246: 600 V Circuit Breakers
246 Technical data ACS880- Frame Input Circuit Circuit Enclos- Drive Circuit breaker (ABB) Maxim- Maxim- 01-… cur- break- break- volume um I um I rent minim- peak maxim- voltage volume cur- rent 65 kA @ 480 V 052A-5 30240 1669 XT2Hαβ070#********...
Page 247 Technical data 247 ACS880- Frame Input Circuit Circuit Enclos- Drive Circuit breaker (ABB) Maxim- Maxim- 01-… cur- break- break- volume um I um I rent minim- peak maxim- voltage volume cur- rent 65 kA @ 600 V 027A-7 28980 1011 XT4Vαβ035#********...
Page 248 Use drive volume for all three types listed in the table when installing multiple drives in the enclosure. 7. The ABB circuit breaker part number listed in the table is a base part number. • Symbol α represents 80% or 100% allowable continuous current. Options allowed are U, Q, C and D.
Page 249: Dimensions, Weights And Free Space Requirements
19. You can use alternative circuit breakers if they meet certain characteristics. For acceptable breakers, refer to Branch Circuit Protection for ABB drives manual supplement (3AXD50000645015 [English]). Dimensions, weights and free space requirements...
Page 250 250 Technical data Frame UL type 1 Weight 16.11 14.80 6.10 9.80 18.71 17.17 6.81 10.28 22.85 22.17 7.99 10.79 28.80 25.70 7.99 10.77 28.60 22.35 9.92 14.10 34.66 25.39 11.18 14.35 38.01 28.50 11.81 15.21 37.59 28.46 14.96 16.27 1) 216 lb for 490A-3 and 477A-5.
Page 251 For dimensions and weights of option +P940 and +P944, refer to ACS880…+P940 and +P944 drive modules supplement (3AUA0000145446 [English]). For dimensions of option +C135, refer to ACS880-01…+C135 drives with flange mounting kit supplement (3AXD50000349814 [English]). For the additional weight of the flange mounting kit, refer to the table below. Frame...
Page 252: Package Dimensions
252 Technical data Frame Weight of flange mounting kit (option +C135) ￭ Package dimensions Frame Package Length Width Height R1 (IP21) R1 (IP55) R2 (IP21) R2 (IP55) R3 (IP21) R3 (IP55) R4 (IP21) R4 (IP55) R5 (IP21) R5 (IP55) 1145 1145 Free space requirements 200 mm (7.87 in) free space is required at top of the drive.
Page 253: Losses, Cooling Data And Noise
Technical data 253 Losses, cooling data and noise ACS880- Frame Air flow Noise Typical power 01-… loss m 3 /h ft 3 /min dB(A) U n = 230 V 04A6-2 06A6-2 07A5-2 10A6-2 16A8-2 24A3-2 031A-2 046A-2 061A-2 075A-2 087A-2 1142 115A-2 1362...
Page 254 254 Technical data ACS880- Frame Air flow Noise Typical power 01-… loss m 3 /h ft 3 /min dB(A) 038A-3 045A-3 061A-3 072A-3 087A-3 1129 105A-3 1215 145A-3 1962 169A-3 2042 206A-3 2816 246A-3 3026 293A-3 3630 363A-3 1150 4688 430A-3 1150 5797...
Page 255 Technical data 255 ACS880- Frame Air flow Noise Typical power 01-… loss m 3 /h ft 3 /min dB(A) 096A-5 1157 124A-5 1673 156A-5 1840 180A-5 2281 240A-5 2912 260A-5 3325 302A-5 1150 3663 361A-5 1150 4781 414A-5 1150 5672 477A-5 1150 6812...
Page 256: Cooling Air Flow And Heat Dissipation For Flange Mounting (Option +C135)
256 Technical data Cooling air flow and heat dissipation for flange mounting (option +C135) ACS880- Frame Air flow (option +C135) Heat dissipation 01-… (option +C135) Heatsink Front Heatsink Front m 3 /h m 3 /h U n = 230 V 04A6-2 06A6-2 07A5-2...
