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ACS880 HardWare Rev G

1. LO w 8 e e ED t I 5 lt 1 m1 CO LI TP 5 N E SAITOH ONTINNOWM 931539915 UA ON a gt 16 SC 859 8 lt 09 gt lt gt Lul YD Th eK Cd e e gt 1 em d a 69 8 E se O SC 869 gt Diu LL 96 099 em 196 Dimension drawings Safe Torque off function 197 13 Safe Torque off function What this chapter contains This chapter describes the Safe torque off function of the drive and gives instructions for its use Description The Safe torque off function can be used for example to construct safety or supervision circuits that stop the drive in case of danger Such as an emergency stop circuit Another possible application is a prevention of unexpected start up switch that enables short time maintenance operations like cleaning or work on non electrical parts of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage of the power semiconductors of the drive output stage A see diagram below thus preventing the drive from generating th
2. TT 106 97 9 79 1010 YOONY Ce qo 110 2 led ee 100 YOONY Lvl TT 68 Tire 01 9 190 Dimension drawings Frame R4 IP55 UL Type 12 1646 067 0 9 16 S3 OH ONILNNON 931539915 88 611606 S3 OH ONILNNON 41 5499 5 LS 9IS9oL el 1162 29 5 0 1921 20 68122 og 9109 V rs 2218 les ellpve 87 2 96 fe Tee Zleoz YSLAWVIG 318VvO v60 GOL dN sode 71 vv 310H ALWId a18vo 65 0 91 GOL dN L3 NIWOS9 sode 780 22 310H 69 221975 Dimension drawings 191 S96L600000ENEE eZ gzloe4 eni 3 06 i si a18vo ez LT OL dn Loz LS ce Tec possem WT 65 o Tia na 9 OS ma N CIN ON N Hio N als 21542 Z S Z x I mM 27 N 98 86 S31OH ONILN
3. 40 Mechanical installation Examining the installation site The drive must be installed in an upright position with the cooling section against a wall All IP21 UL Type 1 and IP55 drives and UL 12 drives of frames R1 to can be installed tightly side by side For UL Type 12 drives of frames R4 to R9 leave 100 mm 4 in between the hoods Make sure that the installation site agrees with these requirements The installation site has sufficient ventilation to prevent overheating of the drive See section Losses cooling data and noise on page 157 The operation conditions of the drive agree with the specifications in section Ambient conditions page 167 The wall is vertical not flammable and strong enough to hold the weight of the drive See page 756 The material below the installation is not flammable e There is enough free space above and below the drive for cooling air flow service and maintenance See page 756 There is enough free space in front of the drive for operation service and maintenance 300 mm 11 81 in Necessary tools e Drill and drill bits e Screwdriver and or wrench with bits The drive cover has Torx screws Mechanical installation 41 Moving the drive Move the transport
4. Electrical installation 93 Connection procedure for frames R6 and R9 1 Remove the front cover For IP21 drives Release the retaining clip with a screwdriver a and lift the cover from the bottom outwards b 2 For IP21 drives Remove the cable entry box cover by undoing the mounting SCrews 3 Attach the residual voltage warning sticker in the local language next to the control unit 4 Remove the side plates of the cable entry box by undoing the mounting screws 5 Remove the shroud on the power cable terminals by releasing the clips on the sides with a screwdriver and lifting a If parallel cables are installed frames and R9 knock out holes for the cables b 6 Knock out the shrouds on the power cable terminals for the cables to be installed 7 Prepare the ends of the input power and motor cables as illustrated in the figure Note Bare shield will be grounded 360 degrees under the clamp 8 Cut adequate holes into the rubber grommets a Slide the grommets onto the cables Slide the cables through the holes of the bottom plate and attach the grommets to the holes b 9 Tighten the clamp onto the stripped part of the cable 10 Fasten the twisted shields of the cables under the grounding clamps 11 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 T
5. 00 00 1 1 IM CD D D D 01010101010 pue sseunsng LEE TE T E ILLE I d E T pue suonaeuuo on Ao41oe e pue se uons sjueuoduioo sjueuieoe deiJ e qissod sJee eouo ggy eAup eui jo pue eoueuuoged eundo NOZ pue oJ1uoo 10 SSSA ees mL ZE EE See iz oz 61 81 121 jor or jer 2 orje e 2 1215 SJeoA pue gH 01 sowed eAup 6 0 9H 5 M Maintenance 123 Heatsink The module heatsink fins pick up dust from the cooling air The drive runs into overtemperature warnings and faults if the heatsink is not clean When necessary clean the heatsink as follows WARNING Follow the safety instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment WARNING Use a vacuum cleaner with antistatic hose and noz
6. 200 Multiple drives internal power 201 Multiple drives external power supply 202 tac eden 203 Start up including acceptance test 203 AUTON 203 Acceptance test reports 203 Acceptance test procedure 204 ee 205 ER ERR aE SCR 206 Falce rm 206 Gala ____________ 206 CERCA oa _ 209 14 Resistor braking What this chapter contains 211 Operation principle and hardware description 211 Planning the braking system 211 Selecting the brake circuit components 211 Selecting and routing the brake resistor cables 212 Minimizing electromagnetic interference 213 Maximum Cable length Pee cede eS ERR ees e Oe eee eee 213 EMC compliance of the complete i
7. ES HOL 10 SUGGESTED MOUNTING DI NI i ee Eom Z Y LI 188 7 6 vcl 6 GI GOP 3AUA0000097621 Dimension drawings 179 Frame R2 IP21 UL Type 1 NI e py UAN ee lt AI dm 3AUA0000097691 5 8 G HOLE 53108 ONTINNON 031539915 dO d UNT ING 10 49 1 98 UGGESTED 3 CO ES d c PS d lt gt LLLI ii lt P ___ __ SF Lago OT 9 LG v1 OLE 4 68 0 71 n 5 5 A EST Mr gt ki 2 gt c gt C x 2 S _ 8 1 180 Dimension drawings Frame R3 IP21 UL Type 1 Zv8Z600000VNVE SATOH 9NTINDON 434154901 lt gt 446 71 Ge Ve 88 v E LY VG 81 Dimension drawings 181 Frame R4 21 UL Type 1 697221976 S828600000vnve AES SE L
8. X 96 Electrical installation Electrical installation 97 L1 L2 L3 T1 U T2 V T3 W R R UDC UDC T Wire screw T Terminal T Wire screw T Terminal T nut nut B MEIN MA EE NN RN Rr 40 40309 24 Mio so Mio 30 98 _ ms Mio 40 24 Mio me 24 98 m 70 mio me 24 for 525 690 V drives 98 Electrical installation Electrical installation 99 Grounding the motor cable shield at the motor end Always ground the motor cable shield at the motor end For minimum radio frequency interference ground the motor cable shield 360 degrees at the lead through of the motor terminal box or ground the flattened twisted shield width gt 1 5 length DC connection The UDC and UDC terminals are intended for common DC configurations of a number of drives allowing regenerative energy from one drive to be utilized by the other drives in motoring mode Contact your local ABB representative for further instructions Connecting the control cables See section Default connection diagram below 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 Connect the cables as described under Control cable connection procedure on page 10
9. 144 Altitude derang seisnema aa Whe C habeo me E CROROR OR p 145 Low noise control mode derating 145 145 aR fuses frames R1 R9 145 gG fuses frames R1 to R6 148 Quick guide for selecting between gG and aR fuses 150 Calculating the short circuit current of the installation 152 ruses WL teases RETE Dimensions weights and free space requirements Losses cooling data and noise Terminal and lead through data for the power cables 160 ee ee oe ok 160 B iL ieri 161 UL listed cable lugs and tools 162 Terminal data for the control cables 162 Electrical power network specification 163 Motor connection data 163 Control unit ZCU 12 connection data 164 ei gt 167 Classes RR E TERRE TOT OI I CL Lett 167 1
10. 71 Continuous motor cable shield enclosure for equipment the motor cable 71 Implementing thermal overload and short circuit protection 71 Protecting the drive and input power cable in short circuits 71 Protecting the motor and motor cable in short circuits 72 Protecting the drive and the input power and motor cables against thermal overload 72 Protecting the motor against thermal overload 72 Protecting the drive against ground faults 73 Residual current device compatibility 73 Implementing the Emergency stop function 73 Implementing the Safe torque off function 73 Implementing the Safety functions options 73 Implementing the ATEX certified Safe motor disconnection function option 0971 73 Implementing the Power loss ride through function 74 Using power factor compensation capacitors with the drive 74 Using a contactor between the drive and the motor 74 Implementing a bypass connection 75 Example bypass connection
11. Uy 525 690 V OTT aas sas o 4 ozar axe MEN 5 24 EN EN Lae 24 _ 43 3 4 3 1 3 1 3x16 3x16 10 9 7 12 16 24 38 44 45 1 24 NC 2 NEM Lu NC CN NN a 745 152 Technical data Calculating the short circuit current of the installation Check that the short circuit current of the installation is at least the value given in the fuse table The short circuit current ot the installation can be calculated as follows U lk2 ph 2 R Zk X where l 2 ph Short circuit current in symmetrical two phase short circuit U network line to line voltage V Rc cable resistance ohm 2 transformer impedance ohm 2 transformer impedance transformer rated voltage V Sy nominal apparent power of the transformer kVA cable reactance ohm Calculation example Drive ACS880 01 145A 3 e supply voltage 410 V Transformer rated power Sy 600 kVA e rated voltage drive supply voltage 430 V e transformer impedance 7 2 Supply cable length 170m resistance length 0 398 ohm km reactance length 0 082 ohm km Technical data 153 Z NM Gon E ad i 600kVA MONT ohm _ Rc
12. 76 Switching the motor power supply from drive to direct on line TT Switching the motor power supply from direct on line to drive 77 Protecting the contacts of relay outputs Connecting a motor temperature sensor to the drive 6 Electrical installation What this chapter contains sica ieee OR es 81 Was tact tGhe hese TATO TEO 81 Checking the insulation of the assembly 81 B be cee are Gal be eo ee 81 Input power cable 81 Motor and motor cable ci cate ie ein dence m ap oor E Ce a Ree a E 82 Brake resistor assembly 82 Checking the compatibility with IT ungrounded systems 83 Connecting the power cables 84 Connection diagrami ow da 84 Connection procedure for frames R1 to R3 85 Connection procedure for frames R4 and R5 88 Connection procedure for frames R6 and RO 93 Grounding the motor cable shield at the motor 99 darai 99 Connecting the
13. 77 82 3525 22 2 88 r2 93s 28 2 M M 2 93s 36 89 M M msa2 950 48 8 M 4 sos 3 v0 19 20 02643 18 082 082 08 at 50 18 19 19 20 at 80 15 19 20 at 80 315 38 40 44 at 50 23 395 38 40 44 at 80 ooms 318 58 82 84 at 50_ 12454 395 58 62 at 80 omas 96 98 10 58 59 62 osas 12 13 88 59 62 ozas 17 18 82 83 87 osas 19 21 82 83 87 mosas axso 68 34 95 37 Technical data 151 Drive type Cable type Supply transformer minimum apparent power Sy ACS880 KVA 01 Copper Aluminium Maximum cable legth Maximum cable legth with gG fuses with aR fuses oars ois 10 39 39 41 56 osos sas 24 24 24 39 4 50_ oss axis 24 24 24 39 4 50_ 5 sas 48 49 52 39 50_ Domos sas 48 49 52 39 4 50_ omes sas 72 75 89 4 50 maos 7345 72 75 39 4i 50 maas we 2 2 72 13 76 _ e s 6 72 76
14. ONTINAOW 031539915 16 2 859 8t CY NI i lt gt a 3AUA0000073151 Dimension drawings 187 Frame 1 55 UL Type 12 N N EN 8 E 601011 9 5 2 T EN z 55108 031539905 a 0 01 us 60 LI Per 977019 SUGGESTED MOUNTING 11 90 NI DI NI A Mm Oo wy NI lt lt gt DI 45 gt cp F KS DI S t Frame R2 IP55 UL Type 12 188 Dimension drawings 69 600000 202 cL LI 06 E PINE poa 57 2 5 B 35 10 1 V Y Y F 0 06 66 LINNON 031539915 9277726 96 I d 18701 dj ae ON Seg gt 80 gt c 01 9 ale RE eX s LL Dimension drawings 189 Frame R3 IP55 UL Type 12 ZV8Z600000VNVE TA da A mM
15. DB FR EDID for a better world
16. UL Type T wae ences wee eek wed Dp aca ea eee 182 Frame R6 IP21 UL Type 1 bomb m o 605008048 GE eee eee 183 Frame R7 P21 UL T 184 Frame R8 IP21 UL Type TY orrore be ea eae a ek 185 Frame R9 IP21 UL Type T a Re we 186 Frame Ri1 IP55 UL Type 12 xus sce eng doe sme CR Pemba mde oe eee 187 Frame R2 IP55 UL 12 REOR Reden 188 Frame I9 UL Red aya ee bees 189 Frame R4 IP55 UL Type 12 190 Frame R5 UL 12 u s xai donde bod ed Ge ewe dri Coed EORR s 191 Frame R6 IP55 UL Type 12 se sucks aea Ro cse e E Oe wade Ge e 192 Frame RY E55 UL Type ee 193 Frame P55 UL Type 12 aos cna x epa SER dues eo 194 Frame R9 IP55 UL 12 ORO RERO R Rt Ce Od Re GR rete 195 13 Safe Torque off function What this chapter Contains 197 DS SCHOUON gt pioli See oe ee oe Om ore 197 Compliance with the European Machinery Directive 198 d ORO RO ET 198 AcCIIVaUObD SWILCDI irta gene eee alas te 198 Cable types and lengths 198 Single drive internal power
17. 16 061 155 DLS 2 MOUNT ING 1 SUGGESTED mee SI DI NI nu 184 Dimension drawings Frame R7 21 UL 1 3AUA0000073149 LAN lt gt ul 4115 4 0 86 2 0 MOUNTING HOLES SI ONT L 9 S Ty t 3 TOI 5 ESTED ar 99 SU Dimension drawings 185 Frame R8 21 UL 1 t 3AUA0000073150 mm LC L OD gt CS SE i 53108 ONTINNON 031539915 DE Ko 89 OL 57 N co 2 d C lt gt 2 lt gt d 2 5 ___ NI uo oO CO c8 9c 189 gt lt gt CR CM 2 a a DI So gt CD X 90 JV 13 0 3 13 HS 9T deg iM T1 GL E 66 d 186 Dimension drawings Frame 9 21 UL Type 1 ui LC 87 V ESTED MOUNTING LES UY VU 5
18. 880 01 091 2 75 18 SACETSREIS as 2 _ acses n 32 SACENSRETS 2 880 01 075 2 185 6 SAFUROOFS75 8 180 45 KACSBBOI087A2 22 6 SAFUROOFS75 8 180 45 KACSSBOI H5A2 35 SAFURI25F500 4 3600 9 _ 880 01 145 2 37 35 SAFURI25F500 4 3600 9 _ ACSSBODIO7AZ3 30 78 80 40 om 880 01 09 43 40 78 __ 80 40 O44 ACSSBOOI 2AG3 55 78 Ros 80 40 om 880 01 072 3 37 8 SAFUROOFS75 8 180 45 KACSSBOOI087A3 45 8 SAFUROOFS75 8 180 45 880 01 105 3 55 54 SAFURBUFSQ 6 2400 6 880 01 145 3 75 54 SAFURBUFSD 6 2400 6 218 Resistor braking Drive type Internal brake Example brake resistor s chopper Er KW ohm om ks w 5880 01 16 3 90 33 SAFURI25FS00 300 9 _ ACS680 01 206A 3 33 SAFURI25F500 3600 9 _ ACSBRCOIOSAZS 30 78 Ros eo 40 om ACS880 01 07A6 5 _40 78 eo 40 O34 ACSBECOI ADS 55 78 Ros 80 40 880 01 065 5 37 8 SAFURSOFSIS 8 1800 45 _ 880 01 077 5 4s 8 SAFURGOFS7s 8 1600 45 _ ACS680 01 096A 5 _55_ 54 SAFURGOF500 6 2400 6 _ ACS680 01 124A 5 75 54 SAFURBOFSDQ 6 20 6 ACS880 01 156A 5 90 33 SAFURI25F500 3600 o ACS680 01 180A 5 110 33 SAFURI25F500 4 3600 9 _ ACS880 01 07A37
19. __ pas we 3 28 seas Rr 3 5 Rr Rs 2 6 70 5 24699 somom o 26085 Re 2 7 9 2x8 80245 Ro 2 95 2x 12 2x30 86145 RS 276020 2x 185 2x250MCM 66 Planning the electrical installation Drive type 5880 Cu cable type Al cable Cu cable type Al cable type 01 type mm mm AWGIREmiI AWGkomi _ RARE 55 2 RS 1 Te Rs 2 __ e Rs __ 9 Rs 8 Rs sas 8 9 osar Rs sas e 9 ox Rs ote 3e Rs sas 8 Re 4 3 2 Rr 23 mw Rs 9957 3 m 40 Hur Rs 34207 39 Re 3985 2x65 230 2x Gxi20 40 MOM 2 40 3AXD00000588487 1 The cable sizing is based on max 9 cables laid on a cable ladder side by side three ladder type trays one on top of the other ambient temperature 30 C PVC insulation surface temperature 70 C EN 60204 1 and IEC 60364 5 52 2001 For other conditions size the cables according to local safety regulations appropriate input voltag
20. 109 30 40 er 220 H4sk2 Re 145 178 198 37 50 105 300 40 Rr 170 247 162 4s 60 145 37 50 aosx2 Rr 206 267 196 55 75 169 4s 60 _ Rs 274 260 75 100 213 55 75 142 Technical data NEMA RATINGS Drive type Fid Output ratings 5880 hw ha ha T _ A A hp A KW hp N i Ri 48 68 48 22 30 34 15 20 oos Ri 521 98 82 30 30 48 18 20 I a n E 20 40 REIT a 35 Rs e 104 i 65 s NM me 06 me 20 15 5 90 tas Rr 180 257 ieo 10 90 24085 Re 240 350 240 132 200 180 110 150 26085 RB 260 418 260 132 200 240 110 150 130245 Ro 302 498 302 200 250 260 132 200_ 36145 Ro 36i 542 36i 200 300 302 200 250_ Ro 4M 4i4 250 350 361 200 300 3AXD00000588487 Technical data 143 Definitions Supply voltage range Nominal rms input current Nominal output current available continuously with no over loading Typical motor power in no overload use Continuous rms output current allowing 10 overload for 1
21. 5 fal lon EIS I Ko 9 EM mio 9 Slo e Qm og 8 gt Z Z H EN z UJ 6 x I 97 1 L 1 662169 S31OH d3LS399NS 08011722 06 cv 0 9109L 7 166702 V us 4 re 0 vz OL dN L3ININOSHO9 I yy 310H 31V ld 318vo 169 0 SL GOL dN 8 0 22 GAIOH 8217 97 L 2218 c8 Tec 182 Dimension drawings Frame R5 21 UL 1 S96Z600000VNVE lt 1 02 o Q mr m IQ V S Oo Mia N CN JN A N lo QR Slo 0 gt S Z 5 gt lt I 97 22 m 1 Yon 985186 5 ONILNNOW d31S399ns 091091 129 SID N 3 N 1921 L 97 158722 sg Tez 2 98 06 clvZ cc z c9 166 1600 2201172 YSLAWNVIC 318vo 97 LT OL LANWOYD Loz LG ALVId 280 zz OL LINNOY9 sodz zl 62 3710H ALVId lez ez oeZ Dimension drawings 183 Frame R6 21 UL 1 3AUA0000098321 LA 54101 9NIINDON 041519905
22. Ri Ri a o Ri M omes Ri M omes mi a Ri M Ri M owas m 1 m o o Planning the electrical installation 65 Drive type 5880 Cu cable type Al cable Cu cable type Al cable type 01 type mmm mm AWGkomi _ WEKS 8 1 _ I osas sas 8 __ Omas 3d 3 oas Rs 3 Hoska Re sto __ 29 Rr saso 30 20683 Rr 24683 2x x70 7 26x95 Re 2x x05 2 12 2x30 7 86383 Ro 2x xi20 2 143083 Ro 2x x150 2 39040 2x250MCM RI lt Rr ss i sas __ 5 RI 25 R o omes maos R 4 sas omas R ato R4 sas 8 Re 3e Rs ss 3 forms Rs s oas Re e
23. FOCH0S2050 _ asp FOCHO320 50 41485 FocHoxosi 3AXD00000588487 Description installation and technical data of the FOCH filters See FOCH du at filters hardware manual 3AFE68577519 English Description installation and technical data of the NOCH filters See AOCH and NOCH du at filters hardware manual 3AFE58933368 English Sine filters Contact your local ABB representative for more information Further information Product and service inquiries Address any inquiries about the product to your local ABB representative quoting the type designation and serial number of the unit in question A listing of ABB sales support and service contacts can be found by navigating to www abb com searchchannels Product training For information on ABB product training navigate to www abb com drives and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www abb com drives and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product documents in PDF format on the Internet Go to www abb com drives and select Document Library You can browse the library or enter selection criteria for example a document code in the search field Contact us www abb com drives www abb com drivespartners 3AUA0000078093 Rev G EN EFFECTIVE 2013 07 01 Power and productivity
24. RE RD 1152 p maximum cable diameter accepted For the lead through plate hole diameters see chapter Dimension drawings M Nm e NNNM NC CN NM e citi Technical data 161 525 690 V drives US Input motor resistor and DC cable terminal screw sizes accepted wire sizes per phase and tightening torques 7 in US units are given below denotes stripping length inside the terminal Cable lead L1 L2 L3 T1 U T2 V T3 W Grounding mee RT miae Per 0 T Wire T Max phase screw Terminal wire size nut pes m m m AWG Wit oa pes 3 Cm a foer o4 os Ra 1 oss 26 13 13 1 20 2 24 oro S a E 1 177 3 300 M10 22 1 1 18 350 7 2 3 300 MCM 22 1 0 5 T 12 300 400 MCM 350 MCM 4 0 400 MCM 350 MCM Cable lead R R UDC and UDC terminals throughs 0 Screw wire am mm 17196 94 pop Lm 0 67 3 amp 1 94 oat 13 os Lm 3 24 om ee ee TM 177 2x M10 29 5 1 18 G
25. The brake chopper handles the energy generated by a decelerating motor The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected Planning the braking system Selecting the brake circuit components 1 Calculate the maximum power generated by the motor during braking Pmax 2 Select a suitable drive brake chopper and brake resistor combination for the application from the rating table on page 217 The braking power of the chopper must be greater or equal than the maximum power generated by the motor during the braking 212 Resistor braking Note A custom resistor can be selected within the limits imposed by the internal brake chopper of the drive e The resistance value of the custom resistor is at least Rmin The braking power capacity of the resistor can be calculated from the following equation where Pmax Maximum power generated by the motor during braking Upc Voltage over the resistor during braking Upc equals to 1 35 1 25 240 V DC when supply voltage is 208 to 240 V AC 1 35 1 25 415 V DC when supply voltage is 380 to 415 V AC 1 35 1 25 500 V DC when supply voltage is 440 to 500 V AC or 1 35 1 25 690 V DC when supply voltage is 525 to 690 AC R Resistor resistance ohm WARNING Never use a bra
26. What this chapter contains This chapter contains a list for checking the mechanical and electrical installation of the drive Checklist Check the mechanical and electrical installation of the drive before start up Go through the checklist together with another person WARNING Only qualified electricians are allowed to carry out the work described below Follow the complete safety instructions of the drive Ignoring the safety instructions can cause injury or death Open the main disconnector of the drive and lock it to open position Measure to ensure that the drive is not powered Check that n The ambient operating conditions meet the specification in chapter Technical data If the drive will be connected to an IT ungrounded supply network Optional EMC filters of type E200 and E202 have been disconnected Consult ABB for the instructions link of the drive have been reformed See page 134 There is an adequately sized protective earth ground conductor between the drive and the switchboard If the drive has been stored over one year The electrolytic DC capacitors in the DC 116 Installation checklist Check that There is an adequately sized protective earth ground conductor between the motor and the drive All protective earth ground conductors have been connected to the appropriate terminals and the terminals have been tightened pull conductors to check The supply voltage matches the n