Page 257 Technical data 257 ACS880- Frame Air flow (option +C135) Heat dissipation 01-… (option +C135) Heatsink Front Heatsink Front m 3 /h m 3 /h 025A-3 032A-3 038A-3 045A-3 061A-3 072A-3 087A-3 105A-3 1075 145A-3 1798 169A-3 1853 206A-3 2593 246A-3 2766 293A-3 3317...
Page 258 258 Technical data ACS880- Frame Air flow (option +C135) Heat dissipation 01-… (option +C135) Heatsink Front Heatsink Front m 3 /h m 3 /h 040A-5 052A-5 065A-5 077A-5 096A-5 1019 124A-5 1521 156A-5 1662 180A-5 2083 240A-5 2659 260A-5 3050 302A-5 1150 3311...
Page 259: Connector And Entry Data For The Power Cables
Technical data 259 ACS880- Frame Air flow (option +C135) Heat dissipation 01-… (option +C135) Heatsink Front Heatsink Front m 3 /h m 3 /h 142A-7 1797 174A-7 2476 210A-7 1150 2612 271A-7 1150 3853 Connector and entry data for the power cables ￭...
Page 260: U L
260 Technical data Frame Cable entries R-, R+/UDC+ and UDC- terminals T (wire screw) Ø * Wire size mm 2 M… N·m 0.75…6 0.5…16 0.5…35 6…70 25…95 25…150 2 × (50…150) 2 × (95…240) * maximum cable diameter accepted. For the entry plate hole diameters, refer to chapter Dimension drawings.
Page 261 Technical data 261 Frame Cable entries L1, L2, L3, T1/U, T2/V, T3/W Grounding terminals T (Wire Ø * Wire size Max. wire size screw) kcmil/AWG M… lbf·ft lbf·ft 0.67 14…10 0.44 0.31 0.83 20…6 1.25 0.39 0.94 20…2 0.70 1.26 6…1/0 11.0 0.70...
Page 262: Connector Data For The Control Cables
262 Technical data Note: • The minimum specified wire size does not necessarily have sufficient current carrying capacity at maximum load. • For IEC installations using mm cable, the terminals do not accept a conductor that is one size larger than the recommended wire size. For NEC installations using AWG cable, this applies only to the R2 frame drive.
Page 263 Technical data 263 Drive type Frame UL (NEC) size ACS880- Cu cable type Al cable type Cu cable type 01-… mm 2 mm 2 AWG/kcmil 145A-2 3×95 3×120 170A-2 3×120 3×150 206A-2 3×150 3x240 300 MCM 274A-2 2 × (3×120) 2 ×...
Page 264 264 Technical data Drive type Frame UL (NEC) size ACS880- Cu cable type Al cable type Cu cable type 01-… mm 2 mm 2 AWG/kcmil U n = 500 V 02A1-5 3x1.5 03A0-5 3x1.5 03A4-5 3x1.5 04A8-5 3x1.5 05A2-5 3x1.5 07A6-5 3x1.5 11A0-5...
Page 265 Technical data 265 Drive type Frame UL (NEC) size ACS880- Cu cable type Al cable type Cu cable type 01-… mm 2 mm 2 AWG/kcmil 14A3-7 3x2.5 019A-7 023A-7 027A-7 3x10 035A-7 3x10 3x25 042A-7 3x16 3x25 049A-7 3x16 3x25 061A-7 3x25 3x35...
Page 266: Electrical Power Network Specification
266 Technical data Electrical power network specification Voltage ( U 1 ) ACS880-01-xxxx-2 drives: 208 … 240 V AC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage level 3~230 V AC. ACS880-01-xxxx-3 drives: 380 … 415 V AC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage level 3~400 V AC.
Page 267: Efficiency
Note: Longer motor cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and characteristics. A sine filter (optional) at the drive output also causes voltage decrease. Contact ABB for more inform- ation. Efficiency Approximately 98% at nominal power level.
Page 268: Ambient Conditions
268 Technical data Protective class (IEC/EN 61800-5-1) Ambient conditions Environmental limits for the drive, including installed options, are given below. Use the drive in a heated, indoor, controlled environment. Operation Storage Transportation installed for stationary in the package in the package Installation site 0 to 4000 m (13123 ft) altitude...