27. 127 Replacing the main cooling fan of frames to R8 128 Replacing the auxiliary cooling fan of frames to R9 129 Replacing the IP55 auxiliary cooling fan of frames R8 and 130 Replacing the cooling fans of frame R9 132 Replacing the drive frames R1 to 5 133 Sais eE EE ie 134 Reforming the capacitors 135 I ee eA oh ee eee wa oe ee ale 135 Replacing the memory unit 135 Replacing the control panel battery 136 Replacing safety functions modules FSO 11 option Q973 136 11 Technical data What this chapter contains 137 Cli ee ee ee 2 137 Bue P 143 DE 143 Ambient temperature 143 21 UL Type 1 drive types and other IP55 UL Type 12 types than listed in the following subheadings 143 IP55 UL Type 12 drive types 274A 2 293A 3 and 260 5 144 IP55 UL Type 12 drive type 240A 5
28. 15V Rin 2 0 kohm Filtering 0 25 ms As outputs Total output current from 24VD is limited to 200 mA 24VD DIOx O DIOGND Reference voltage for analog inputs VREF and VREF XAI 1 and XAI 2 Analog inputs and Al2 XAI 4 XAI 7 Current voltage input mode selection by jumpers See page 107 Analog outputs AO1 and AO2 XAO Drive to drive link XD2D Safe torque off connection XSTO Control panel PC connection Technical data 165 Connector pitch 5 mm wire size 2 5 mm 10 V 196 and 10 V 1 Rigag 1 10 kohm Connector pitch 5 mm wire size 2 5 mm Current input 20 20 mA Rin 100 ohm Voltage input 10 10 V Rin gt 200 kohm Differential inputs common mode range 30 V Sampling interval per channel 0 25 ms Hardware filtering 0 25 ms adjustable digital filtering up to 8 ms Resolution 11 bit sign bit Inaccuracy 1 of full scale range Connector pitch 5 mm wire size 2 5 mm 0 20 mA lt 500 ohm Frequency range 0 300 Hz Resolution 11 bit sign bit Inaccuracy 2 of full scale range Connector pitch 5 mm wire size 2 5 mm Physical layer RS 485 Termination by switch Connector pitch 5 mm wire size 2 5 mm Current consumption per channel 55 mA continuous For the drive to start both connections must be closed OUT1 to IN1 and IN2 Connector RJ 45 Cable length lt 3 m The terminals on the board fulfil the Protect
29. 170 m 0 398 km 67 66 mohm X 170 0 082 13 94 mohm 410 V Ik2 ph 2 7 dica 67 66 mohm 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 gt The 500 V gG fuse ABB Control OFAF00H160 can be used Fuses UL UL class T fuses for branch circuit protection per NEC are listed below Fast acting class T or faster fuses are recommended in the USA Check on the fuse time current curve to ensure the operating time of the fuse is below 0 5 seconds for units of frame sizes R1 to R6 and below 0 1 seconds for units of frame sizes R7 to R9 Follow local regulations Note 1 See also mplementing thermal overload and short circuit protection on page 71 Note 2 Fuses with higher current rating than the recommended ones must not be used Smaller fuses can be used Note 3 Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table 154 Technical data Drive type Input Fuse one fuse per phase ACS880 01 current A 208 240 V EE T ___ 46 5 600 4845 T 66 5 60 Bussmann 75 5 60 Bussmann 06 2 60 Bussmann 4520 T 62 168 25 Bussmann 4825
30. 28000 690 Bussmann 170M1570 000 169 815 46500 690 Bussmann 170MS817 1 206 3 206 815 46500 690 Bussmann 170 8817 1 246A3 246 350 68500 690 Bussmann 170 8818 1 299A 295 400 405000 690 Bussmann 70MS819 1 3634 3 365 550 190000 690 Bussmann 170M5611 2 630 275000 690 Bussmann_ 1705812 2 Uy 500 V 2415 25 690 Bussmann 170 1561 000 25 130 600 Bussmann 170 156 000 65 03457 6 34 25 130 690 Bussmann 170 156 000 anes 6 48 25 130 690 Bussmann 170 156 000 0525 6 52 25 130 690 Bussmann 170 156 000 07465 776 180 690 Bussmann 170 4561 000 Technical data 147 Ultrarapid aR fuses one fuse per phase Drive Min Input use type short current A A s ACS880 circuit A IEC 60263 A 5 110 25 0 690 Bussmann 900 i20 14 40 460 690 Bussmann 1 0M1563 000 i20 21 40 460 690 Bussmann 170M1563 000 27 63 1450 690 Bussmann_ 170M1565 000 _ osas 170 34 63 1450 690 Bussmann 170 1565 000 20 40 80 2550 690 Bussmann t70M1566 000 05245 30 52 100 4650 690 Bussmann 170 1567 000 765 125 8500 690 Bussmann_ 170M1568 00
31. Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Remove the lower front cover see page 93 o Unplug the control panel power supply wires from the control unit terminal X13 and the auxiliary cooling fan power supply wires from the terminal X208 FAN2 Remove the upper front cover Release the retaining clips Lift the fan up N Qe ox Install the new fan in reverse order Make sure that the arrow on the fan points up 130 Maintenance Replacing the IP55 auxiliary cooling fan of frames R8 and R9 WARNING Follow the safety instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage Remove the IP55 front cover Remove the lower front cover from the IP55 cover Unplug the fan power supply wires Remove the fan p SL d pr N Install the new fan in reverse order Maintenance 131 132 Maintenance _ Replacing the cooling fans of frame R9 WARNING Follow the safety instructions page 14 Ignoring the instructions 4 can cause physical injury or death or damage to the equipment 1 Disconnect the drive from the power line Lock
32. Position the drive onto the screws on the wall as shown in section Frames R5 to R9 without vibration dampers on page 50 2 Put the hood onto the upper screws 3 Tighten the upper screws in the wall securely Tighten the lower screws in the wall securely Note Do not open or remove the cable entry box for easier installation The gaskets do not fulfill the degree of protenciton if the box is opened 50 Mechanical installation SN 6 7 Frames 5 to R9 without vibration dampers See the dimensions in chapter Dimension drawings Mark the locations for the four or six mounting holes Drill the mounting holes Start the screws or bolts into the mounting holes Remove the front cover For IP21 units Attach the cable entry box to the drive frame For instructions see the assembly drawing in the cable entry box A view of frame R5 is shown below Position the drive onto the screws on the wall Tighten the accessible screws in the wall securely Note If you use the lower mounting screws you can replace the drive module without unfastening the cable entry box Mechanical installation 51 52 Mechanical installation Cabinet installation See ACS880 01 cabinet installation supplement 3AUA0000145446 English Planning the electrical installation 53 Planning the electrical installation What this chapter contains Th
33. Shielded power cables are available from Belden LAPPKABEL OLFLEX and Pirelli Selecting the control cables Shielding All control cables must be shielded Use a double shielded twisted pair cable for analog signals This type of cable is recommended for the pulse encoder signals also Employ one individually shielded pair for each signal Do not use common return for different analog signals A double shielded cable figure a below is the best alternative for low voltage digital signals but single shielded b twisted pair cable is also acceptable Signals in separate cables Run analog and digital signals in separate shielded cables Never mix 24 V DC and 115 230 V AC signals in the same cable Signals allowed to be run in the same cable Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals The relay controlled signals should be run as twisted pairs Relay cable type The cable type with braided metallic screen for example OLFLEX by LAPPKABEL Germany has been tested and approved by ABB 70 Planning the electrical installation Control panel cable length and type In remote use the cable connecting the control panel to the drive must not exceed three meters 10 ft Cable type shielded CAT 5e or better Ethernet patch cable with RJ 45 ends Routing the cables Route the motor cable away from other cable routes Motor cables of several dri
34. and frame size or lt IEC 315 315 lt frame size lt IEC 400 lt 134 134 lt Py lt 469 hp and frame size or lt NEMA 500 NEMA 500 lt frame size lt NEMA 580 Non ABB motors Random Uy lt 420 V Standard N or CMF wound 1300 V and form 490 V lt Uy lt 500 V Standard du dt du dt N or CMF wound 1300 V r Reinforced N or CMF 1600 V 0 2 microsecond rise time 500 V lt Un lt 600V Reinforced du dt du dt N or CMF 1600 V or Reinforced N or CMF 1800 V 600 V lt Un lt 690 V Reinforced du dt du dt N Ou 1800 V Reinforced N CMF 2000 V 0 3 microsecond rise time Ifthe intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking check with the motor manufacturer if additional output filters are needed in the applied drive operation range 58 Planning the electrical installation The abbreviations used in the table are defined below Nominal AC line voltage Peak line to line voltage at motor terminals which the motor insulation must withstand PN Motornominalpower nominal Motor nominal power MO du dt filter at the output of the drive Available from ABB as an optional add on kit CMF Common mode filter Depending on the drive type CMF is available from ABB as an optional add on kit N end bearing insulated motor non d
35. 245 40 60 Bussmann 4840 T 310 so 60 Bussmann 1680 T a2 80 60 Bussmann 4880 61 60 Bussmann 2 640 T Dora ___ 75 125 Bussmann 464 125 60 Bussmann 464 Bussmann Haska 5 200 60 Bussmann 355 200 T 170 250 Bussmann 48250 T 206 300 60 Bussmann 355 300 T 274 400 Bussmann 45400 T 21 3 60 WSS T ___ 30 6 60 Bussmann 166 T joss 34 6 60 186 T ___ 48 60 Bussmann 4840 Domos ___ 52 Bussmann 4840 omes ___ 76 5 60 Bussmann maos n 20 60 Bussmann 4820 T ___ 4 25 Bussmann 4825 ___ 21 5 Busmam JuS 35 x 40 Busmam 4840 T so 60 Busmam 4850 40 60 60 Bussmann 4880 5 so 60 Bussmann 4880 osas 65 90 60 Bussmann 4890 _ mo 60 Bussmann T 124 20 60 Bussmann 355200 T ___ 156 25 60 Bussmann T 240 350 600 Bussmann 45350 T 26045 20 400 60 Bussmann 35400 T Technical data 155 Drive type Input Fuse one fuse p
36. D D lei 88 Electrical installation Connection procedure for frames R4 and R5 Remove the front cover 21 units Release the retaining clip with a screwdriver a and lift the cover from the bottom outwards b For 21 drives Remove the cable entry box cover by undoing the mounting Screw For frame R4 Remove the EMC shroud that separates the input and output cabling if needed for earier installation Remove the shroud on the power cable terminals by releasing the clips and lifting the shroud up from the sides with a screwdriver a Knock out holes in the shroud for the cables to be installed b Attach the residual voltage warning sticker in the local language next to the control unit top Cut adequate holes into the rubber grommets Slide the grommets onto the cables Slide the cables through the holes of the bottom plate and attach the grommets to the holes Prepare the ends of the input power and motor cables as illustrated in the figure Note Bare shield will be grounded 360 degrees under the grounding clamp Ground the cable shields 360 degrees under the grounding clamps Connect the twisted cable shields to the grounding terminals 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 fr
37. Frame R8 cable entry box IP21 UL Type 1 46 Frame R9 cable entry box IP21 UL Type 1 47 installing drive eee eee ee 48 Frames RTIORA EDI 48 Frames R4 and R7 UL Type 12 49 Frames R5 to R9 without vibration dampers 50 CabinetriastaliaHioni acea ace 52 5 Planning the electrical installation What this chapter contains 53 Limitation of i cous Sere at eS dine he eh i 53 Selecting the supply disconnecting device 53 8 cede ok oe 54 Gg PCT De A 54 Selecting and dimensioning the main contactor 54 Checking the compatibility of the motor and drive 54 Protecting the motor insulation and bearings 55 Requirements table 55 Additional requirements for ABB motors of types other than M2_ M3_ M4_ HX Lalli eer ee 58 Additional requirements for ABB high output and IP23 motors 59 Additional requirements for non ABB high output and IP23 motors 60 Additional data for calculating the rise ti
38. N CMF 1800 V Reinforced N CMF N CMF 2000 V 0 3 microsecond rise time If the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking check with the motor manufacturer if additional output filters are needed in the applied drive operation range Planning the electrical installation 61 Additional data for calculating the rise time and the peak line to line voltage If you need to calculate the actual peak voltage and voltage rise time considering the actual cable length proceed as follows Peak line to line voltage Read the relative Uy value from the appropriate diagram below and multiply it by the nominal supply voltage Uy e Voltage rise time Read the relative values Uy and du dt Uy from the appropriate diagram below Multiply the values by the nominal supply voltage Un and substitute into equation t 0 8 du dt 62 Planning the electrical installation 7 8 pirewn OOO Note ULL and du dt values are approximately 20 higher with resistor braking Planning the electrical installation 63 Additional note for sine filters Sine filters protect the motor insulation system Therefore du dt filter can be replaced with a sine filter The peak phase to phase voltage with the sine filter is approximately 1 5 Selecting the power cables General rules Select the input power a
39. cable or drive are listed below Either fuse type can be used for frames R1 to R6 if it operates rapidly enough 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 ultra rapid aR fuses must be used Note 1 See also mplementing thermal overload and short circuit protection on page 71 Note 2 Fuses with higher current rating than the recommended ones must not be used Smaller fuses can be used Note 3 Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table aR fuses frames R1 to R9 Ultrarapid aR fuses one fuse per phase Min Input short current V Type Type circuit A IEC 60263 current 1 A Ux 208 240 V foans 2 9 46 6 48 690 Bussmann 170MT559 000 A62 66 48 690 Bussmann 170MT559 000 foras 2 30 75 6 48 690 Bussmann 170 4558 000 53 106 20 78 690 Bussmann 170MT560 000 65 168 25 130 690 Bussmann 170 4561 000 120 243 40 460 690 Bussmann 170 4563 000 fosia2 160 310 50 770 690 Bussmann 170M1564 000 A62 280 46 50 2550 690 Bussmann 170M1566 000 2 300 6i 100 2450 690 Bussmann TOMGBI2 1 jorsa2 380 75 125 3700 690 Bussmann 1
40. control cables 99 Default I O connection 100 NOS fe Sexe ees Eh irreale 101 Jumpers and switches 101 External power supply for the control unit XPOW 102 and Al2 as Pt100 and KTY84 sensor inputs 102 Drive to drive link 020 103 DL WE QS ZAI 103 016 XDI 6 as PTC sensor 104 Sale torque off Ss 104 Safely MUNCIONS LA T2 ee 104 Control cable connection procedure 105 si cerere are week bse re Gras ee Dae 107 Chaining a control panel to several drives 108 IPSS UE Type 12 44 cick dob ici eee Rad eee 109 Installing Optional modlBS e Rd bd eiat 109 Mechanical installation of I O extension fieldbus adapter and pulse encoder interface 109 Wiring I O extension fieldbus adapter and pulse encoder interface modules 110 Installati
41. disabled with a parameter refer to the firmware manual Residual current device compatibility The drive is suitable to be used with residual current devices of Type B Note The EMC filter of the drive includes capacitors connected between the main circuit and the frame These capacitors and long motor cables increase the ground leakage current and may cause fault current circuit breakers to function Implementing the Emergency stop function For safety reasons install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed You can use the Safe torque off function of the drive to implement the Emergency stop function See chapter Safe Torque off function on page 197 Note Pressing the stop key Q on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential Implementing the Safe torque off function See chapter Safe Torque off function on page 197 Implementing the Safety functions options The drive can be equipped with a safety functions module as factory installed option Q973 The module is also available as a retrofilt kit The safety functions module includes for example the following functions Safe torque off STO Safe brake control SBC and Safely limited speed SLS The option uses the internal Safe torque off function of the drive For the installation of the safety functions mo
42. for controlling asynchronous AC induction motors permanent magnet synchronous motors and AC induction servomotors 28 Operation principle and hardware description Main circuit The main circuit of the drive is shown below ACS880 01 5 A R UDC UDC R Rectifier Converts alternating current and voltage to direct current and voltage DC link DC circuit between rectifier and inverter Inverter Converts direct current and voltage to alternating current and voltage Brake chopper Conducts the surplus energy from the intermediate DC circuit of the drive to the brake resistor when necessary The chopper operates when the DC link voltage exceeds a certain maximum limit The voltage rise is typically caused by deceleration braking of a high inertia motor User obtains and installs the brake resistor when needed Operation principle and hardware description 29 Layout IP21 UL Type 1 The components of the standard 21 drive are shown below view of frame R5 Control panel Front cover Cable entry box N gt Four fastening points at the back of the unit Heatsink 6 Lifting holes 30 Operation principle and hardware description Layout IP55 The components of the IP55 drive option B056 are shown below view of frame R4 1 Control panel behind the control panel cover 2 Front cover 3 Four fastening points at the back of the unit 4 Heatsink 5 L
43. helix of copper tape or copper wire The better and tighter the shield the lower the emission level and bearing currents Additional US requirements Use type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used For the North American market 600 V AC cable is accepted for up to 500 V AC 1000 V AC cable is required above 500 V AC below 600 V AC For drives rated over 100 amperes the power cables must be rated for 75 C 167 F Conduit Couple separate parts of a conduit together bridge the joints with a ground conductor bonded to the conduit on each side of the joint Also bond the conduits to the drive enclosure and motor frame Use separate conduits for input power motor brake resistor and control wiring When conduit is employed type MC continuous corrugated aluminum armor cable or shielded cable is not required A dedicated ground cable is always required Note Do not run motor wiring from more than one drive in the same conduit Planning the electrical installation 69 Armored cable shielded power cable Six conductor 3 phases and 3 ground type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers trade names in parentheses e Anixter Wire amp Cable Philsheath BICC General Corp Philsheath Rockbestos Co Gardex Oaknite CLX
44. in in frames R4 and R5 155 mm 6 10 in in frames R7 Note For more information on dimensions see chapter Dimension drawings 200 mm 7 87 in free space is required at top of the drive 300 mm 11 81 in free space when measured from the drive base without the cable entry box is required at bottom of the drive Technical data 157 Losses cooling data and noise Drive type Air flow Heat ACS880 01 dissipation BA 208 240 V 4462 06462 07452 10462 16 8 2 2483 0372 046A 2 0672 075A2 087A2 115A 2 Re 25 8 145A 2 Re 2 8 1260 2062 1500 2742 Re so 20 Uy 380 415 V 245 0383 3 0480 3 2586 3 TAS TE 1246 3 IAS 0253 03243 2 5 8 39 e wr 158 Technical data Drive type Air flow Heat ACS880 01 dissipation w 2993 363 3 Re 1150 4800 68 _ 4308 3 Re 1150 6000 UN 7 440 500 V 02 1 5 03A0 5 03A4 5 04A8 5 052 5 OTAG TAOS 021 5 027A 5 034A 5 0404 5 052A 5 065A 5 1117 077A 5 1120 096A 5 Re 45 256 1295 124 5 Re 45 256 140 1564 8 1940 180 5 2310 240 5 R amp 550 324 3300 2608 5 550 324 3900 302 5 Re 1150 20 3614 5 Re 1150 0 88 _ 41455 Re 1150 6000 68 UN 525 690 V 07A37 09A87 1402 7 R amp 28 939 62
45. is used in the safety value calculations 670 on off cycles per year with T 71 66 C 1340 on off cycles per year with 61 66 C 30 on off cycles per year with 7 10 0 C 32 board temperature at 2 0 of time CO 59 WI WY GW CO CO CW 59 WY WY WY GW GW CO C2 60 C board temperature at 1 5 of time e 85 C board temperature at 2 3 of time The STO is a type A safety component as defined in IEC 61508 2 Relevant failure modes The STO trips spuriously safe failure e 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 No accumulated failures have been analyzed 208 Safe Torque off function e STO reaction time shortest detectable break 1 ms e STO response time 2 ms typical 5 ms maximum Fault detection time Channels in different states for longer than 200 ms Fault reaction time Fault detection time 10 ms e STO fault indication parameter 31 22 delay lt 500 ms e STO warning indication parameter 31 22 delay lt 1000 ms Safe Torque off function 209 Certificate TuV NORD Certificate T V NORD Systems GmbH amp Co KG hereby cortifies ABB Oy Hiomatie 13 21 00381 Helsinki Finland that the realization of the safety function Safe Torque
46. requirements for CE and other markings Dimension drawings contains dimension drawings of the drives and auxiliary components Safe Torque off function describes the Safe torque off function of the drive and gives instructions on its implementing Resistor braking describes selection protection and wiring of brake choppers and resistors The chapter also contains technical data Common mode du dt and sine filters describes selection external filters for the drive Related manuals See List of related manuals on the inside of the front cover Categorization by frame size and option code The instructions technical data and dimension drawings which concern only certain drive frame sizes are marked with the symbol of the frame size R1 R2 etc The frame size is marked on the type designation label The instructions and technical data which concern only certain optional selections are marked with option codes such as E200 The options included in the drive can be identified from the option codes visible on the type designation label The option selections are listed in section designation key on page 35 Introduction to the manual 23 Quick installation start up and operating flowchart Task See Plan the electrical installation and acquire the Planning the electrical installation accessories needed cables fuses etc page 53 Check the ratings required cooling air flow input Technical data page 137
47. requirements stated for drives See section Compliance with the EN 61800 3 2004 below 1 0 Technical data Compliance with the European RoHS Directive The RoHS Directive defines the restriction of the use of certain hazardous substances in electrical and electronic equipment Compliance with the European Machinery Directive The drive is an electronic product which is covered by the European Low Voltage Directive However the drive includes the Safe torque off function and can be equipped with other safety functions for machinery which as safety components are in the scope of the Machinery Directive These functions of the drive comply with European harmonized standards such as EN 61800 5 2 The declaration of conformity is shown below Technical data 171 Declaration of Conformity Declaration of Conformity According to Machinery Directive 2006 42 EC Manufacturer ABB Oy Drives Address Hiomotie 13 Box 184 FIN 00381 Helsinki Finland hereby declares that product 5880 01 with regard to the following safaty functions Safe torque olf Sate stop 1 with option code 0973 Safe stop emergency with option code 0973 Safely limited speed with option code 0973 Sale maximum speed with option code 0973 Safe brake control with option code 0973 fulfil all the relevant safety component requirements of EC Machinery Directive 2006 42 EC when the listed safety functions are used for safety co
48. start command to verify that the STO function blocks the drive operations The motor should not start Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Test the operation of the STO function when the motor is running Start the drive and make sure the motor is running Open the STO circuit The motor should stop The drive generates an indication if one is defined for running state in parameter 31 22 see the firmware manual Reset any active faults and try to start the drive Make sure that the motor stays at standstill and the drive operates as described above in testing the operation when the motor is stopped Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Document and sign the acceptance test report which verifies that the safety function is safe and accepted for operation Safe Torque off function 205 Use 1 Open the activation switch or activate the safety functionality that is wired to the STO connection 2 STO inputs on the drive control unit de energize and the drive control unit cuts off the control voltage from the inverter IGBTs 3 The control program generates an indication as defined by parameter 31 22 refer to the firmware manual of the drive 4 Motor coasts to stop if running The drive will not restart while the activation switch or safety relay contacts are open 5 Dea
49. temperature sensor must be isolated from the I O terminals Electrical installation 103 Drive to drive link XD2D The drive to drive link is a daisy chained RS 485 transmission line that allows basic master follower communication with one master drive and multiple followers Set termination activation jumper J3 see section Jumpers and switches above next to this terminal block to the ON position on the drives at the ends of the drive to drive link On intermediate drives set the jumper to the OFF position Use shielded twisted pair cable 100 ohm for example PROFIBUS compatible cable for the wiring For best immunity high quality cable is recommended Keep the cable as short as possible the maximum length of the link is 50 meters 164 ft Avoid unnecessary loops and running the cable near power cables such as motor cables The following diagram shows the wiring of the drive to drive link DIIL input XD24 1 The DIIL input can be selected as the source of for example an emergency stop command or an external event See the firmware manual for more information 104 Electrical installation DI6 XDI 6 as PTC sensor input PTC sensors can be connected to this input for motor temperature measurement as follows The sum of the sensor resistances must not exceed the threshold resistance of the digital input at the motor normal operating temperature Do not connect both ends of the cable shield directly to g
50. the control unit is powered from an external power source After power up the drive will scan the memory unit If different parameter settings are detected they are copied to the drive This may take several minutes Replacing the memory unit Undo the memory unit mounting screw and take the memory unit up Replace the unit in reverse order Note There is a spare screw next to the memory unit slot 136 Maintenance Replacing the control panel battery The battery is housed on the rear of the control panel Replace with a new CR 2032 battery Dispose the old battery according to local disposal rules or applicable laws Replacing safety functions modules FSO 11 option Q973 Do not repair safety functions modules Replace a faulty module with a new one as described under nstallation of safety functions modules on page 111 Technical data 137 Technical data What this chapter contains This chapter contains the technical specifications of the drive for example the ratings sizes and technical requirements provisions for fulfilling the requirements for CE and other markings Ratings The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below The symbols are described below the table IEC RATINGS Drive type Output ratings ACS880 Light overload Heavy duty use 01 use hw max n Pu ha Pha _ A kw KW Ux
51. the main disconnecting device and ensure by measuring that there is no voltage 2 Undo the two mounting screws of the fan mounting plate view from drive bottom below Turn the mounting plate downwards Disconnect the fan power supply wires Remove the fan mounting plate Remove the fan by undoing the two mounting screws pU D JM 9 Install the new fan in reverse order Maintenance 133 Replacing the drive frames R1 to R5 This section gives instructions for replacing the drive module without the cable entry box You can replace the drive with or without its cable entry box The latter option allows you to leave the cables installed except from disconnecting the conductors WARNING Follow the safety instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Remove the front covers See section Connection procedure for frames R1 to R3 on page 85 or Connection procedure for frames R4 and 5 on page 88 Disconnect the power and control cables Undo the screw s that fasten drive module to the cable entry box Undo the two screws that fasten drive module to the wall from top Lift the drive off 3 4 5 6 T he principle of undoing the mounting screws in frames R1 to R3 is shown below view of an IP21 uni
52. to 40 to 70 C 40 40 to 70 C 40 131 F to 158 F to 158 F No frost allowed See section Ratings Relative humidity humidity is 60 in the presence of corrosive gases Contamination levels IEC 60721 3 3 IEC 60721 3 2 Chemical gases Chemical gases Chemical gases IEC 60721 3 1 Class 3C2 Class 1C2 Class 2C2 Solid particles Solid particles Solid particles Class 352 Class 153 Class 252 168 Technical data Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa 0 7 to 1 05 0 7 to 1 05 0 6 to 1 05 atmospheres atmospheres atmospheres Vibration IEC 60068 2 Max 1 1 3 5 0 04 0 04 0 14 in 5 13 2 2 5 13 2 2 2 to 9 Hz max 7 m s max 7 m s max 15 m s 23 1 52 23 1 52 49 ft s 13 2 to 100 Hz 13 2 to 100 Hz 9 to 200 Hz sinusoidal sinusoidal sinusoidal Shock IEC 60068 2 27 Not allowed 100 m s 100 m s 330 ft s 11 ms 330 ft s 11 ms Not allowed 100 mm 4 in for 100 mm 4 in for weight over 100 weight over 100 kg 220 Ib kg 220 Ib Materials Drive enclosure PC ABS 3 mm color NCS 1502 Y RAL 9002 PMS 1C Cool Grey and RAL 9017 PC 10 GF 3 0mm Color RAL 9017 in frames R1 to R3 only hot dip zinc coated steel sheet 1 5 to 2 5 mm thickness of coating 100 micrometers color NCS 1502 Y Package Plywood and cardboard Foam cushions PP E bands PP Dis
53. which can result in physical injury and or damage to the equipment A Electrostatic sensitive devices warning warns of electrostatic discharge which can damage the equipment 14 Safety instructions Safety in installation and maintenance Electrical safety These warnings are intended for all who work on the drive motor cable or motor WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment Only qualified electricians are allowed to install and maintain the drive e Never work on the drive motor cable or motor when main power is applied After disconnecting the input power always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive motor or motor cable Always ensure by measuring with a multimeter impedance at least 1 Mohm that voltage between drive input phases L1 L2 and L3 and the frame is close to 0 V voltage between terminals UDC and UDC and the frame is close to O V e Do not work on the control cables when power is applied to the drive or to the external control circuits Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off e Do not make any insulation or voltage withstand tests on the drive Do not connect the drive to a voltage higher than what is marked on the type designation label High
54. 0 7777 125 8500 690 Bussmann_ 170M1568 000 796 160 16000 690 _Bussmann_ 170M1569 000 1248 5 7124 200 28000 690 Bussmann 170M1570 000 156A 156 215 46500 690 Bussmann 170 3817 1 180 5 77180 315 46500 690 _ _ 170 3817 1 7240 350 68600 690 Bussmann_ 170M3618 1 260 400 105000 690 Bussmann_ 170M3670 __1__ 361 550 190000 690 Bussmann 170MS6T1 2 7444 650 275000 690 Bussmanm_ 170MS612 2 Dr 40 73 16 48 600 Bussmann 170W1559 000 53 98 20 78 690 Bussmann 170 1560 000 anor 94 142 32 270 Bussmann 170 1562 000 i20 18 40 460 690 Bussmann 170M1563 000 _ 160 160 170 22 so 770 690 Bussmann 170M1564 000 _ 26 so 770 690 Bussmann 170 1564 000 35 63 1450 690 Bussmann_ 170M1565 000 42 80 2550 690 Bussmann_ 170M1566 000 7749 80 2550 690 Bussmann_ 170M1566 000 7 81 125 8500 690 Bussmann_ 170M1568 000 7784 160 16000 690 Bussmann_ 170M1569 000 98 1601 16000 690 Bussmann_ 170M1569 0 OAT 77119 200 15000 690 Bussmann 170 3815 1 14247 142 250 28500 690 Bussmann 170 3816 1 _ 77174 815 46500 690 Bussmann 1 _ OKT 1610 210 400 74000 690 Bussmann 1705808 2 aria 1610 271 400 74000 690 Bus
55. 0 124 160 185000 500 ABB 160 00 07457 73 16 1200 690 ABB 0006616 000 45 98 20 2400 690 ABB OFAA0006G20 000 90 142 25 4000 690 ABB OFAAO00GG25 000 280 18 35 12000 690 ABB OFAAO00GGS5 000 aso 22 50 24000 690 ABB OFAA000GGS0 000 26 50 24000 690 ABB OFAA0008G50 000 38 83 30000 690 ABB OFAA0006G63 000 42 51000 690 ABB OFAAOGGB0 0 49 51000 690 ABB OFAAOGGB0 o 1 minimum short circuit current of the installation 150 Technical data Quick guide for selecting between gG and aR fuses The combinations cable size cable length transformer size and fuse type in this table fulfil the minimum requirements for the proper operation of the fuse Use this table to select between gG and aR fuses or calculate the short circuit current of the installation as described under Calculating the short circuit current of the installation on page 752 ACS880 kVA with gG fuses with aR fuses 315 __ _ tt 1 12 0662 oas 22 24 tt 12 O52 as 33 12 10462 oas t9 18 55 58 18 18 masa oe o7 M 938 35 ato M 2 46 7 2
56. 04 113 F the rated output current is derated by 1 for every added 1 C 1 8 F In the temperature range 45 55 C 113 131 F the rated output current is derated by 2 5 for every added 1 C 1 8 F The output current can be calculated by multiplying the current given in the rating table by the derating factor k 0 70 15 C 40 45 C 50 C 55 59 F 104 F 113 542296 131 F IP55 UL Type 12 drive type 240A 5 In the temperature range 40 50 C 104 122 F the rated output current is derated by 1 for every added 1 C 1 8 F In the temperature range 50 55 C 122 131 F the rated output current is derated by 2 5 for every added 1 C 1 8 F The output current can be calculated by multiplying the current given in the rating table by the derating factor k 0 75 15 C 440 C 45 C 50 C 55 59 F 104 113 F 122 F 131 F Technical data 145 Altitude derating At altitudes from 1000 to 4000 m 3300 to 13123 ft above sea level the continuous output currents given above must be derated 1 for every 100 m 328 ft For a more accurate derating use the DriveSize PC tool Low noise control mode derating When low noise drive control mode is used the motor and braking powers are derated Please contact ABB for more information Fuses IEC gG and fuses for protection against short circuit in the input power
57. 112 10 Connect the other wires as shown FSO 11 user s manual 34UA0000097054 English 112 Electrical installation Electrical installation 113 Installation next to the control unit in frames R7 to R9 WARNING Follow the safety instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Remove the front cover see page 94 3 Insert the module carefully into its position 4 Attach the module with four screws Note Correct installation of the grounding screw a is essential for fulfilling the EMC requirements and for proper operation of the module 5 Tighten the grounding screw of the electronics 6 Connect the data communication cable to slot X110 on the module and to connector X12 on the drive control unit 7 Connect the Safe torque off wires to connector X111 on the module and to connector XSTO on the drive module control unit as shown in section Wiring on page 198 8 Connect the external 24 V power supply cable to connector X112 9 Connect the other wires as shown in FSO 11 user s manual 0 0000097054 English 114 Electrical installation EER Eb E J N 5 5 ENTE EZ Installation checklist 115 Installation checklist
58. 1300 500 OFAFOOOHGS 000 061A3 800 6 50 57000 500 OFAFOOOHEO 000 072A3 1000 72 100 63600 500 OFAF000H100 _000_ 087A3 1000 87 100 63600 500 OFAFO00H100 _000_ 1300 105 125 108000 500 ABB OFAFOOHT25 00 A53 1700 145 185000 500 ABB OFAFOOHT60 00 B B Technical data 149 gG fuses one fuse per phase st NN short circuit current size 500 V 7 21 s 500 ABB OFAFOOOHA 000 40 30 6 50 ABB OFAFOOOH6 000 08445 40 6 50 ABB 000_ so 48 10 365 S00 ABB OFAFOCOHIO 000_ josaas so 52 10 365 500 ABB OFAFOCOHIO 000_ 76 16 700 S00 ABB OFAFOOOHI6 000 110 16 700 S00 ABB OFAFOOOHI6 000 200 14 28 2500 500 ABB 25 000 250 21 32 4500 500 ABB OFAFO00H32 000 350 27 7700 500 ABB OFAFO00H4O 000 400 34 50 15400 500 OFAF000HSO 000 500 40 63 21300 500 ABB OFAFO00H63 000 52 37000 500 ABB OFAFOOHEO 000 1000 65 100 63600 500 ABB OFAFO00H100 000 1000 77 100 63600 S00 ABB OFAFOO0H100 000 1300 96 125 103000 500 ABB 125 00 _ 124A5 170
59. 19 Common mode du dt and sine filters What this chapter contains This chapter describes how to select external filters for the drive Common mode filters When is a common mode filter needed See section Checking the compatibility of the motor and drive page 54 A common mode filter kit is available from ABB with order number is 64315811 for the drive The kit includes three wound cores For installation instructions of the cores see the instruction included in the core package du dt filters When is a du dt filter needed See section Checking the compatibility of the motor and drive page 54 222 Common mode du dt and sine filters du dt filter types Drive type du dt filter type Drive type du dt filter type Drive type du dt filter type ACS880 01 ACS880 01 ACS880 01 380 415 V 500 V 525 690 V NOCH0016 6X NOCH0016 6X NOCH0016 6X NOCH0030 6X NOCH0030 6X NOCH0030 6X NOCH0070 6X NOCH0070 6X NOCH0070 6X NOCH0120 6X NOCH0120 6X NOCH0120 6X 260 70 260 70 260 70 260 70 260 70 1693 FOCHO260 70 15685 2070 __ 20843 FOCHO260 70 18085 FOCHOZ6070 246A 3 FOCHO260 70 240A5 FOCHOZ6070 293433 25085 FOCHO26070 31SA S FOCHOS20 50 30245 FOCH0S2050 FOCHO320 50 3614
60. 208 240 V 6462 Ri 66 78 66 1i 11 46 075 R 7s n2 75 15 71 15 66 8 45 o ize er m 2 7 138 Technical data IEC RATINGS Drive type Output ratings ACS880 m uda Heavy duty use 01 RE tas 16 9 39 5 S Hask2 Re 145 178 Ms 37 138 37 105 300 mua 274 274 260 75 zs 55 5483 Ri 56 88 56 22 83 22 40 15 oos mi 72 95 72 68 30 56 22 Ri 94 122 94 40 89 40 72 30 ms 72 104 72 68 61 moas R 105 148 105 55 100 55 8 45 Haska R 145 178 Ms 75 138 75 105 55 meas Rr i9 247 161 90 145 75 Rr 206 27 206 1 169 90 _ 24643 Re 246 350 246 192 234 132 206 29343 293 48 293 160 276 160 246 192_ 136343 89 363 498 363 200 345 200 295 160 43043 Ro 430 545 450 250 400 200 3637 200 Technical data 139 IEC RATINGS Drive type Output ratings ACS880 eo Heavy duty use 01 Uy 380 500 V esso n 465 Ri 48 48 22 46 22 34 15 5 Re 148 06 55 9i 55 77 45 Hzaks Re 124 17a 124 75 M8 75 96 55 Hsexs Rr 15
61. 5 100 Electrical installation Default I O connection diagram XPOW External power input Wire sizes 0 5 2 5 mm E o 24 C2 24 12 AWG XAI Reference voltage and analog inputs Tightening VREF 10 V DC R 1 10 kohm torques 0 5N m VREF 10 V DC 1 10 kohm 5 Ibf in for both oo DUNG 7 d d Speed reference 0 2 10 V Ri gt 200 kohm solid wiring By default not in use 0 4 20 mA R gt 100 2 current voltage selection jumper Al2 current voltage selection jumper Motor speed rpm 0 20 mA lt AGND 500 ohm Motor current 0 20 mA lt 500 ohm 1 2 Drive to drive link 3 BGND Drive to drive link termination switch XRO1 XRO2 XRO3 Relay outputs NC Em Ready 250 V AC 30 V DC 2A NC Running 250 V AC 30 V DC Faulted 1 250 V 30 V DC XD24 Digital interlock 1 2 3 4 5 XDIO Digital input outputs 1 2 Output Running XDI Digital inputs Stop 0 Start 1 Forward 0 Reverse 1 DI6 Bydefaultnotinuse XSTO Safe torque off Safe torque off Both circuits must be closed for the drive to start X12 Safety functions module connection X13 Control panel connection X205 Memory unit connection See the next page for the notes Electrical installation 101 Notes 1 Current 0 4 20 mA Rin gt 100 ohm or voltage 0 2 10 V Rin gt 200 kohm input sele
62. 6 18 SACEWREM 44 20 1 ACS880 01 09A8 7 8 18 SACEBREM 44 210 1 ACSRRDGTAAAZT m 38 SACEDREM ACS880 01 018A 7 17 18 SACENSRE22 2 amp 0 2 ACS880 01 022A7 23 18 SACEISREz2 22 420 2 2 Resistor braking 219 Fa Pron om Drive type Internal brake Example brake resistor s chopper ACS680 01 098A 7 _90_ 8 SAFURSUFSIS 8 1800 45 rAcseao o7 110a 7 10 8 SAFUR60F575 1600 45 ACSBB0 01 142A 7 132 6 SAFUR80F500 6 2400 6 ACS6B0 01 174A 7 _160 6 SAFUR80F500 6 2400 6 ACSBBCOIAIDAT 200 4 SAFURI25F500 4 3600 9 ACS6B0 01 271A 7 _250 4 SAFURI25F500 4 5600 9 _ 3AXD00000588487 Ppreont The internal brake chopper will withstand this continuous braking power Rmin The minimum allowed resistance value of the brake resistor R Resistance value for the listed resistor assembly En Short energy pulse that the resistor assembly withstands every 400 seconds Continuous power heat dissipation of the resistor when placed correctly Connected in series 2s Connected in paralell The rating apply at an ambient temperature of 40 C 104 F Degree of protection of JBR SACE and SAFUR resistors Terminals and cable lead through data See section Terminal and lead through data for the power cables on page 160 220 Resistor braking Common mode du dt and sine filters 221
63. 6 247 i56 00 128 75 045 Rr 287 180 iri mo 156 90 _ 24045 240 350 240 192 226 132 180 2605 Re 260 418 260 160 247 160 240 132 36145 Ro 361 52 361 200 343 200 302 200 maas Ro 414 ata 250 393 250 361 200 140 Technical data IEC RATINGS Drive type Output ratings ACS880 m uda Heavy duty use 01 Uy 660 690 V UL IN DAMM NE RS 73 122 78 55 9 55 88 4 ns 98 18 98 75 93 75 73 55_ ms 2 22 142 188 98 75 a a an et eT 042A 7 R5 42 74 42 37 40 37 35 30 Re 61 1M ei 5 56 55 49 4 ORAT R M X4 M 75 80 75 61 s osar Rr 98 9 90 93 90 84 75 moar Rr no 198 H9 mo ms mo 98 90 Re 142 250 142 132 1 132 Rs iva 274 v 160 165 160 42 132 210 210 200 200 200 174 160 Ro 2 271 250 257 250 20 200 3AXD00000588487 Technical data 141 NEMA RATINGS Drive type Output ratings 5 Lim Hw wi Un 208 240 V 0962 Ri 66 78 63 15 46 075 10 RT 75 r1 15 20 86 15 msa2 rRe ns
64. 67 gt 168 OE MANIAC 169 Compliance with the European Low Voltage Directive 169 Compliance with the European EMC Directive 169 Applicable Standards cedo te mee EUR ac tan 169 Compliance with the European RoHS Directive 170 Compliance with the European Machinery Directive 170 Declaration of Conformity 171 Compliance with the EN 61800 3 2004 173 ok 173 OZ Pekan ae wake 173 suite Leelee REL eterea 174 CHIEN i E Ia 174 UP ARINC siae iii 175 UL checklist PE 175 CORMANO MP 176 176 GOST R Cenilicate Of 4 2 cot 176 DisclaiMer lider ener i bi ae 176 10 12 Dimension drawings What this chapter contains 177 Frame R1 IP21 UL Type 1 178 Frame 2 P21 UL Type T ata pa RR cenis 179 Frame UL cusa iink we e a e SOR ea 180 Frame Aaa 181 Frame