Page 269 Technical data 269 Chemical gases IP00, IP20 and IP21 Class 1C2 Class 2C2 drives: IEC Class C3 ANSI-ISA 71.04 Class G2 IP55 drives: IEC Class C4 ANSI-ISA 71.04 Class G3/GX up to 2300 Å/30d corrosivity Drives with +P968 corro- Class 1S3 Class 2S2 sion resistance variant: IEC Class C5/CX...
Page 270: Storage Conditions
1) For neutral-grounded TN and TT systems and non-corner grounded IT systems. 2) For corner-grounded TN, TT and IT systems. 3) Contact ABB for higher humidity levels than 60% in the presence of corrosive gases. Storage conditions Store the drive in humidity controlled enclosed environments. Keep the drive in its package.
Page 271: Package Materials For Large Wall-Mounted Drives And Converter Modules
Technical data 271 • EPP (foam) • PP (strapping) • PE (plastic bag). ￭ Package materials for large wall-mounted drives and converter modules • Cardboard heavy duty quality with wet strength glue • Plywood • Wood • PP (strapping) • PE (VCI foil) •...
Page 272: Applicable Standards
Contact your local ABB distributor for further information on environmental aspects. End of life treatment must follow international and national regulations. For more information on ABB end of life services, refer to new.abb.com/service/end-of-life-services. Applicable standards The drive complies with the following standards.
Page 273: Markings
Technical data 273 EN 60204-1:2006 + A1 Safety of machinery. Electrical equipment of machines. Part 1: Gen- 2009 + AC:2010 eral requirements. Provisions for compliance: The final assembler of the machine is re- sponsible for installing: • emergency-stop device • supply disconnecting device EN 60529:1991 + Degrees of protection provided by enclosures (IP code) A2:2013...
Page 274: Emc Compliance (Iec/En 61800-3)
Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of Conformity is available from https://library.abb.com. WEEE mark At the end of life the product should enter the recycling system at an appropriate collection point and not placed in the normal waste stream.
Page 275: Category C2
Technical data 275 electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes. Second environment includes establishments connected to a network not supplying domestic premises.
Page 276: Category C3
276 Technical data Note: Note: Do not install a drive with the EMC filter +E202 connected to a system that the filter is not suitable for. This can cause danger, or damage the drive. Note: Do not install a drive with the ground-to-phase varistor connected to a system that the varistor is not suitable for.
Page 277 Technical data 277 and cables is sufficient. If in doubt, a supply transformer with static screening between the primary and secondary windings can be used. Medium voltage network Equipment Neighboring network Supply transformer Point of measurement Static screen Low voltage Drive Equipment (victim) 2.
Page 278: Ul Checklist
278 Technical data UL checklist WARNING! Operation of this drive requires detailed installation and operation instructions provided in the hardware and software manuals. The manuals are provided in electronic format in the drive package or on the Internet. Keep the manuals with the drive at all times. Hard copies of the manuals can be ordered through the manufacturer.
Page 279: Approvals
National Electrical Code and any additional local codes. • The drive provides motor overload protection. The protection is not enabled when the drive leaves the ABB factory. For enabling the protection, see the firmware manual. • The drive overvoltage category according to IEC 60664-1 is III.
Page 280: Declarations Of Conformity
280 Technical data ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information. Declarations of conformity Link to Declaration of conformity according to EU Machinery Directive...
Page 281: Dimension Drawings
Dimension drawings 281 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the standard drive (IP21, UL Type 1) and drive with option +B056 (IP55, UL Type 12). For dimension drawings with options +P940 and +P944 (IP20, UL Open Type), see ACS880…+P940 and +P944 drive modules supplement (3AUA0000145446 [English]).