65. 708818 1 146 Technical data Ultrarapid aR fuses one fuse per phase Min Input short current A A2s V Type Type circuit A IEC 60263 current 1 A 380 87 125 3700 690 Bussmann WOMSBIS 1 500 118 160 7500 690 Bussmann WOMGBi 1 700 145 200 15000 690 Bussmann WOMGBIS 1 i70A 2 1000 170 250 28500 690 Bussmann 170 3818 1 2062 1280 206 315 46500 690 Bussmann 1 274 400 105000 690 Bussmann 170 819 1 y Uy 380 415 V 24 130 6901 Bussmann 170 1561 900 25 130 600 Bussmann 1701561 000 40 25 130 600 Bussmann 170 1864 000 756 25 130 60 Bussmann_ 1701561 000 772175 130 690 Bussmann 1701561 000 94 25 130 690 Bussmann 1701561 000 126 25 130 690 Bussmann 1701561 000 717 40 460 600 Bussmann 701563 000 _ 25 40 460 690 Bussmann 701563 000 32 es 1450 690 Bussmann 17011565 000 78 63 1450 690 _Bussmann_ 1701565 000 ossaa 20 45 80 2550 690 Bussmann 170 4566 000 380 61 100 4650 690 Bussmann 170 4567 000 480 72 125 8500 690 Bussmann 170 1568 000 087A 3 7 87 25 8500 690 Bussmann 170 1568 000 7105 760 16000 690 Bussmann 170 1560 000 1583 145 200
66. 80 01 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 see page 63 360 degree grounding is recommended if shielded cable is used Ground the other end of the input cable shield or PE conductor at the distribution board 360 degree grounding is required External brake resistor Use a separate grounding cable if the shield does not meet the requirements of IEC 61439 1 see page 63 and there is no symmetrically constructed grounding conductor in the cable see page 68 7 filter or sine filter optional see 227 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 see page 63 Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear Electrical installation 85 Connection procedure for frames R1 to R3 1 Undo the mounting screws at the sides of the front cover 2 Remove the cover by sliding it forward 3 Attach the residual voltage warning sticker in the local language to the control panel mounting platform 4 Remove the rubber grommets from the lead through plate for the cables to be connected 5 21 un
67. ABB industrial drives ACS880 01 drives 0 55 to 250 kW 0 75 to 350 hp Power and productivity ED for a better world PA List of related manuals Drive hardware manuals and guides Code English ACS880 01 hardware manual 3AUA0000078093 ACS880 01 quick installation guide for frames R1 to 3AUA0000085966 ACS880 01 quick installation guide for frames R4 and R5 3AUA0000099663 ACS880 01 quick installation guide for frames R6 to R9 3AUA0000099689 ACS880 01 cabinet installation supplement 3AUAO0000145446 ACS880 01 assembly drawings for cable entry boxes of 3AUA0000119627 IP21 frames R5 to R9 ACS AP x assistant control panels user s manual 3AUA0000085685 Drive firmware manuals and guides ACS880 primary control program firmware manual 3AUA0000085967 Quick start up guide for ACS880 drives with primary 3AUA0000098062 control program Option manuals and quides Manuals and quick guides for I O extension modules fieldbus adapters etc You can find manuals and other product documents in PDF format on the Internet See section Document library on the Internet on the inside of the back cover For manuals not available in the Document library contact your local ABB representative The QR code below opens an online listing of the manuals applicable to this product ACS880 01 manuals Hardware manual ACS880 01 drives 0 55 to 250 kW 0 75 to 350 hp 2013 ABB Oy All Rights Reserved 3AUA0000078093 Re
68. Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods EN 61800 5 1 2007 Adjustable speed electrical power drive systems Part 5 1 Safety requirements electrical thermal and energy EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional UL 508C 2002 UL Standard for Safety Power Conversion Equipment third edition NEMA 250 2008 Enclosures for Electrical Equipment 1000 Volts Maximum CSA C22 2 No 14 10 Industrial control equipment GOST R 51321 1 2007 Low voltage switchgear and control gear assemblies Part 1 Requirements for type tested and partially type tested assemblies General technical requirements and methods of tests CE marking A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage EMC and RoHS Directives The CE marking also verifies that the drive in regard to its safety functions such as Safe torque off conforms with the Machinery Directive as a safety component Compliance with the European Low Voltage Directive The compliance with the European Low Voltage Directive has been verified according to standards EN 60204 1 and EN 61800 5 1 Compliance with the European EMC Directive The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 2004 covers
69. CO 1 DI lt PT eh E LiMn SS zi 8 4 i Ee Y EX ee E m 2 199 69 lt lt gt CO a MR di 99 LC 0 lt lt ce OD pe 2 c 194 Dimension drawings Frame R8 IP55 UL 12 e 3AUA0000073150 Fie Sc 859 Ck dx 10 33 SUGGESTED MUUNTING HOLES 18 8 4 35 he 04 3 95 kga EL 450 17 78 LIFTING PUINTS 4 PCS 9 91 00 1 791 18621 879 28920 189 25 1 981 106 6 596 62 12 44 108 71 90 3 54 65 2 54 300 11 81 _ a 90 3541 865 cpl Lele 75 S620 5 7 L88 See 18 14 631 Dimension drawings 195 Frame 9 55 UL 12 1
70. EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality First environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Drive of category C2 drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment Note A professional is a person or organization having necessary skills in installing and or starting up power drive systems including their EMC aspects Drive of category C3 drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment Drive of category C4 drive of rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Category C2 The drive complies with the standard with the following provisions 1 The drive is equipped with EMC filter E202 2 The motor and control cables are selected as specified in the hardware manual 3 The drive is installed according to the instructions given in the hardware manual 4
71. Maximum motor cable length is 150 meters WARNING The drive may cause radio interference if used in residential or domestic environment The user is required to take measures to prevent interference in association to the requirements for the CE compliance listed above if necessary Note Do not install a drive equipped with EMC filter E202 on IT ungrounded systems The supply network becomes connected to ground potential through the EMC filter capacitors which may cause danger or damage to the unit 174 Technical data Category C3 The drive complies with the standard with the following provisions 1 The drive is equipped with EMC filter E200 or E201 2 The motor and control cables are selected as specified in the hardware manual 3 The drive is installed according to the instructions given in the hardware manual 4 Maximum motor cable length is 150 meters WARNING A drive of category C3 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network Category C4 If the provisions under Category C3 cannot be met the requirements of the standard can be met as follows 1 Itis ensured that no excessive emission is propagated to neighboring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the pri
72. NOW 031539915 059091 gt l g y is S1 gt LO we 921202 o DIL 68122 S LL a18vo 8 0 zz GOL dN LAWWOUD cV 62 310H 31V ld 192 Dimension drawings Frame R6 IP55 UL Type 12 la 3AUA0000098321 SITOH NIINNOW 931539915 16 bes LUE 9 S A UE x 09 86 961 Dimension drawings 193 Frame R7 IP55 UL Type 12 NE 55125 5 TE N gm icti e LC DI Q D lt D Y IC lt m og di dl oe 1 0 ur C 1 oe or Le 310H ONILNNOW 031539915 p 56 421 989 65 07 a LC LO 2 a gt LN m B DI EE Y p d o Vesti 1 p 1 us LS eo C gt 0 t d _ gt gt gt ul NI E E 29 60 009 V co P t i 4
73. Off STO in the ABB industrial drives series Type ACS880 are capable for safety related applications up to SIL 3 SlLcl 3 and PL e and meet the requirements in the Eun sanc 61508 part 1 2010 part 2 2010 capable up to SIL 3 150 13849 1 2006 ISO 13849 2 2003 capable up to PL e category 3 62061 2005 capable up to SIL 3 61800 5 2 2007 capable up to SIL The drive series can also be used in safety applications up to SIL 3 according to IEC 61511 The released versions of the certified 8880 drives are given In the tracking list for released versions of the certified 5880 drives This list is an add on to this certificate The certification is based on the reports in the valid version referenced in the tracking ist This certificate entities the holder to use the pictured Safety Approved mark Expiry date 2017 06 04 TV Syria Derbi Ca Bath 17 88150 cigni Germary 210 Safe Torque off function Resistor braking 211 Resistor braking What this chapter contains This chapter describes how to select protect and wire brake choppers and resistors The chapter also contains technical data 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 Brake resistors are available as add on kits
74. Safe Torque off function Multiple drives external power supply Lee ul li A gt 7 SINE I I zcu SGND _ i IN1 Safe Torque off function 203 Operation principle 1 The Safe torque off activates the activation switch is opened or safety relay contacts open 2 STO inputs on the drive control unit de energize 3 The control unit cuts off the control voltage from the drive IGBTs 4 The control program generates an indication as defined by parameter 31 22 refer to the firmware manual of the drive 5 Motor coasts to stop if running The drive cannot restart while the activation switch or safety relay contacts are open After the contacts close a new start command is required to start the drive Start up including acceptance test To ensure safe operation of the Safe torque off function validation is required The final assembler of the machine must validate the function by performing an acceptance test The acceptance test must be performed e at initial start up of the safety function after any changes related to the safety function circuit boards wiring components settings etc after any maintenance work related to the safety function Authorized person The acceptance test of the safety function must be carried out by an authorized person with expertise and knowledge of the safety function The test must be documented and signed by th
75. T Type designation see section Type designation Rey on page dS _ S Ratings inthe supply volge ne _ Valid markings Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the units manufacturing year and week respectively The remaining digits complete the serial number so that there are no two units with the same number Operation principle and hardware description 35 Type designation key The type designation contains information on the specifications and configuration of the drive The first digits from left express the basic configuration eg ACS880 01 12A6 3 The optional selections are given thereafter separated by plus signs eg L519 The main selections are described below Not all selections are available for all types For more information refer to ACS880 01 Ordering Information 3AXD10000014923 available on request CODE DESCRIPTION Basic codes When no options are selected Wall mounted drive IP21 UL Type 1 ACS AP I assistant control panel no EMC filter DC choke ACS880 primary control program Safe torque off function cable entry box brake chopper in frames R1 to R4 coated boards printed multilingual quick guides and CD containing all manuals Voltage range Option codes plus codes Degree of protection B056 IP55 UL Type 12 Construction C131 Vibration dampers Resistor braking D150 Brake chopper for frame R5 a
76. The drives of frame sizes R1 to R3 are CSA marked The CSA marking is pending for the other frames The approval is valid with rated voltages C tick marking C tick marking is required in Australia and New Zealand A C tick mark is attached to the 380 500 V drives to verify compliance with the relevant standard IEC 61800 3 2004 mandated by the Trans Tasman Electromagnetic Compatibility Scheme C tick marking is pending for drives of voltage ranges 204 240 V and 525 690 V For fulfilling the requirements of the standard see section Compliance with the EN 61800 3 2004 on page 173 GOST R certificate of conformity The drive has been given a GOST R certificate of conformity Disclaimer The manufacturer shall have no obligation hereunder with respect to any product which i has been improperly repaired or altered ii has been subjected to misuse negligence or accident iii has been used in a manner contrary to the Manufacturer s instructions or iv has failed as a result of ordinary wear and tear Dimension drawings 1 7 Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive 178 Dimension drawings Frame 1 21 UL Type 1 6 10 25 25 GG 0 7 28 m 23 AO Tl 1 1 0 Com LE
77. _ 18 R amp 20 490 62 _ 022427 RS 98 8 0264 7 R amp 20 65 60 0954 7 RS 20 16 84 042A 7 RS 8 16 98 8 4947 R amp 280 65 o 06147 pre 45 26 12 Technical data 159 Drive type Air flow Heat ACS880 01 dissipation f mi w dB 084A7 E NER NE E 09847 1940 mar so 34 8 Re so 34 8 mox no o 2o 8 m m 8 160 Technical data Terminal and lead through data for the power cables IEC Input motor resistor and DC cable terminal screw sizes accepted wire sizes per phase and tightening torques 7 are given below denotes stripping length inside the terminal Cable lead L1 L2 L3 T1 U T2 V T3 W Grounding throughs terminals Per Wire srew T Terminal T phase nut mm m Nm mm W Wm mw Wm ELEM NE ee D 3 LR 1 08 6 25 18 ___ 24 05 3 38 ie 25 20 E NN NA OM 150 3 30 ass R7 1 95 240 M10 40 185 OSE 460 badd p ad a E 50 P e 95 240 Cable lead R R UDC and UDC terminals throughs V mw Nm mm ete tees ee 95 Lm pm 05 95 m8 EC 25 150 M10 m Lm E
78. a risk of malfunction in other parts of the system Install the protective component as close to the inductive load as possible Do not install protective components at the relay outputs 78 Planning the electrical installation 230 V AC 230 V AC 1 Relay outputs 2 Varistor 3 RC filter 4 diode Planning the electrical installation 79 Connecting a motor temperature sensor to the drive I O WARNING IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non conductive or conductive but not connected to the protective earth To fulfill this requirement the connection of a thermistor and other similar components to the digital inputs of the drive can be implemented in three alternate Ways 1 There is double or reinforced insulation between the thermistor and live parts of the motor 2 Circuits connected to all digital and analog inputs of the drive are protected against contact and insulated with basic insulation the same voltage level as the drive main circuit from other low voltage circuits 3 An external thermistor relay is used The insulation of the relay must be rated for the same voltage level as the main circuit of the drive For connection see the firmware manual 80 Planning the electrical installation Electrical installation 81 Electrical installation What this chapter contains This chapter g
79. al Gc S m Lud Kol od 2 13 2x 4 0 400 maximum cable diameter accepted Cable connector inside diameter 3 4 frames R1 R2 1 For the lead through plate hole diameters see chapter Dimension drawings 162 Technical data 525 690 V drives UL listed cable lugs and tools Wire size kemilAWG fe A Betts 54136 Betts TBM45S ei Betts Betts Betts 54142TB Betts TBM4S Bumdy YA2C L480x Bumdy 2 iso ORO2 disco 1 Iso CCL238 1 BEEN MEN BN Betts Betts Bumdy VAICL4BOX Bumdy 2 Betts Betts 12 1 ___ 1 1 38 25 YAL26T38 WY2ss iso iso 605 20 38 ras 2 0 Thomas amp 154110 Thomas amp 8 3 Betts Betts Terminal data for the control cables See Control unit ZCU 12 connection data below Technical data 163 Electrical power network specification Voltage U4 Network type Rated conditional short circuit current IEC 61439 1 Short circuit current protection UL 508C CSA C22 2 No 14 05 Frequency Imbalance Fundamental power factor cos phi ACS880 01 xxxx 2 units 208 240 V AC 3 phase 10 15 ACS880 01 xxxx 3 units 380 415 VAC 3 phase 10 15 ACS880 01 xxxx 5 units 380 500 V AC 3 phase 10 15 ACS880 01 xxxx 7 units 525 690 V AC 3
80. al voltage range 1 6 2 Uy e motor nominal current range 1 6 2 of the drive in DTC control and 0 2 in scalar control The control mode is selected by a drive parameter Planning the electrical installation 55 Protecting the motor insulation and bearings The drive employs modern IGBT inverter technology Regardless of frequency the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time The pulse voltage can almost double at the motor terminals depending on the attenuation and reflection properties 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 This can gradually erode the bearing races and rolling elements Optional du dt filters protect motor insulation system and reduce bearing currents Optional common mode filters mainly reduce bearing currents Insulated N end non drive end bearings protect the motor bearings Requirements table The following table shows how to select the motor insulation system and when an optional drive du dt and common mode filters and insulated N end non drive end motor bearings are required Ignoring the requirements or improper installation may shorten motor life or damage the motor bearings and voids the warran
81. ame R5 For easier installation the power cable terminals can be removed by undoing their mounting nuts Fasten the terminals back to their place by tightening the mounting nuts Electrical installation 89 11 Install the EMC shroud separating the input and output cabling if not installed yet 12 Units with option D150 Slide the brake resistor cable through the brake resistor and control cable clamp assembly Connect the conductors to the R and R terminals and tighten to the torque given in the figure 13 Reinstall the shroud on the power terminals 14 Secure the cables outside the unit mechanically Install the rubber grommets to the unused lead through plate holes Note For US cable conduit installation see the quick installation guide In case of a cable lug installation use UL listed cable lugs and tools to agree with UL requirements See page 762 90 Electrical installation 4 Taw A 1 2 nu N DU gt NC Electrical installation 91 Y AMY SEQ 92 Electrical installation de oO M L1 L2 L3 T1 U R RY UDC T2 V T3 W UDC N m N m
82. arallel cabling separation distance should be 0 3 meters Cross the other cables at right angles Keep the cable as short as possible in order to minimize the radiated emissions and stress on chopper IGBTs The longer the cable the higher the radiated emissions inductive load and voltage peaks over the IGBT semiconductors of the brake chopper Maximum cable length The maximum length of the resistor cable s is 10 m 33 ft EMC compliance of the complete installation Note ABB has not verified that the EMC requirements are fulfilled with external user defined brake resistors and cabling The EMC compliance of the complete installation must be considered by the customer Placing the brake resistors Install the resistors outside the drive in a place where they will cool Arrange the cooling of the resistor in a way that e no danger of overheating is caused to the resistor or nearby materials the temperature of the room the resistor is located in does not exceed the allowed maximum Supply the resistor with cooling air water according to the resistor manufacturer s instructions WARNING The materials near the brake resistor must be non flammable The A surface temperature of the resistor is high Air flowing from the resistor is of hundreds of degrees Celsius If the exhaust vents are connected to a ventilation system ensure that the material withstands high temperatures Protect the resistor against contact 214 Re
83. ch an emergency stop push button switch or the contacts of a safety relay or safety PLC e manually operated activation switch is used the switch must be of a type that can be locked out to the open position The contacts of the switch or relay must open close within 200 ms of each other AnFSO xx safety functions module can also be used For more information see the FSO xx module documentation e safety PLC is used test pulses longer than 1 ms are not allowed Cable types and lengths Double shielded twisted pair cable is recommended Safe Torque off function 199 Maximum cable lengths e 30m 100 ft between activation switch and drive control unit 60 m 200 ft between multiple drives e 60m 200 ft between external power supply first drive Note that the voltage at the INx terminals of each drive must be atleast 17 V DC to be interpreted as 1 200 Safe Torque off function Single drive internal power supply T1 U T2 V T3 W Safe Torque off function Multiple drives internal power supply 97 IN1 pere 6 la ee ee O O N Edd ee Td 4 5880 01 B I zu HL SGND w fo ee ee Z i A 5880 1 fe da d E OUT1 SGND d IN1 1 IN2 201 202
84. cted with jumper J1 Change of setting requires reboot of control unit 2 Current 0 4 20 mA Rin gt 100 ohm or voltage 0 2 10 V Rin gt 200 kohm input selected with jumper J2 Change of setting requires reboot of control unit 3 Total load capacity of these outputs is 4 8 W 200 mA 24 V minus the power taken by DIO1 and DIO2 4 0 open 1 closed Ramp times according to o Parameters 23 12 and 23 13 Parameters 23 14 and 23 15 Further information on the usage of the connectors and jumpers is given in the sections below See also section Control unit ZCU 12 connection data on page 164 Jumpers and switches Jumper Description Switch Determines whether analog input Al1 is used Current 1 as a Current or voltage input Voltage 0 Determines whether analog input 2 is used Current 1 as a current or voltage input Voltage U Drive to drive link termination Must be set to Cona Bus is terminated terminated position when the drive is the last unit on the link Common digital input ground selection switch DICOM DIOGND Determines whether DICOM is separated from connected default DIOGND ie common reference for digital inputs floats See Ground isolation diagram DICOM and DIOGND on page 166 Bus is not terminated separated 102 Electrical installation External power supply for the control unit KPOW External 24 V 2 A power su
85. ctivate the STO by closing the activation switch or reseting the safety functionality that is wired to the STO connection 6 Reset any faults before restarting WARNING The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply WARNING With permanent magnet or synchronous reluctance SynRM motors only In case of a multiple IGBT power semiconductor failure the drive system can produce an alignment torque which maximally rotates the motor shaft by 180 p with permanent magnet motors or 180 2p with synchronous reluctance SynRM motors degrees regardless of the activation of the Safe torque off function p denotes the number of pole pairs Notes e Ifa running drive is stopped by using the Safe torque off function the drive will cut off the motor supply voltage and the motor will coast to a stop If this causes danger or is not otherwise acceptable stop the drive and machinery using the appropriate stop mode before activating the Safe torque off function The Safe torque off function overrides all other functions of the drive 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 i
86. d to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation bearing currents and wear The protective conductor must always have an adequate conductivity The table below shows the minimum cross sectional area related to the phase conductor size according to IEC 61439 1 when the phase conductor and the protective conductor are made of the same metal 64 Planning the electrical installation Cross sectional area of the phase Minimum cross sectional area of the conductors corresponding protective conductor S mm Sp mm Typical power cable sizes The table below gives copper and aluminum cable types with concentric copper shield for the drives with nominal current Drive type ACS880 Cu cable type AI cable Cu cable type AI cable type 01 type mm mm AWGlkcmil AWGlkcmil Uy 208 240 V Ri mw 2 Ri o Ri o2 Ri M m m o SS ato 3535 6e SSS 3535 4 RS 3 RS so 3 msa sm 1 M52 R6 3 m 20 sa mw Rr m _
87. due to their easy controllability and high switching frequency connected to the control unit or optional I O extensions mounted on it R Safe acceleration range Safe brake control Introduction to the manual 25 Term Explanation Abbreviation Safely limited speed without encoder Safe stop emergency Safe minimum speed Safety data SIL PL EN ISO 13849 1 Common cause failure EN ISO 13849 1 Diagnostic coverage IEC 61508 Failure In time 1E 9 hours IEC 61508 Hardware fault tolerance PFD EN ISO 13849 1 Mean time to dangerous failure The total number of life units the number of dangerous undetected failures during a particular measurement interval under stated conditions PFD IEC 61508 Probability of failure on demand IEC 61508 Probability of dangerous failures per hour Pe EN ISO 13849 1 Performance level corresponds SIL Levels a e PL SFF IEC 61508 Safe failure fraction IEC 61508 Safety integrity level SILCL EN 62061 Maximum SIL level 1 3 that can be claimed for a safety function or subsystem EN 61800 5 2 Safe stop 1 EN 61800 5 2 Safe torque off IEC 61508 Proof test interval 26 Introduction to the manual Operation principle and hardware description 27 Operation principle and hardware description What this chapter contains This chapter briefly describes the operation principle and construction of the drive Product overview The ACS880 01 is a drive
88. dule see section nstallation of safety functions modules on page 111 For the safety data and more information on the option see FSO 11 user s manual 3AUA0000097054 English Implementing the ATEX certified Safe motor disconnection function option Q971 With option Q971 the drive supplies ATEX certified safe motor disconnection without contactor that uses the drive Safe torque off function For more information see ACS880 ATEX certified Safe disconnection function application guide 3AUA00001 32231 English 74 Planning the electrical installation Implementing the Power loss ride through function Implement the power loss ride through function as follows Check that the power loss ride through function of the drive is enabled with parameter 30 31 Undervoltage control in the ACS880 primary control program e Ifthe installation is equipped with a main contactor prevent its tripping at the input power break For example use a time delay relay hold in the contactor control circuit WARNING Make sure that the flying restart of the motor will not cause any danger If you are in doubt do not implement the Power loss ride through function Using power factor compensation capacitors with the drive Power factor compensation is not needed with AC drives However if a drive is to be connected in a system with compensation capacitors installed note the following restrictions WARNING Do not connect power factor compen
89. e and the load current of the drive See also page 160 for the accepted cable sizes of the drive 2 The cable sizing is based on NEC Table 310 16 for copper wires 75 C 167 F wire insulation at 40 C 104 F ambient temperature Not more than three current carrying conductors in raceway or cable or earth directly buried For other conditions size the cables according to local safety regulations appropriate input voltage and the load current of the drive See also page 161 for the accepted cable sizes of the drive 3 The biggest cable size accepted by the connection terminals of frame R8 is 2 x 3x150 Biggest possible cable size is 3x240 or 400 if the terminal type is changed and the cable entry box is not used Alternative power cable types The recommended and not allowed power cable types to be used with the drive are presented below Planning the electrical installation 67 Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield The shield must meet the requirements of IEC 61439 1 see page 63 Check with local state country electrical codes for allowance Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield A separate PE conductor is required if the shield does not meet the requirements of IEC 61439 1 see page 63 Symmetrical shielded cable with three phase conductors and symmetrically con
90. e authorized person Acceptance test reports Signed acceptance test reports must be stored in the logbook of the machine The report shall include documentation of start up activities and test results references to failure reports and resolution of failures Any new acceptance tests performed due to changes or maintenance shall be logged into the logbook 204 Safe Torque off function Acceptance test procedure After wiring the Safe torque off function validate its operation as follows Setting of the control program parameters is not needed If an FSO xx safety functions module is installed refer to its documentation WARNING Follow the Safety instructions page 13 Ignoring the instructions can cause physical injury or death or damage to the equipment Ensure that the drive can be run and stopped freely during start up Stop the drive if running switch the input power off and isolate the drive from the power line by a disconnector Check the Safe torque off STO circuit connections against the circuit diagram Close the disconnector and switch the power on Test the operation of the STO function when the motor is stopped e Give a stop command for the drive if running and wait until the motor shaft is at a standstill Make sure that the drive operates as follows Open the STO circuit The drive generates an indication if one is defined for stopped state in parameter 31 22 see the firmware manual Give a
91. e is no voltage Remove the front cover s See section Connecting the power cables starting from page 84 Cut adequate holes into the rubber grommets and slide the grommets onto the cables Slide the cables through the holes of the bottom plate and attach the grommets to the holes Route the cables as shown on page 106 Ground the outer shields of all control cables 360 degrees at a grounding clamp in the cable entry box see page 106 Tighten the clamp to 1 5 N m 13 Ibf in Keep the shields continuous as close to the terminals of the control unit as possible Secure the cables mechanically at the clamps below the control unit Frames R1 to R3 Ground also the pair cable shields and grounding wires at the cable entry box grounding clamp Frames R4 to R9 Ground the pair cable shields and all grounding wires to the clamp below the control unit see page 706 Connect the conductors to the appropriate terminals see page 100 of the control unit and tighten to 0 5 N m 5 Ibf in Note Leave the other ends of the control cable shields unconnected or ground them indirectly via a high frequency capacitor with few nanofarads eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by i
92. e of hot surfaces Some parts such as heatsinks of power semiconductors remain hot for a while after disconnection of the electrical supply e Ensure that debris from borings and grindings does not enter the drive when installing Electrically conductive debris inside the unit may cause damage or malfunction Ensure sufficient cooling e Do not attach the drive by riveting or welding 18 Safety instructions Printed circuit boards 4 WARNING Ignoring the following instructions can cause damage to the printed circuit boards e Wear a grounding wrist band when handling the boards Do not touch the boards unnecessarily The printed circuit boards contain components sensitive to electrostatic discharge Safe start up and operation General safety These warnings are intended for all who plan the operation of the drive or operate the drive WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment Before you connect voltage to the drive make sure that the drive covers are on Keep the covers on during the operation Before adjusting the drive and putting it into service make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line e Do not activate an
93. e torque required to rotate the motor If the motor is running when Safe torque off is activated it coasts to a stop The Safe torque off function has a redundant architecture that is both channels must be used in the safety function implementation The safety data given in this manual is calculated for redundant use and does not apply if both channels are not used 198 Safe Torque off function The Safe torque off function of the drive complies with e EN 61800 5 2 2007 e IEC 61508 1 2 2010 e EN 62061 2005 AC 2010 e EN ISO 13849 1 2008 AC 2009 e EN ISO 13849 2 2008 e EN 60204 1 2006 AC 2010 e IEC 61511 2003 IEC 61326 3 1 2008 The function also corresponds to prevention of unexpected start up as specified by EN 1037 1995 A1 2008 and uncontrolled stop stop category 0 as specified in EN 60204 1 2006 AC 2010 Compliance with the European Machinery Directive See section Compliance with the European Machinery Directive on page 170 Wiring The following diagrams show examples of Safe torque off wiring for e single drive page 200 e multiple drives page 207 e multiple drives when an external 24 V DC power supply is used page 202 For information on the specifications of the STO input see section Control unit ZCU 12 connection data on page 164 Activation switch In the wiring diagrams below the activation switch has the designation K This represents a component such as a manually operated swit
94. er phase ACS880 01 current v Manufacturer Type UL class ATI 2 49 50 Bee 09400 T 36145 36i 500 60 Bussmann JuS 500 maas 600 Bussmann 355 600 T 156 Technical data Dimensions and free space requirements UL 1 H2 bed H2 mm mm mm mm 405 ae pepe pas a 6s eor 80 8 i654 677 Re 726 569 251 367 45 2560 2240 992 1409 99 Rr 880 600 254 365 55 3470 2360 1122 1457 127 963 661 300 386 70 2682 181 1821 3154 ee ENT C UL type 12 450 162 292 1772 72 6 38 38 11 11 50 20 M per NRE 0 8 ms 525 180 327 10 2070 70 1287 22 m 576 _ __ 20 185 2270 789 1354 4 RS _ __ 20 sa __28 _ 2675 79 1354 5T 252 421 45 2660 992 1646 Rr _ ___2 423 5 3466 ____ 148 1665 __121 m8 965 30 42 __72 sro 1181 1778 359 Ro oss _ ___ 477 100 1496 1878 220 _ H1 Height with cable entry box H1 H2 TW H1 H3 mm mm mm H2 Height without cable entry box H3 Height with hood W Width with cable entry box D Depth with cable entry box Hood inreases height with 155 mm 6 10 in in frames R4 to R7 A Hood inreases width with 23 mm 0 91
95. er voltage can activate the brake chopper and lead to brake resistor overload or activate the overvoltage controller what can lead to motor rushing to maximum speed Note motor cable terminals on the drive are at a dangerously high voltage when the input power is on regardless of whether the motor is running or not The DC terminals UDC UDC carry a dangerous DC voltage over 500 V when internally connected to the intermediate DC circuit Depending on the external wiring dangerous voltages 115 V 220 V or 230 V may be present on the terminals of relay outputs XRO1 XRO2 and XRO3 The Safe torque off function does not remove the voltage from the main and auxiliary circuits The function is ineffective against deliberate sabotage or misuse Safety instructions 15 Grounding These instructions are intended for all who are responsible for the grounding of the drive WARNING Ignoring the following instructions can cause physical injury death increased electromagnetic interference and equipment malfunction e Ground the drive motor and adjoining equipment to ensure personnel safety in all circumstances and to reduce electromagnetic emission and interference e Make sure that grounding conductors are adequately sized as required by safety regulations namultiple drive installation connect each drive separately to protective earth PE e Where EMC emissions must be minimized make a 360 hi
96. function must be reported to ABB Safety data SIL PL The safety data for the Safe torque off function is given below Note The safety data is calculated for redundant use and does not apply if both channels are not used SIL T1 2 33E 09 2 33 FIT 1 9981 4 58E 7 2 33E 09 2 33 FIT 1 9981 4 58E 7 Rs 3 zssEceQasHm 1 998 2 3697 3 zoeen 1 998 S85ET Rs 3 2436 09 043m 1 998 S857 86 3 1 9979 8707 Rr 3 1 9979 29 8707 Rs 3 sson i 20 1554 7 gt 1 Safe Torque off function 207 IEC 61508 SIL T1 im LT my ms 3 Gsm 1 oos 20 15664 UN 525 690 V EN ISO 13849 1 PL CCF DC Cat SILCL SIL m mmm _ Uy 208 500 V Rm gt o 3 3 3 R 9 7m 9 3 3 3 e s gt o 3 3 3 e 9 sa gt o 3 3 3 sa gt o 3 3 3 e gt o 3 3 93 Rr e s gt o 3 3 93 Re e 9 3 3 3 3 3 Uy 525 690 V m e gt 3 3 3 rere e 198 gt o 3 3 according to Table E 1 in EN ISO 13849 1 This temperature profile
97. gh frequency grounding of cable entries in order to suppress electromagnetic disturbances In addition connect the cable shields to protective earth PE in order to meet safety regulations e Do not install a drive with EMC filter option E200 or E202 on an ungrounded power system or a high resistance grounded over 30 ohms power system Note Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations e Standard EN 61800 5 1 section 4 3 5 5 2 requires that as the normal touch current of the drive is higher than 3 5 mA AC or 10 mA DC you must use a fixed protective earth connection and across section of the protective earthing conductor of at least 10 mm Cu 16 mm Al or automatic disconnection of the supply in case of discontinuity of the protective earthing conductor or e second protective earthing conductor of the same cross sectional area as the original protective earthing conductor 16 Safety instructions Permanent magnet motor drives These are additional warnings concerning permanent magnet motor drives WARNING Ignoring the instructions can cause physical injury or death or damage to the equipment Do not work on the drive when the permanent magnet motor is rotating Also when the supply power is switched off and the inverter is stopped a rotating permanent magnet motor feeds power to the intermediate circuit of the dri
98. ifting holes Operation principle and hardware description 31 Layout UL 12 The components of the UL Type 12 drive option B056 are shown below view of frame R6 1 Control panel behind the control panel cover 2 Front cover Four fastening points at the back of the drive Heatsink 5 Lifting holes Hood included in frames R4 to R7 32 Operation principle and hardware description Overview of power and control connections The diagram shows the power connections and control interfaces of the drive Slot 1 1 Option modules be inserted into slots 1 2 and 3 as follows Modules Into slots Analog and digital extension modules except FDIO 1 2 3 Feedback interface modules 1 2 3 Fieldbus communication modules and FDIO 1 2 Safety functions modules 2 See section Type designation key page 35 Memory unit see page 135 Connector for safety functions modules alternative to Slot 2 See page 33 Default connection diagram page 100 and Control unit ZCU 12 connection data page 164 See section Control panel page 34 8 du dt common mode or sine filter optional see page 227 Operation principle and hardware description 33 External control connection terminals The layout of external control connection terminals of the drive is shown below m XRO1 J1 J2 Description External power input A
99. ighten the screws to the torque given in the figure Note The phase connectors are detachable 12 Units 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 14 14 Reinstall the shroud on the power terminals 15 Reinstall the side plates of the cable entry box 16 Install the control cable grounding shelf in the cable entry box 17 Secure the cables outside the unit mechanically Install the rubber grommets to the unused lead through plate holes Note For US cable conduit installation see the quick installation guide In case of a cable lug installation use UL listed cable lugs and tools to agree with UL requirements See page 162 94 Electrical installation ob N BA UN i RON N TAN 5 AX X A N N H NI Des IN LOS d D N T T EM mA N Pe WN N De Wwe EP N PN MS se N N N N N x NIN IS ul 5 gt N 0 HH d By NO 3 Es b U Electrical installation 95 R8 R9 C woe T T2N H
100. ing the motor power supply from drive to direct on line 1 Stop the drive and the motor with the drive control panel drive in local control mode or with the external stop signal drive in remote control mode 2 Open the main contactor of the drive with S11 3 Switch the motor power supply from the drive to direct on line with S40 4 Wait for 10 seconds to allow the motor magnetization to die away 5 Start the motor with S41 Switching the motor power supply from direct on line to drive 1 Stop the motor with 542 2 Switch the motor power supply from direct on line to the drive with S40 3 Close the main contactor of the drive with switch S11 gt turn to position ST for two seconds and leave at position 1 4 Start the drive and the motor with the drive control panel drive in local control mode or with the external start signal drive in remote control mode Protecting the contacts of relay outputs Inductive loads relays contactors motors cause voltage transients when switched off The relay contacts on the drive control unit are protected with varistors 250 V against overvoltage peaks In spite of this it is highly recommended that inductive loads are equipped with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductively to other conductors in the control cable and form
101. instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage Remove the front cover Unplug the fan power supply wires Lift the fan up 0 IAS OI Install the new fan in reverse order Make sure that the arrow in the fan points to the direction marked on the drive frame 128 Maintenance _ Replacing the main cooling fan of frames to R8 WARNING Follow the safety instructions page 14 Ignoring the instructions 4 can cause physical injury or death or damage to the equipment Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage Undo the mounting screws of the fan mounting plate view from bottom below Pull the fan mounting plate down from the side edge Unplug the power supply wires Lift the fan mounting plate off Remove the fan from the mounting plate O5 dx gt Install the new fan in reverse order Maintenance 129 Replacing the auxiliary cooling fan of frames R6 to R9 WARNING Follow the safety instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Disconnect the drive from the power line
102. ion end motor bearings system Py lt 100kW 100 lt Py lt Py gt 200 kW 200 kW Py lt 140 hp 140 hp lt Py lt Py gt 268 hp 268 hp lt 500 V Standard N I 500 V lt Ux lt 600 V Standard du dt du dt N du dt N CMF du dt N du dt N CMF 60 Planning the electrical installation Additional requirements for non ABB high output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 2001 The table below shows the requirements for random wound and form wound non ABB motors Nominal AC line Requirement for voltage Motor ABB du dt filter insulated N end bearing and ABB insulation common mode filter system lt 100 kW frame 100 kW lt Py lt 350 kW size IEC 315 or IEC 315 lt frame size lt 400 Py lt 134 hp or frame 134 hp lt Py lt 469 hp size lt NEMA 500 or NEMA 500 lt frame size lt NEMA 580 lt 420 V Standard N or CMF N 1300 V 420 V lt Uy x 500 V Standard du dt N or du dt N CMF V N or N O 1600 V 0 2 microsecond rise time 500 V lt Uy lt 600 V Reinforced du dt N or du dt N CMF E _ V nr cc NorCMF N CMF O 1800 V 600 V lt Ux lt 690 V Reinforced du dt N du dt