Page 282: Frame R1 (Ip21, Ul Type 1)
282 Dimension drawings Frame R1 (IP21, UL Type 1)
Page 283: Frame R1 (Ip55, Ul Type 12)
Dimension drawings 283 Frame R1 (IP55, UL Type 12)
Page 284: Frame R2 (Ip21, Ul Type 1)
284 Dimension drawings Frame R2 (IP21, UL Type 1)
Page 285: Frame R2 (Ip55, Ul Type 12)
Dimension drawings 285 Frame R2 (IP55, UL Type 12)
Page 286: Frame R3 (Ip21, Ul Type 1)
286 Dimension drawings Frame R3 (IP21, UL Type 1)
Page 287: Frame R3 (Ip55, Ul Type 12)
Dimension drawings 287 Frame R3 (IP55, UL Type 12)
Page 288: Frame R4 (Ip21, Ul Type 1)
288 Dimension drawings Frame R4 (IP21, UL Type 1)
Page 289: Frame R4 (Ip55, Ul Type 12)
Dimension drawings 289 Frame R4 (IP55, UL Type 12)
Page 290: Frame R5 (Ip21, Ul Type 1)
290 Dimension drawings Frame R5 (IP21, UL Type 1)
Page 291: Frame R5 (Ip55, Ul Type 12)
Dimension drawings 291 Frame R5 (IP55, UL Type 12)
Page 292: Frame R6 (Ip21, Ul Type 1)
292 Dimension drawings Frame R6 (IP21, UL Type 1)
Page 293: Frame R6 (Ip55, Ul Type 12)
Dimension drawings 293 Frame R6 (IP55, UL Type 12)
Page 294: Frame R7 (Ip21, Ul Type 1)
294 Dimension drawings Frame R7 (IP21, UL Type 1)
Page 295: Frame R7 (Ip55, Ul Type 12)
Dimension drawings 295 Frame R7 (IP55, UL Type 12)
Page 296: Frame R8 (Ip21, Ul Type 1)
296 Dimension drawings Frame R8 (IP21, UL Type 1)
Page 297: Frame R8 (Ip55, Ul Type 12)
Dimension drawings 297 Frame R8 (IP55, UL Type 12)
Page 298: Frame R9 (Ip21, Ul Type 1)
298 Dimension drawings Frame R9 (IP21, UL Type 1)
Page 299: Frame R9 (Ip55, Ul Type 12)
Dimension drawings 299 Frame R9 (IP55, UL Type 12)
Page 301: Contents Of This Chapter
Resistor braking 301 Resistor braking Contents of this chapter This chapter contains information and instructions on resistor braking, brake choppers and brake resistors. Operation principle and hardware description Frames R1 to R4 have a built-in brake chopper as standard. Frames R5 and up can be equipped with optional built-in brake chopper (+D150).
Page 302: Selecting A Custom Resistor
302 Resistor braking Note: If the E value is not sufficient, it is possible to use a four-resistor assembly in which two standard resistors are connected in parallel, two in series. The E value of the four-resistor assembly is four times the value specified for the standard resistor.
Page 303: Selecting And Routing The Brake Resistor Cables
The maximum length of the resistor cable(s) is 10 m (33 ft). ￭ EMC compliance of the complete installation 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 304: Protecting The System Against Thermal Overload
The drive has a brake thermal model which protects the brake resistor against overload. ABB recommends to enable the thermal model at start up. ABB recommends to equip the drive with a main contactor for safety reasons even when you have enabled the resistor thermal model. Wire the contactor so that it opens in case the resistor overheats.
Page 305 Resistor braking 305 ABB recommends that you also wire the thermal switch to a digital input of the drive, and configure the input to cause a fault trip at resistor overtemperature indication. Θ +24V Drive input power connection with a main contactor...
Page 306: Protecting The Resistor Cable Against Short-Circuits
306 Resistor braking +24VD Θ Protecting the resistor cable against short-circuits The input fuses will also protect the resistor cable when it is identical with the input cable. Mechanical installation Brake resistors must be installed outside the drive. Obey the resistor manufacturer’s instructions.
Page 307: Connection Diagram
Resistor braking 307 ￭ Connection diagram See section Connection diagram (page 104). ￭ Connection procedure • Connect the resistor cables to the R+ and R- terminals in the same way as the other power cables. If a shielded three-conductor cable is used, cut the third conductor, insulate it, and ground the twisted shield of the cable (protective earth conductor of the resistor assembly) at both ends.
Page 308: Technical Data
308 Resistor braking Technical data ￭ Ratings ACS880- Internal brake Example brake resistor(s) 01-… chopper P brcont R min Type P Rcont U n = 230 V 04A6-2 0.75 JBR-03 0.14 06A6-2 JBR-03 0.14 07A5-2 JBR-03 0.14 10A6-2 JBR-03 0.14 16A8-2 SACE15RE22 24A3-2...
Page 309 Resistor braking 309 ACS880- Internal brake Example brake resistor(s) 01-… chopper P brcont R min Type P Rcont 025A-3 SACE08RE44 032A-3 SACE15RE22 038A-3 18.5 SACE15RE22 045A-3 SACE15RE13 061A-3 SACE15RE13 072A-3 SAFUR90F575 1800 087A-3 SAFUR90F575 1800 105A-3 SAFUR80F500 2400 145A-3 SAFUR80F500 2400 169A-3 SAFUR125F500...
Page 310 310 Resistor braking ACS880- Internal brake Example brake resistor(s) 01-… chopper P brcont R min Type P Rcont 052A-5 SACE15RE13 065A-5 SAFUR90F575 1800 077A-5 SAFUR90F575 1800 096A-5 SAFUR80F500 2400 124A-5 SAFUR80F500 2400 156A-5 SAFUR125F500 3600 180A-5 SAFUR125F500 3600 240A-5 SAFUR200F500 5400 13.5 260A-5...
Page 311: Degree Of Protection And Thermal Constant Of The Resistor
Resistor braking 311 ACS880- Internal brake Example brake resistor(s) 01-… chopper P brcont R min Type P Rcont 210A-7 SAFUR125F500 3600 271A-7 SAFUR125F500 3600 Note: The insulation resistance of SACE and SAFUR resistors is 2 kV/min. The insulation resistance of JBR resistors is 3.5 kV/min. P brcont Maximum continuous braking power.
Page 312: Dimensions And Weights Of External Resistors
312 Resistor braking Dimensions and weights of external resistors ￭ JBR-03 JBR-03 brake resistor Dimension A 340 mm (13.39 in)
Page 313: Sace08Re44
Resistor braking 313 JBR-03 brake resistor Dimension B 200 mm (7.87 in) Dimension C 170 mm (6.69 in) Weight 0.8 kg (1.8 lb) 10 mm 2 (AWG6) Maximum wire size of main terminals Tightening torque of main terminals 1.5 … 1.8 N·m (13 … 16 lbf·in) 4 mm 2 (AWG12) Wire size of thermal switch terminals Tightening torque of thermal switch termin-...
Page 314: Sace15Re13 And Sace15Re2
314 Resistor braking ￭ SACE15RE13 and SACE15RE2 SACE15RExx Ø 6 Weight: 6 kg (13 lb) ￭ SAFUR80F500 and SAFUR90F575 Ø 7 Brake resistor type Weight SAFUR80F500 14 kg (31 lb) SAFUR90F500 12 kg (26 lb)
Page 315: Safur125F500 And Safur200F500
Resistor braking 315 ￭ SAFUR125F500 and SAFUR200F500 5 5 Ø 7 Brake resistor type Weight SAFUR125F500 25 kg (55 lb) SAFUR200F500 30 kg (66 lb)
Page 317: The Safe Torque Off Function
The Safe torque off function 317 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 318: Compliance With The European Machinery Directive And The Uk Supply
318 The Safe torque off function The Safe torque off function complies with these standards: Standard Name IEC 60204-1:2021 Safety of machinery – Electrical equipment of machines – Part 1: General requirements EN 60204-1:2018 IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards –...
Page 319: Wiring
For more information, see the module documentation. ￭ Cable types and lengths • ABB recommends double-shielded twisted-pair cable. • Maximum cable lengths: • 300 m (1000 ft) between activation switch [K] and drive control unit •...
Page 320: Single Drive (Internal Power Supply)
320 The Safe torque off function ￭ Single drive (internal power supply) Dual-channel connection OUT1 +24 V SGND Drive Control unit Activation switch...
Page 321: Single-Channel Connection
The Safe torque off function 321 Single-channel connection XSTO OUT1 +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.
Page 322: Multiple Drives
322 The Safe torque off function ￭ Multiple drives Internal power supply XSTO OUT1 +24 V SGND XSTO OUT1 SGND XSTO OUT1 SGND Drive Control unit Activation switch...
Page 323: External Power Supply
The Safe torque off function 323 External power supply 24 V DC – XSTO OUT1 +24 V SGND XSTO OUT1 SGND XSTO OUT1 SGND Drive Control unit Activation switch...
Page 324: Operation Principle
324 The Safe torque off function Operation principle 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 325: Start-Up Including Validation Test
The Safe torque off function 325 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 at initial start-up of the safety function 2.