103. is chapter contains instructions for planning the electrical installation of the drive Some instructions are mandatory to follow in every installation others provide useful information that only concerns certain applications Limitation of liability The installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability wnatsoever 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 Selecting the supply disconnecting device Install a hand operated input disconnecting device between the AC power source and the drive The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work 54 Planning the electrical installation European Union To meet the European Union Directives according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types e SWitch disconnector of utilization category AC 23B EN 60947 3 e disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector EN 60947 3 circuit breaker suitable for isolation in accordance with EN 60947 2 Other regions The disconnecting device must confor
104. its Fasten the cable connectors included in the delivery in a plastic bag to the cable lead through plate holes 6 Prepare the ends of the input power a and motor cables b as illustrated in the figure Note Bare shield will be grounded 360 degrees 7 21 units Ground the shields 360 degrees in the connectors by tightening the connector onto the stripped part of the cable IP55 units Tighten the clamps onto the stripped part of the cables 8 Connect the twisted shields of the power cables to the grounding terminals 9 Connect the additional PE conductor if used see page 75 of the input cable to the grounding terminal 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 Connect the brake resistor conductors if present to the R and R terminals Tighten the screws to the torque given in the figure below 11 Install the control cable grounding shelf in the cable entry box 12 Secure the cables outside the unit mechanically Note The drawings below show IP21 unit The IP55 unit looks slightly different A For US cable conduit installation see the quick installation guide 86 Electrical installation Electrical installation 87 gt PO E Fa N _ gt aN u
105. ive 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 166 Technical data Ground isolation diagram AGND 1 24VD 2 DICOM 9 gt 6 Common mode voltage between channels 30 V Switch J6 settings All digital inputs and outputs share common ground Ground of digital V inputs DI DI5 and DIIL DICOM is separated from the DIO signal ground DIOGND insulation voltage 50 V Ground Technical data 167 Efficiency Approximately 98 at nominal power level Protection classes Degree of protection IP21 IP55 IEC EN 60529 Enclosure types UL508C UL Type 1 UL Type 12 For indoor use only Overvoltage category IEC 60664 1 Protective class IEC EN 61800 5 1 Ambient conditions Environmental limits for the drive are given below The drive is to be used in a heated indoor controlled environment Operation Storage Transportation installed for in the protective in the protective stationary use package package Installation site altitude 1 0104000 13123 ft above sea level 2 Oto 2000 m 6561 ft above sea level Above 1000 m 3281 ft see page 145 1 for neutral grounded TN and TT systems and non corner grounded IT systems 2 for corner grounded TN TT and IT systems Air temperature 15 to 55 C 5
106. ives instructions on wiring the drive Warnings WARNING Only qualified electricians are allowed to carry out the work described in this chapter Follow the Safety instructions in the first chapter of this manual Ignoring the safety instructions can cause physical injury or death Checking the insulation of the assembly Drive Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive Every drive has been tested for insulation between the main circuit and the chassis at the factory Also there are voltage limiting circuits inside the drive which cut down the testing voltage automatically Input power cable Check the insulation of the input cable according to local regulations before connecting it to the drive 82 Electrical installation Motor and motor cable Check the insulation of the motor and motor cable as follows 1 Check that the motor cable is disconnected from the drive output terminals T1 U T2 V and T3 W Measure the insulation resistance between each phase conductor and the Protective Earth conductor using a measuring voltage of 1000 V DC The insulation resistance of an ABB motor must exceed 100 Mohm reference value at 25 C or 77 F For the insulation resistance of other motors please consult the manufacturer s instructions Note Moisture inside the motor casing will reduce the insulation resistance If moisture is suspected d
107. ke resistor with a resistance below the AN value specified for the particular drive brake chopper resistor combination The drive and the chopper are not able to handle the overcurrent caused by the low resistance 3 Check the resistor selection The energy generated by the motor during a 400 second period must not exceed the resistor heat dissipation capacity Ep Note If the Ep 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 Ep value of the four resistor assembly is four times the value specified for the standard resistor Selecting and routing the brake resistor cables Use the same cable type for the resistor cabling as for the drive input cabling to ensure that the input fuses also protect the resistor cable Alternatively a two conductor shielded cable with the same cross sectional area can be used Resistor braking 213 Minimizing electromagnetic interference Follow these rules in order to minimize electromagnetic interference caused by the rapid current changes in the resistor cables e Shield the braking power line completely either by using shielded cable or a metallic enclosure Unshielded single core cable can only be used if it is routed inside a cabinet that efficiently suppresses the radiated emissions Install the cables away from other cable routes Avoid long parallel runs with other cables The minimum p
108. l installation Frame R8 cable entry box 21 UL 1 This illustration shows the contents of the cable entry box package There is also an assembly drawing which shows how to install the cable entry box to the drive module frame 3aua0000112174 Mechanical installation 47 Frame R9 cable entry box IP21 UL Type 1 This illustration shows the contents of the cable entry box package The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame 3aua0000112356 48 Mechanical installation Installing the drive These instructions are for drives without vibration dampers For drives with vibration dampers option C131 see the additional instructions included with the dampers and on the manuals CD Frames R1 to R4 See the dimensions in chapter Dimension drawings Mark the locations for the four mounting holes Drill the mounting holes Start the screws or bolts into the mounting holes Position the drive onto the screws on the wall ce 9 Tighten the screws in the wall securely Q MW M EN x 4 Mechanical installation 49 Frames R4 and R7 UL Type 12 1
109. le who plan the installation install start up use and service the drive Read the manual before working on the drive You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Contents of the manual This manual contains the instructions and information for the basic drive configuration The chapters of the manual are briefly described below Safety instructions gives safety instructions for the installation start up operation and maintenance of the drive Introduction to the manual introduces the manual Operation principle and hardware description describes the drive Mechanical installation describes how to install the basic drive mechanically Planning the electrical installation contains instructions for the motor and cable selection protections and cable routing 22 Introduction to the manual Electrical installation gives instructions on wiring the drive Installation checklist contains a list for checking the mechanical and electrical installation of the drive Start up describes the start up procedure of the drive Fault tracing describes the fault tracing of the drive Maintenance contains preventive maintenance instructions Technical data contains the technical specifications of the drive eg the ratings sizes and technical requirements provisions for fulfilling the
110. m Disable the overvoltage control of the drive by parameter 30 30 Overvoltage control Set parameter 31 01 External event 1 source to point to the digital input where the thermal switch of the brake resistor is wired Set parameter 31 02 External event 1 type to Fault Enable the brake chopper by parameter 43 06 Brake chopper enable Enabled with thermal model is selected set also the brake resistor overload protection parameters 43 08 and 43 09 according to the application For frames R5 to R9 Set parameter 43 07 Brake chopper runtime enable to Other bit and select from parameter 10 01 DI status the digital input where the thermal switch of the brake resistor is wired Check the resistance value of parameter 43 10 Brake resistance With these parameter settings the drive stops by coasting on brake resistor overtemperature WARNING If the drive is equipped with a brake chopper but the chopper is not enabled by the parameter setting the internal thermal protection of the drive against resistor overheating is not in use In this case the brake resistor must be disconnected For settings of other control programs see the appropriate firmware manual Resistor braking 217 Technical data Ratings Drive type Internal brake Example brake resistor s Focal Type 208 240 V a i SAIL 880 01 07 52 18 80 40 om 880 01 10462 22 65 __ 80 40 om
111. m to the applicable safety regulations Selecting and dimensioning the main contactor If a main contactor is used its utilization category number of operations under load must be AC 1 according to IEC 60947 4 Low voltage switchgear and controlgear Dimension the main contactor according to the nominal voltage and current of the drive Checking the compatibility of the motor and drive Use an asynchronous AC induction motor permanent magnet synchronous motor or AC induction servomotor with the drive Several induction motors can be connected to the drive at a time Select the motor size and drive type from to the rating tables in chapter Technical data on basis of the AC line voltage and motor load Use the DriveSize PC tool if you need to tune the selection more in detail Ensure that the motor withstands the maximum peak voltage in the motor terminals See the Requirements table on page 55 For basics of protecting the motor insulation and bearings in drive systems refer to section Protecting the motor insulation and bearings below Note Consult the motor manufacturer before using a motor whose nominal voltage differs from the AC line voltage connected to the drive input The voltage peaks at the motor terminals are relative to the supply voltage of the drive not the drive output voltage e motor and drive are not of the same size consider the following operation limits of the drive control program e motor nomin
112. mage Read the data on the type designation label of the drive to make sure that the drive is of the correct type Hes Een e besoin Cable entry box Power and control Cardboard sleeve cable grounding shelves in a plastic bag assembly drawing Note The cable entry box is mounted to the IP55 drive module frame at the DOE Top cardboard cover Printed quick guides and manuals CD and multilingual residual voltage warning sticker 44 Mechanical installation To unpack e Cut the straps 6 Remove the top cardboard cover 3 and cushion 4 Lift the cardboard sleeve 5 Attach lifting hooks to the lifting eyes of the drive Lift the drive with a hoist Frame R6 cable entry box 21 UL 1 This illustration shows the contents of the cable entry box package The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame 3aua00001 12044 Mechanical installation 45 Frame R7 cable entry box 21 UL 1 This illustration shows the contents of the cable entry box package The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame 3aua0000111117 46 Mechanica
113. mary and secondary windings can be used Medium voltage network d Supply transformer ace DSL sn Neighboring network LN us Static screen Point of measurement Low voltage Equipment Equipment Equipment 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local ABB representative Low voltage 3 The motor and control cables are selected as specified in the hardware manual 4 The drive is installed according to the instructions given in the hardware manual Technical data 175 WARNING A drive of category C4 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network UL marking cULus Listed UL Type 1 IP21 drives frames R1 to R3 of voltage range 208 240 frames R1 to R9 of voltage ranges 380 415 V and 380 500 V e frames R5 to of voltage range 525 600 V cULus Listed UL Type 12 IP55 drives frames R1 to R3 of voltage range 208 240 V frames R1 to R5 of voltage ranges 380 415 V and 380 500 V frames R5 of voltage range 525 600 V The listing is pending for the other types The approval is valid with rated voltages UL checklist e The drive is to be used in a heated indoor controlled environment The drive must be in
114. mation on maintenance counters see the firmware manual Consult your local ABB Service representative for more details on the maintenance On the Internet go to www abb com searchchannels 122 Maintenance ive maintenance table Prevent yBiy si peo jewou SI peo au JO piwny Ajsnp 9 suonipuoo jueiquue JO 4 2 uey JeuBiu si suonipuoo ui Jo peo snonumnuoo ou pue ou si pue 4 POL MOJO S jueuoduuoo Y JOUJO JO sjueuJeJnseoeuu 85159 HUIUOISSILULUOD Jo d p p u uonoe pue uonoedsul ensiA suoneouiseds seunsnp suonipuoo uonesado jeu ejns Josn Aq suonoedsur jenuue y JO syursjeau UBA I au uo ejui peJey4 ed IN pue IN eur 4osn Aq jenuue 1oyoeded _
115. me and the peak line to line voltage 61 Additional note for sine 63 Selecting the power cables 63 General 63 Typical power cable SIZES 64 Alternative power cable types 66 Recommended power cable typeS 67 Power cable types for limited use 67 Not allowed power cable typeS 67 Motor cable shield suu uod gov __ 68 Additional US requirements 68 68 Armored cable shielded power cable 69 Selecing t control cables 424 a acd Ae Gee dE CRO EAR EROR CE Ra 69 E notate iter 69 Signals in separate cables 69 Signals allowed to be run in the same cable 69 Relay cable a ke Roux 3 ER pi arie A aan 69 Control panel cable length and type 70 NG Cables screzi retata toa i pietre Roa deo PU YR E 8 ede ee 70 Separate control Cable ducts
116. minute every 5 minutes Typical motor power in light overload use Imax Maximum output current Available for 10 seconds at start then as long as allowed by drive temperature Continuous rms output current allowing 50 overload for 1 minute every 5 minutes Continuous rms output current allowing 30 overload for 1 minute every 5 minutes Continuous rms output current allowing 25 overload for 1 minute every 5 minutes Typical motor power in heavy duty use Note 1 The ratings apply at an ambient temperature of 40 C 104 F Note 2 To achieve the rated motor power given in the table the rated current of the drive must be higher than or equal to the rated motor current The DriveSize dimensioning tool available from ABB is recommended for selecting the drive motor and gear combination Derating Ambient temperature derating IP21 UL Type 1 drive types and other IP55 UL Type 12 types than listed in the following subheadings 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 The output current can be calculated by multiplying the current given in the rating table by the derating factor k k 1 00 0 95 0 90 0 85 0 80 4592 2222 40 C 50 55 C T 59 F 104 F 122 131 F 144 Technical data IP55 UL Type 12 drive types 274A 2 293A 3 and 260A 5 In the temperature range 40 45 C 1
117. mode and motor coast stop or scalar control mode open the contactor as follows 1 Give a stop command to the drive 2 Open the contactor WARNING When the DTC motor control mode is in use never open the AN output contactor while the drive controls the motor The DTC motor control operates extremely fast much faster than it takes for the contactor to open its contacts When the contactor starts opening while the drive controls the motor the DTC control will try to maintain the load current by immediately increasing the drive output voltage to the maximum This will damage or even burn the contactor completely Implementing a bypass connection If bypassing is required employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line Ensure with interlocking that the contactors cannot be closed simultaneously WARNING Never connect the drive output to the electrical power network The connection may damage the drive 76 Planning the electrical installation Example bypass connection An example bypass connection is shown below 511 Drive main contactor on off control Q4 Bypass circuit breaker S40 Motor power supply selection drive or direct on line K1 Drive main contactor 541 Start when motor is connected direct on line Bypass contactor Stop when motor is connected direct on line Planning the electrical installation 77 Switch
118. mponent functionality The following harmonized standards below were used sacs edi ac Adjustable speed alectical power drive systems Part 5 2 Safely EN 61800 5 2 2007 EN 62061 2006 AC 2010 Safety of machinery Functional safety of safety related electrical andai anna Ac anna Salty of machinery Sadely related parts of contro systems Part 1 EN ISO 13849 1 2008 AC 2009 TRE Ei nme EN ISO 13849 2 2008 DN MNT Sadety calatec parts af the contro systems Part 4 4 Safety of machinery Electrica equipment af machinas Part 1 EN 60204 1 2006 AC 2010 Other used standards Functional safety of electrical electronic programmable electronic IEC 81508 ad 2 2010 sadety related The products referred in this Declaration of Conformity fulfil the relevant provisions of the Low Voltage Directive 2006 95 EC and EMC Directive 2004 108 EC Declaration of conformity according to these directives is available from the manufacturer 172 Technical data HD HD Declaration of Conformity According to Machinery Directive 2006 42 EC Person authorized to compile the technical file Name Risto Myntlinen Address P O Box 184 FIN 00381 Helsinki Finland Helsinki 29 Nov 2012 Mika Kulpu Vice President ABB Oy JAWO 10000858848 Page 212 Technical data 173 Compliance with the EN 61800 3 2004 Definitions
119. nalog inputs Analog outputs Drive to drive link Relay output 1 Relay output 2 Relay output 3 Start interlock connection DIIL and 24 V output Digital input outputs Digital inputs Safe torque off connection Connector for safety functions modules optional Control panel PC connection Option slot 1 Option slot 2 Option slot 3 Memory unit connection Auxiliary cooling fan connection Voltage Current selection jumpers J1 J2 for analog inputs Drive to drive link termination jumper J3 common digital input ground selection jumper J6 34 Operation principle and hardware description Control panel The control panel can be removed by pulling it forward from the top edge and reinstalled in reverse order For the use of the control panel see the firmware manual or ACS AP assistant control panels user s manual 0 0000085685 English Type designation label The type designation label includes an IEC and NEMA rating appropriate markings a type designation and a serial number which allow identification of each unit The type designation label is located on the front cover An example label is shown below AL EP ED ACSBBO 0 1 024 1 5 1 A PRIDE 8 8 4 0 75 KW 121 Ui 3 30 500 V 1 3 440 4BD V C 4 i hp UL type 1 lin 214 1119 21 LN 11 47 63 Hz 11 47 64 Hz Uz deh UW Uz 30 01 Y MO G 0 500 Hr C 0 500 JU GIN 112080 0909 S
120. nce 125 Replacing the auxiliary cooling fan of IP55 frames R1 to R3 WARNING Follow the safety instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage Remove the front cover by undoing the mounting screws at the sides Unplug the fan power supply wires Lift the fan off oe Install the new fan in reverse order Make sure that the arrow a on the fan points down Note Bundle the wires under the clip b otherwise the cover will not fit properly 126 Maintenance Replacing the main cooling fan of frames R4 and R5 WARNING Follow the safety instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage Lift the fan mounting plate up from the front edge Unplug the power supply wires Lift the fan mounting plate off Remove the fan from the mounting plate OS Install the new fan in reverse order Maintenance 127 Replacing the auxiliary cooling fan of frame R4 and IP55 frame R5 and IP21 frame R5 types ACS880 01 xxxx 07 WARNING Follow the safety
121. nd motor cables according to local regulations Select a cable capable of carrying the drive nominal current See section Ratings page 737 for the rated currents Select a cable rated for at least 70 C maximum permissible temperature of conductor in continuous use For US see Additional US requirements page 68 The inductance and impedance of the PE conductor cable grounding wire must be rated according to permissible touch voltage appearing under fault conditions so that the fault point voltage will not rise excessively when a ground fault Occurs e 600 VAC cable is accepted for up to 500 V AC 750 V AC cable is accepted for up to 600 V AC For 690 V AC rated equipment the rated voltage between the conductors of the cable should be at least 1 kV Use symmetrical shielded motor cable see page 66 for drive frame size R5 and larger or motors larger than 30 kW 40 hp A four conductor system can be used up to frame size R4 with up to 30 kW 40 hp motors but shielded symmetrical motor cable is always recommended Ground motor cable shields 360 at both ends Keep the motor cable and its PE pigtail twisted shield as short as possible to reduce high frequency electromagnetic emissions Note When continuous metal conduit is employed shielded cable is not required The conduit must have bonding at both ends A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended Compare
122. nd up E200 EMC filter for second environment TN grounded system category C3 E201 EMC filter for second environment IT ungrounded system category C3 Available for 380 500 V frames R6 to R9 E202 EMC filter for first environment TN grounded system category C2 Cable entry box Fieldbus adapters 36 Operation principle and hardware description K473 FENA 11 high performance Ethernet IP Modbus TCP and PROFINET adapter module FEN 11 absolute encoder interface module FAIO 01 analog I O extension module FDIO 01 digital I O extension module Specialties Extended warranty ATEX certified function ATEX certified Safe motor disconnection function using the Safe torque off function Safety functions modules Q973 FSO 11 safety functions module Full set of printed manuals in selected language Note The delivered manual set may include manuals in English if the translation is not available Operation principle and hardware description 37 DE RIPTIO 38 Operation principle and hardware description Mechanical installation 39 Mechanical installation What this chapter contains This chapter gives a description of the mechanical installation of the drive Safety WARNING For frame sizes R6 to RY Use the lifting eyes of the drive when you lift the drive Do not tilt the drive The drive is heavy and its center of gravity is high An overturning drive can cause physical injury
123. nductive coupling 106 Electrical installation Electrical installation 107 Connecting a PC Connect a PC to the drive with an USB data cable USB Type A lt gt USB Type Mini B as follows 1 Lift the USB connector cover from bottom upwards 2 Insert the USB cable Mini B plug in the control panel USB connector 3 Insert the USB cable A plug in the USB connector of the PC gt The panel displays USB connected 108 Electrical installation Chaining a control panel to several drives A control panel can be chained to control several drives with standard Ethernet cables as follows 1 Set parameters of group 49 Panel port communication in ACS880 primary control program for each drive N Connect a cable to the control panel RJ 45 connector Connect the other end of the cable to the left hand side RJ 45 connector in the control panel housing of the first drive 99 4 Connect another cable to the right hand side RJ 45 connector the control panel housing of the first drive 5 Connect the other end of the cable to the left hand side RJ 45 connector in the control panel housing of the second drive and so on 6 In the last drive move the switch in the control panel housing upwards lo Electrical installation 109 IP55 UL Type 12 drives To preserve the degree of
124. nstallation 213 Placing the brake resistors 213 Protecting the system against thermal overload 214 TORT paroliere it 214 Pr 214 Protecting the resistor cable against short circuits 215 Mechanical installation 215 Electrical installation 215 Checking the insulation of the 215 Connection ses caule ww ti i ek cr EE CR a 215 Connection procedure is i GR BOR S 215 216 2 Se eee 217 acp 217 Degree of protection of JBR SACE and SAFUR 510 5 219 Terminals and cable lead through 15 Common mode du dt and sine filters What this chapter contains 221 COMMON mode ink oad dade deed a a OO DR Gn 221 When is a common mode filter needed 221 tea 221 When is a d
125. ominal input voltage of the drive Check the type designation label The input power cable has been connected to appropriate terminals the phase order is right and the terminals have been tightened pull conductors to check Appropriate supply fuses and disconnector have been installed The motor cable has been connected to appropriate terminals the phase order is right and the terminals have been tightened pull conductors to check The brake resistor cable if present has been connected to appropriate terminals and the terminals have been tightened pull conductors to check The motor cable and brake resistor cable if present has been routed away from other cables No power factor compensation capacitors have been connected to the motor cable The control cables if any have been connected to the control unit If a drive bypass connection will be used The direct on line contactor of the motor and the drive output contactor are either mechanically or electrically interlocked cannot be closed simultaneously There are no tools foreign objects or dust from drilling inside the drive Drive and motor connection box covers are in place The motor and the driven equipment are ready for start up E Start up 117 Start up What this chapter contains This chapter describes the start up procedure of the drive Startup procedure 1 setup of the drive control program according to the start up instr
126. on of safety functions modules 111 Installation procedure into Slot 2 111 Installation next to the control unit in frames R7 to R9 113 7 Installation checklist What this chapter contains 115 dac sirene 115 8 Start up What this chapter contains 117 LT LES LUTTE IT LUTTE 117 9 Fault tracing What this chapter contains 119 eee ee ree rrr 119 Warning and fault messages 119 10 Maintenance What this Chapter contains 121 Maintenance intervals 121 Preventive maintenance table 122 ee ee E 123 ko 123 Replacing the main cooling fan of frames R1 124 Replacing the auxiliary cooling fan of IP55 frames R1 to R3 125 Replacing the main cooling fan of frames R4 and R5 126 Replacing the auxiliary cooling fan of frame R4 and IP55 frame R5 and IP21 frame R5 types 5880 01 07
127. package by pallet truck to the installation site Upacking and examining the delivery frames R1 to R5 This illustration shows the layout of the transport package Examine that all items are present and there are no signs of damage Read the data on the type designation label of the drive to make sure that the drive is of the correct type Wem Description Wem Description 1 5 Drive with factory installed options Cardboard sleeve Control cable grounding shelf Romex connectors in IP21 frames R1 to R3 in a plastic bag inside the cable entry box Manuals CD Cushions 3 Printed quick guides and manuals 10 straps multilingual residual voltage warning sticker Cardboard tray Top cardboard cover Pf 12 Hood included with option 8056 42 Mechanical installation To unpack e Cut the straps 10 Remove the top cardboard cover 11 and cushions 6 9 Lift the cardboard sleeve 5 e Lift the drive Frame RS cable entry box 21 UL Type 1 This illustration shows the contents of the cable entry box package The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame 3aua0000118007 Mechanical installation 43 Upacking and examining the delivery frames R6 to R9 This illustration shows the layout of the transport package Examine that all items are present and there are no signs of da
128. phase 10 15 TN grounded and IT ungrounded systems 65 kA when protected by fuses given in the fuse tables US and Canada The drive is suitable for use on a circuit capable of delivering not more than 100 kA symmetrical amperes rms at 600 V maximum when protected by fuses given in the fuse table 47 to 63 Hz maximum rate of change 17 s Max 3 of nominal phase to phase input voltage 0 98 at nominal load Motor connection data Motor types Voltage U gt Frequency Current Switching frequency Maximum recommended motor cable length Asynchronous AC induction motors permanent magnet synchronous motors and AC induction servomotors to U 3 phase symmetrical Umax at the field weakening point 0 500 Hz See section Ratings 2 7 kHz typically For ACS880 01 xxxx 2 ACS880 01 xxxx 3 and ACS880 01 xxxx 5 frames R1 to R3 and for types ACS880 01 07A3 7 ACS880 01 09A8 7 ACS880 01 14A2 7 and ACS880 01 018A 7 150 m 492 ft For ACS880 01 xxxx 2 ACS880 01 xxxx 3 and ACS880 01 xxxx 5 frames R4 to R9 and for types from ACS880 01 022A 7 to ACS880 01 271A 7 300 m 984 ft Note With motor cables longer than 150 m 492 ft the EMC Directive requirements may not be fulfilled 164 Technical data Control unit ZCU 12 connection data Power supply XPOW Relay outputs RO1 RO3 XRO1 XRO3 24 V output XD24 2 and XD24 4 Digital inputs DI1 DI6 XDI 1 XDI 6 Start interlock inp
129. posal The main parts of the drive can be recycled to preserve natural resources and energy Produt parts and materials should be dismantled and separated Generally all metals such as steel aluminum copper and its alloys and precious metals can be recycled as material Plastics rubber cardboard and other packaging material can be used in energy recovery Printed circuit boards and DC capacitors C1 1 to C1 x need selective treatment according to IEC 62635 guidelines To aid recycling plastic parts are marked with an approppriate identification code Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers End of life treatment must follow international and local regulations Technical data 169 Applicable standards The drive complies with the following standards The compliance with the European Low Voltage Directive is verified according to standard EN 61800 5 1 EN 60204 1 2006 A1 2009 Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing emergency stop device supply disconnecting device IEC EN 60529 1991 A1 2000 Degrees of protection provided by enclosures IP code IEC 60664 1 2007 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests EN 61800 3 2004
130. power connection compatibility of the motor motor connection and other technical data Check the installation site Ambient conditions page 167 Unpack and examine the units only intact units Mechanical installation page 41 or 43 may be started up If the drive has been non operational Examine that all necessary optional modules and for more than one year the converter equipment are present and correct DC link capacitors need to be Mount the drive reformed page 134 Route the cables Routing the cables page 70 Check the insulation of the supply cable the Checking the insulation of the motor and the motor cable assembly page 81 Connect the power cables Connecting the power cables page Connect the control cables 84 Connecting the control cables page 99 Check the installation Installation checklist page 115 Start the drive up Start up page 117 Operate the drive start stop speed control etc ACS880 quick start up guide firmware manual 24 Introduction to the manual Terms and abbreviations Term Explanation Abbreviation Electromagnetic compatibility Electromagnetic interference Electrical metallic tubing FIO 01 Optional digital I O extension module FIO 11 Optional analog I O extension module FENA 11 Optional dual port Ethernet IP and Modbus TCP and PROFINET adapter module Insulated gate bipolar transistor a voltage controlled semiconductor type widely used in inverters
131. pply for the control unit can be connected to terminal block XPOW Using an external supply is recommended if the control board needs to be kept operational during input power breaks for example due to continuous fieldbus communication immediate restart is needed after power breaks that is no control board power up delay is allowed Al1 and Al2 as Pt100 and KTY84 sensor inputs XAI XAO Three Pt100 sensors or one KTY84 sensor for motor temperature measurement can be connected between an analog input and output as shown below Alternatively you can connect the KTY to FEN 11 analog I O extension module or FEN xx encoder interface module Do not connect both ends of the cable shields directly to ground If a capacitor cannot be used at one end leave that end of the shield unconnected 1 3 x Pt100 or 1 x KTY T V AC 1 Set the input type to voltage with switch J1 for analog input Al1or with J2 for analog input Al2 Set the appropriate analog input unit to V volt in parameter group 12 Standard Al 2 Select the excitation mode in parameter group 13 Standard AO WARNING As the inputs pictured above are not insulated according to IEC 60664 the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfill the requirement the I O board terminals must be protected against contact and must not be connected to other equipment or the
132. protection Remove the drive front cover Put the cables through the control cable lead throughs Connect the cables as described above e Install the front cover Installing optional modules Note In frames R1 and R2 90 connector cannot be used in Slot 1 In other frames there is 50 to 55 mm free space for the connector and its cable available on Slots 1 2 and 3 Mechanical installation of I O extension fieldbus adapter and pulse encoder interface modules See page 32 for the available slots for each module Install the optional modules as follows WARNING Follow the safety instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Remove the front cover see the section Connecting the power cables starting from page 84 3 Frames R1 to R3 Pull the control panel mounting platform upwards to gain access to the optional module slots A 4 Insert the module carefully into its position on the control unit 5 Fasten the mounting screw Note The screw tightens the connections and grounds the module It is essential for fulfilling the EMC requirements and for proper operation of the module 110 Electrical installation Wiring I O extension fieldbus adapter and pulse encoder interface modules See
133. rive end bearing n a Motors of this power range are not available as standard units Consult the motor manufacturer Additional requirements for explosion safe EX motors If you will use an explosion safe EX motor follow 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 Additional requirements for the braking applications When the motor brakes the machinery the intermediate circuit DC voltage of the drive increases the effect being similar to increasing the motor supply voltage by up to 20 percent Consider this voltage increase when specifying the motor insulation requirements if the motor will be braking a large part of its operation time Example Motor insulation requirement for a 400 V AC line voltage application must be selected as if the drive were supplied with 480 V Planning the electrical installation 59 Additional requirements for ABB high output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 2001 This table shows the requirements for ABB random wound motor series for example M3AA M3AP and M3BP Nominal mains Requirement for voltage AC line Motor ABB du dt and common mode filters insulated N voltage insulat
134. round If a capacitor cannot be used at one end leave that end of the shield unconnected See the firmware manual for parameter settings Note PTC sensors can alternatively be connected to FEN xx encoder interface module 0 gt 4 kohm 1 lt 1 5 kohm Imax 5 mA WARNING As the inputs pictured above are not insulated according to IEC 60664 the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfill the requirement the I O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the terminals Safe torque off XSTO For the drive to start both connections OUT1 to IN1 and IN2 must be closed By default the terminal block has jumpers to close the circuit Remove the jumpers before connecting an external Safe torque off circuitry to the drive See page 197 Safety functions X12 See section mplementing the Safety functions options on page 73 and FSO 11 user s manual 0 0000097054 English Electrical installation 105 Control cable connection procedure iN WARNING Follow the safety instructions page 74 Ignoring the instructions can cause physical injury or death or damage to the equipment Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that ther
135. ry the motor and repeat the measurement Brake resistor assembly Check the insulation of the brake resistor assembly if present as follows 1 Check that the resistor cable is connected to the resistor and disconnected from the drive output terminals R and R At the drive end connect the R and R conductors of the resistor cable together Measure the insulation resistance between the combined conductors and the PE conductor by using a measuring voltage of 1 kV DC The insulation resistance must be higher than 1 Mohm Electrical installation 83 Checking the compatibility with IT ungrounded systems EMC filters E200 and E202 are not suitable for use in an IT ungrounded system If the drive is equipped with filter E200 or E202 disconnect the filter before connecting the drive to the supply network Undo the two screws which are marked with EMC AC and EMC DC on the skeleton See EMC filter disconnecting instructions for ACS880 01 drives with filters E200 and E202 3AUA0000125152 English For frame R4 contact ABB WARNING If a drive with EMC filter E200 or E202 is installed on an IT AN system an ungrounded power system or a high resistance grounded over 30 ohm power system the system will be connected to earth potential through the EMC filter capacitors of the drive This may cause danger or damage the unit 84 Electrical installation Connecting the power cables Connection diagram ACS8
136. s seco o RE Re eal Bh dem Bebe hess a tn 27 CCUG serene ek hk Roe EE Se es oe 28 Layout IP21 UL Type 1 29 Lay OU a e a ae aed i at 30 Layout DL TYPE 12 3e vee ee toon ed de Daley RT SERO Far 31 Overview of power and control connections 32 External control connection terminals 33 34 Type designation 34 Type deslgrnauor Key ua rk ea 95 4 Mechanical installation What this chapter contains 39 oculo Arm 39 Examining the installation site 40 OOS resres EE E Bee EE E 40 Moving Medve arte hee an gt ce ant 41 Upacking and examining the delivery frames R1 to R5 41 Frame R5 cable entry box IP21 UL Type 1 42 Upacking and examining the delivery frames to R9 43 Frame R6 cable entry box IP21 UL Type 1 44 Frame R7 cable entry box IP21 UL Type 1 45
137. s not always possible to eliminate all potential hazards The assembler of the machine must inform the final user about the residual risks 206 Safe Torque off function Maintenance After the operation of the circuit is verified at start up it does not need any maintenance However it is a good practice to check the operation of the function when the other maintenance procedures are carried out on the machinery Include the Safe torque off operation test described above in the routine maintenance program of the machinery that the drive runs If any wiring or component change is needed after start up or the parameters are restored follow the test given in section Start up including acceptance test page 203 Fault tracing The indications given during the normal operation of the Safe torque off function are selected by drive parameter 31 22 The diagnostics of the Safe torque off function cross compare the status of the two STO channels In case the channels are not in the same state a fault reaction function is performed and the drive trips on an STO hardware failure fault An attempt to use the STO in a non redundant manner for example activating only one channel will trigger the same reaction See the drive firmware manual for the indications generated by the drive and for details on directing fault and warning indications to an output on the control unit for external diagnostics Any failures of the Safe torque off
138. sation capacitors or harmonic filters to the motor cables between the drive and the motor They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves If there are power factor compensation capacitors in parallel with the three phase input of the drive 1 Do not connect a high power capacitor to the power line while the drive is connected The connection will cause voltage transients that may trip or even damage the drive 2 f capacitor load is increased decreased step by step when the drive is connected to the power line ensure that the connection steps are low enough not to cause voltage transients that would trip the drive 3 Check that the power factor compensation unit is suitable for use in systems with AC drives ie harmonic generating loads In such systems the compensation unit should typically be equipped with a blocking reactor or harmonic filter Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate See also section mplementing a bypass connection on page 75 Planning the electrical installation 75 When you have selected to use DTC motor control mode and motor ramp stop open the contactor as follows 1 Give a stop command to the drive 2 Wait until the drive decelerates the motor to zero speed 3 Open the contactor When you have selected to use DTC motor control
139. sistor braking Protecting the system against thermal overload The brake chopper protects itself and the resistor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive The drive control program includes a resistor and resistor cable thermal protection function which can be tuned by the user See the firmware manual Frames R1 to R4 Equipping the drive with a main contactor is highly recommended for safety reasons Wire the contactor so that it opens in case the resistor overheats This is essential for safety since the drive will not otherwise be able to interrupt the main supply if the chopper remains conductive in a fault situation An example wiring diagram is shown below ABB resistors are equipped with a thermal switch 1 inside the resistor assembly as standard The switch indicates overtemperature and overload We recommend that you also wire the thermal switch to a digital input ot the drive L1 L2 L3 nr ACS880 1 12 13 Frames R5 to R9 A main contactor is not required for protecting against resistor overheating when the resistor is dimensioned according to the instructions and the internal brake chopper is in use The drive will disable power flow through the input bridge if the chopper remains conductive in a fault situation but the charging resistor may fail Note If an external brake chopper outside the drive module is used a main contactor is alwa