Page 326 326 The Safe torque off function Action Check the STO circuit connections against the wiring diagram. Close the disconnector and switch the power on. 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.
Page 327: Use
The Safe torque off function 327 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. 3.
Page 328 328 The Safe torque off function • The Safe torque off function is ineffective against deliberate sabotage or misuse. • The Safe torque off function has been designed to reduce the recognized hazardous conditions. In spite of this, it is not always possible to eliminate all potential hazards.
Page 329: 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 325). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook.
Page 330: Competence
330 The Safe torque off function ￭ Competence The maintenance and proof test activities of the safety function must be carried out by a competent person with adequate expertise and knowledge of the safety function as well as functional safety, as required by IEC 61508-1 clause 6. ￭...
Page 331: Simplified Proof Test Procedure
The Safe torque off function 331 ￭ Simplified proof test procedure Action WARNING! Obey the safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Test the operation of the STO function. If the motor is running, it will stop during the test.
Page 332: 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 333: Safety Data
The Safe torque off function 333 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and applies only if both STO channels are used.
Page 334 334 The Safe torque off function...
Page 335 The Safe torque off function 335...
Page 336 336 The Safe torque off function • The STO is a type B safety component as defined in IEC 61508-2.
Page 337: Terms And Abbreviations
The Safe torque off function 337 • Relevant failure modes: • The STO trips spuriously (safe failure) • The STO does not activate when requested • A fault exclusion on the failure mode “short circuit on printed circuit board” has been made (EN 13849-2, table D.5). The analysis is based on an assumption that one failure occurs at one time.
Page 338: Tüv Certificate
338 The Safe torque off function Term or Reference Description abbreviation PFH diag IEC/EN 62061 Average frequency of dangerous failures per hour for the diagnostic function of STO EN ISO 13849-1 Performance level. Levels a…e correspond to SIL Proof test IEC 61508, IEC Periodic test performed to detect failures in a 62061...
Page 339: Filters
See section Examining the compatibility of the motor and drive (page 68). A common mode filter kits are available from ABB. The kits includes three wound cores. For installation instructions of the cores, see the instruction included in the core package.
Page 340: D U /D T Filters
340 Filters Name Code Input side common mode filter kit for ACS880-01-490A-3, -477A-5 and - 3AXD50001192297 453A-4 (option +E202) and for ACS580-01, ACH580-01 and ACQ580-01 -490A-4 and -477A-4 installation instructions d u /d t filters ￭ d u /d t filter types...
Page 341: Description, Installation And Technical Data Of The D U /D T Filters
AOCH and NOCH du/dt filters hardware manual (3AFE58933368 [English]). Sine filters ￭ Selecting a sine filter for a drive Check housing of sine filters from the manufacturer’s internet pages. Go to https://en.tdk.eu ACS880-01-… Sine filter type I cont. P cont. Heat dissipation Noise Drive...
Page 342 342 Filters ACS880-01-… Sine filter type I cont. P cont. Heat dissipation Noise Drive Filter Total dB (A) 087A-3 B84143V0095R229* 58.0 1120 1520 105A-3 B84143V0130S230** 68.6 1295 1895 145A-3 B84143V0162S229** 94.6 1440 1990 169A-3 B84143V0162S229** 115.0 1940 2490 206A-3 B84143V0230S229** 140.6...
Page 343 Filters 343 ACS880-01-… Sine filter type I cont. P cont. Heat dissipation Noise Drive Filter Total dB (A) 180A-5 B84143V0162S229** 121.3 2310 2860 240A-5 B84143V0230S229** 154.3 3300 4200 260A-5 B84143V0230S229** 166.7 3900 4800 361A-5 B84143V0390S229** 217.9 4800 1570 6370 414A-5 B84143V0390S229** 250.1...
Page 344: Definitions
344 Filters ACS880-01-… Sine filter type I cont. P cont. Heat dissipation Noise Drive Filter Total dB (A) 271A-7 B84143V0207S230** 156.4 4800 5730 3AXD00000588487 * minimum switching frequency 4.5 kHz ** minimum switching frequency 3.6 kHz ￭ Definitions P cont.
Page 345: 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/contact-centers.

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