140. smann 170 5808 2 1 minimum short circuit current of the installation 148 Technical data gG fuses frames R1 to R6 Check on the fuse time current curve to ensure the operating time of the fuse is below 0 5 seconds Follow the local regulations gG fuses one fuse per phase circuit current Drive type ACS880 01 size Ux 208 240 V 46 6 50 ABB OFAFOOOHG 00 756 10 360 500 ABB OFAFOOOHTO 000 75 16 740 500 ABB OFAFOOOHTE 000 ABB fosia2 800 61 80 37500 500 OFAFOOOHEO O75 A2 087A 2 87 A52 2300 145 200 300000 500 ABB OFAFOH200 0 Ux 380 415 V 24 4 83 500 ABB OFAFOOOHA 000 40 33 6 ABB 000 40 40 6 500 ABB 000 0563 80 56 10 355 500 ABB OFAFOOOHTO 000 o7A23 72 10 356 500 OFAFOOOHTO 000_ oars 120 94 700 500 ABB 000 2465 120 126 6 700 500 ABB OFAFOOOHT6 000 OA 200 17 25 2500 50 OFAFOOOH25 000 025A3 260 25 32 4500 S00 OFAFOOOHS2 000 03243 360 32 40 7700 500 OFAFOOOHAO 000 03843 400 38 50 15400 500 OFAFO00HS0 000 45 3 500 45 63 2
141. stalled in clean air according to enclosure classification Cooling air must be clean free from corrosive materials and electrically conductive dust See page 16r The maximum ambient air temperature is 40 104 F at rated current The current is derated for 40 to 55 C 104 to 131 F The drive is suitable for use in a circuit capable of delivering not more than 100 000 rms symmetrical amperes 600 V maximum The ampere rating is based on tests done according to UL 508C The cables located within the motor circuit must be rated for at least 75 C 167 F in UL compliant installations e The input cable must be protected with fuses Circuit breakers must not be used without fuses in the USA Suitable IEC class aR fuses are listed on page 145 and UL class T fuses on page 153 For suitable circuit breakers contact your local ABB representative Forinstallation in the United States branch circuit protection must be provided in accordance with the National Electrical Code NEC and any applicable local codes To fulfill this requirement use the UL classified fuses Forinstallation in Canada branch circuit protection must be provided in accordance with the Canadian Electrical Code and any applicable provincial codes To fulfill this requirement use the UL classified fuses The drive provides overload protection in accordance with the National Electrical Code NEC 1 6 Technical data CSA marking
142. structed PE conductor and a shield The PE conductor must meet the requirements of IEC 61439 1 A four conductor system three phase conductors and a protective conductor on a cable tray is not allowed for motor cabling it is allowed for input cabling A four conductor system three phase conductors and a PE conductor in a PVC conduit is allowed for input and motor cabling with phase conductor cross section less than 10 mm 8 AWG or motors lt 30 kW 40 hp Not allowed in USA Corrugated or EMT cable with three phase conductors and a protective conductor is allowed for motor cabling with phase conductor cross section less than 10 mm 8 AWG or motors lt 30 kW 40 hp Symmetrical shielded cable with individual shields for each phase conductor is not allowed on any cable size for input and motor cabling 68 Planning the electrical installation Motor cable shield If the motor cable shield is used as the sole protective earth conductor of the motor ensure that the conductivity of the shield is sufficient See subsection General rules above or IEC 61439 1 To effectively suppress radiated and conducted radio frequency emissions the cable shield conductivity must be at least 1 10 of the phase conductor conductivity The requirements are easily met with a copper or aluminum shield The minimum requirement of the motor cable shield of the drive is shown below It consists of a concentric layer of copper wires with an open
143. t 134 Maintenance The principle of undoing the mounting screws in frames R4 and 5 is shown below view of an IP21 unit Capacitors The drive intermediate DC circuit employs several electrolytic capacitors Their lifespan depends on the operating time of the drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature In frames R1 to R3 the capacitors are integrated to the ZINT board and in frames R4 to R5 to the ZMAC board In frames R6 to R8 the capacitors are separate Maintenance 135 Capacitor failure is usually followed by damage to the unit and an input cable fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements are available from ABB Do not use other than ABB specified spare parts Reforming the capacitors The capacitors must be reformed if the drive has been stored for a year or more See page 34 for information on finding out the manufacturing date For information on reforming the capacitors see Converter module capacitor reforming instructions 3BFE64059629 English Memory unit When a drive is replaced the parameter settings can be retained by transferring the memory unit from the defective drive to the new drive The memory unit is located on the control unit see page 33 WARNING Do not remove or insert a memory unit when the drive is powered or
144. the appropriate optional module manual for specific installation and wiring instructions See page 706 for the routing of the cables Electrical installation 111 Installation of safety functions modules The safety functions module can be inserted into Slot 2 on the control unit or in frames R7 to R9 also next to the control unit Installation procedure into Slot 2 iN WARNING Follow the safety instructions page 74 Ignoring the instructions 9 can cause physical injury or death or damage to the equipment Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage Remove the front cover see the section Connecting the power cables on page 84 Frames R1 to R3 Pull the control panel mounting platform upwards to gain access to the optional module slots Insert the module carefully into its position on the control unit Attach the module with four screws Note The grounding screw a is essential for fulfilling the EMC requirements and for proper operation of the module Tighten the grounding screw of the electronics Connect the data communication cable to slot X110 on the module and to connector X12 on the drive control unit Connect the Safe torque off wires to connector X111 on the module and to connector XSTO on the drive module control unit as shown in section Wiring on page 198 Connect the external 24 V power supply cable to connector X
145. the shields of both the incoming and outgoing cable or connect the shields of the cables otherwise together US Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding runs consistently without breaks from the drive to the motor Implementing thermal overload and short circuit protection Protecting the drive and input power cable in short circuits Protect the drive and input cable with fuses as follows 72 Planning the electrical installation Size the fuses at the distribution board according to instructions given in chapter Technical data The fuses will protect the input cable in short circuit situations restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Note Circuit breakers must not be used without fuses For more information contact ABB Protecting the motor and motor cable in short circuits The drive protects the motor cable and motor in a short circuit situation when the motor cable is sized according to the nominal current of the drive No additional protection devices are needed Protecting the drive and the input power and motor cables against thermal overload The drive protects itself and the input and motor cables against thermal overload when the cables are sized according to the nominal current of the drive No additional thermal protection devices are needed WARNING If the drive is connected to mul
146. tiple motors use a separate circuit breaker or fuses for protecting each motor cable and motor against overload The drive overload protection is tuned for the total motor load It may not trip due to an overload in one motor circuit only Protecting the motor against thermal overload According to regulations the motor must be protected against thermal overload and the current must be switched off when overload is detected The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary Depending on a drive parameter value the function either monitors a calculated temperature value based on a motor thermal model or an actual temperature indication given by motor temperature sensors The user can tune the thermal model further by feeding in additional motor and load data The most common temperature sensors are e motor sizes IEC180 225 thermal switch eg Klixon e motor sizes IEC200 250 and larger PTC Pt100 See the firmware manual for more information on the motor thermal protection and the connection and use of the temperature sensors Planning the electrical installation 73 Protecting the drive against ground faults The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable This is not a personnel safety or a fire protection feature The ground fault protective function can be
147. ty 56 Planning the electrical installation Nominal AC supply Requirement for voltage Motor ABB du dt and common mode filters insulation insulated N end motor bearings system Py lt 100 kW 100 kW lt Py lt 350 kW and frame size or lt IEC 315 315 lt frame size lt IEC 400 lt 134 134 lt Py lt 469 and frame size or lt NEMA 500 NEMA 500 lt frame size lt NEMA 580 ABB motors Old form Uy lt 500 V Standard l N 500 V lt Un lt 600 Standard du dt du dt N or T 600 V lt Un lt 690 V Reinforced du dt du dt N cable length lt 150 m N 600 V lt Un lt 690 V Reinforced cable length gt 150 m 380 V lt Un lt 690 V Standard N CMF HX_ and modular Random 0 V lt Uy lt 500 V Enamelled N CMF wound 500 lt lt 690 v Wire with fiber du dt N HX_ and glass taping AM_ Kk kk 380 V lt Un lt 690 V Check with du dt with voltages over 500 V N the motor CMF wound manufacturer Consult the motor manufacturer manufactured before 1 1 1998 For motors manufactured before 1 1 1998 check for additional instructions with the motor manufacturer Planning the electrical installation 57 Nominal AC supply Requirement for voltage Motor ABB du dt and common mode filters insulation insulated N end motor bearings system Py lt 100 kW 100 kW lt Py lt 350 kW
148. u dt filler needed 221 dud nter WY DOS xc dcus tent dub TCU unt i dU a 222 Description installation and technical data of the FOCH filters 222 Description installation and technical data of the NOCH filters 222 EROE eU d EOS AE UR P 222 Further information Product and service inquiries 223 uet dcos arce ae oV de a 223 Providing feedback on ABB Drives manuals 223 Document library on the Internet 223 12 Safety instructions 13 Safety instructions What this chapter contains This chapter contains the safety instructions which you must follow when installing operating and servicing the drive If ignored physical injury or death may follow or damage may occur to the drive motor or driven equipment Read the safety instructions before you work on the unit Use of warnings Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment and advise on how to avoid the danger The following warning symbols are used in this manual Electricity warning warns of hazards from electricity which can cause physical injury and or damage to the equipment General warning warns about conditions other than those caused by electricity
149. uctions given in Quick start up guide for ACS880 primary control program or in the firmware manual 2 Validate the Safe torque off function according to the instructions given in chapter Safe Torque off function on page 197 3 Validate the Safety functions option Q973 as described in FSO 11 user s manual 3AUA0000097054 English 118 Start up Fault tracing 119 Fault tracing What this chapter contains This chapter describes the fault tracing possibilities of the drive LEDs When the LED is lit Control panel POWER Green Control unit is powered and 15 V is supplied to mounting the control panel platform FAULT Red Drivein fault state 000000000 0 in fault state Warning and fault messages See the firmware manual for the descriptions causes and remedies of the drive control program warning and fault messages 120 Fault tracing Maintenance 121 Maintenance What this chapter contains This chapter contains preventive maintenance instructions Maintenance intervals If installed in an appropriate environment the drive requires very little maintenance The table below lists the routine maintenance intervals recommended by ABB The recommended maintenance intervals and component replacements are based on specified operational and environmental conditions ABB recommends annual drive inspections to ensure the highest reliability and optimum performance For more infor
150. ut DIIL XD24 1 Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 Input output mode selection by parameters DIO1 can be configured as a frequency input 0 16 kHz with hardware filtering of 4 microseconds for 24 V level square wave signal sinusoidal or other wave form cannot be used DIO2 can be configured as a 24 V level square wave frequency output See the firmware manual parameter group 11 24 V 10 DC Supplied from the power unit of the drive or from an external power supply through connector XPOW pitch 5 mm wire size 2 5 mm Connector pitch 5 mm wire size 2 5 mm 250 VAC 30 V DC 2 Protected by varistors Connector pitch 5 mm wire size 2 5 mm Total load capacity of these outputs is 4 8 W 200 mA 24 V minus the power taken by DIO1 and DIO2 Connector pitch 5 mm wire size 2 5 mm 24 V logic levels 0 lt 5 V 17 gt 15V Rin 2 0 kohm Input type NPN PNP DI1 DI5 NPN DI6 Hardware filtering 0 04 ms digital filtering up to 8 ms 016 XDI 6 can alternatively be used as an input for PTC sensors 0 gt 4 kohm 1 lt 1 5 kohm Imax 15 MA for DIG 5 mA Connector pitch 5 mm wire size 2 5 mm 24 V logic levels 0 lt 5 V 17 gt 15V Rin 2 0 kohm Input type NPN PNP Hardware filtering 0 04 ms digital filtering up to 8 ms 2 2 Connector pitch 5 mm wire size 2 5 mm As inputs 24 V logic levels 0 lt 5 V 17 gt
151. v G EN EFFECTIVE 2013 07 01 Table of contents List of related manuals 2 1 Safety instructions What this chapter contains Use 9 aps e ow ee Safety in installation and maintenance Eel srs e A e iii TORA ERI IR Permanent magnet motor drives General Salesi RIE EIA SILE PHINISG GINGUIE ucc heus i Cn oe he c Safe start up and operation Genera each vivaio innate ee TII Permanent magnet motor drives 2 Introduction to the manual What this chapter contains 1 3 21 rt 21 Contents of the manual 21 Related Manuals 24k cx excea ZE ee 22 Categorization by frame size and option code 22 Quick installation start up and operating flowchart 23 Terms abbreviations 24 Safety data SIL PL Y 55So0 era 25 3 Operation principle and hardware description What this chapter contains 27 Product oVer VIP Wa
152. ve and the supply connections become live Before installation and maintenance work on the drive e Stop the motor e Ensure that there is no voltage on the drive power terminals according to step 1 or 2 or if possible according to the both steps 1 Disconnect the motor from the drive with a safety switch or by other means Check by measuring that there is no voltage present on the drive input or output terminals L1 L2 L3 U T1 V T2 W T3 UDC UDC 2 Ensure that the motor cannot rotate during work Make sure that no other system like hydraulic crawling drives is able to rotate the motor directly or through any mechanical connection like felt nip rope etc Check by measuring that there is no voltage present on the drive input or output terminals L1 L2 L3 U T1 V T2 W T3 UDC UDC Ground the drive output terminals temporarily by connecting them together as well as to the PE Safety instructions 17 General safety These instructions are intended for all who install and service the drive WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment e Handle the unit carefully Frame sizes R6 to R9 Lift the drive using the lifting eyes of the unit Do not tilt the drive The drive is heavy and its center of gravity is high An overturning unit can cause physical injury Bewar
153. ves can be run in parallel installed next to each other The motor cable input power cable and control cables should be installed on separate trays Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power cables ensure they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive The cable trays must have good electrical bonding to each other and to the grounding electrodes Aluminum tray systems can be used to improve local equalizing of potential A diagram of the cable routing is shown below Motor cable Powercable min 300 mm 12 in Input power cable Motor cable min 200 mm 8 in 90 min 500 mm 20 in Control cables Planning the electrical installation 71 Separate control cable ducts Lead 24 V and 230 V 120 V control cables in separate ducts unless the 24 V cable is insulated for 230 V 120 V or insulated with an insulation sleeving for 230 V 120 V 230 V 24V 120 V Continuous motor cable shield or enclosure for equipment on the motor cable To minimize the emission level when safety switches contactors connection boxes or similar equipment are installed on the motor cable between the drive and the motor European Union Install the equipment in a metal enclosure with 360 degree grounding for
154. y automatic fault reset functions of the drive control program if dangerous situations can occur When activated these functions will reset the drive and resume operation after a fault The maximum number of drive power ups is five in ten minutes Too frequent power ups can damage the charging circuit of the DC capacitors Make sure that any safety circuits for example emergency stop and Safe torque off are validated in start up See chapter Start up for reference of the validation instructions Note e Ifan external source for start command is selected and it is ON the drive will start immediately after an input voltage break or fault reset unless the drive is configured for 3 wire a pulse start stop e When the control location is not set to local the stop key on the control panel will not stop the drive Safety instructions Permanent magnet motor drives WARNING Do not run the motor over the rated speed Motor overspeed leads to overvoltage which may damage or explode the capacitors in the intermediate circuit of the drive 19 20 Safety instructions Introduction to the manual 21 Introduction to the manual What this chapter contains This chapter describes the manual It contains a flowchart of steps for checking the delivery installing and starting up the drive The flowchart refers to chapters sections in this manual and to other manuals Target audience This manual is intended for peop
155. ys required Resistor braking 215 A thermal switch standard in ABB resistors is required for safety reasons The thermal switch cable must be shielded and may not be longer than the resistor cable Wire the switch to a digital input on the drive control unit as shown in the figure below 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 All brake resistors must be installed outside the drive Follow the resistor manufacturer s instructions Electrical installation Checking the insulation of the assembly Follow the instructions given under Brake resistor assembly on page 82 Connection diagram See section Connection diagram on page 84 Connection procedure Connect the resistor cables to the and R terminals the same way as the other power cables If a shielded three conductor cable is used cut the third conductor and ground the twisted shield of the cable protective earth conductor of the resistor assembly at both ends e Connect the thermal switch of the brake resistor as described above in section Frames R1 to R4 or Frames R5 to R9 Start up Note Protective oil on the brake resistors will burn off when the brake resistor is used for the first time Make sure that the airflow is sufficient 216 Resistor braking Set the following parameters ACS880 primary control progra
156. zle Using a A normal vacuum cleaner creates static discharges which can damage circuit boards 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Remove the cooling fan s See section Fans below 3 Blow clean compressed air not humid from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note If there is a risk of dust entering adjoining equipment perform the cleaning in another room 4 Refit the cooling fan Fans The lifespan of the cooling fans of the drive depend on the running time of the fan ambient temperature and dust concentration See the firmware manual for the actual signal which indicates the running time of the cooling fan Reset the running time signal after a fan replacement Replacement fans are available from ABB Do not use other than ABB specified spare parts 124 Maintenance Replacing the main cooling fan of frames R1 to R3 WARNING Follow the safety instructions page 74 Ignoring the instructions 4 can cause physical injury or death or damage to the equipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Release the retaining clip by pushing with a flat screwdriver and turning to the right 3 Lift the fan cassette up 4 Install the new fan in reverse order Maintena

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