Page 1 — ABB INDUSTRIAL DRIVES ACS880-07 drives (560 to 2800 kW) Hardware manual...
Page 3 ACS880-07 drives (560 to 2800 kW) Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 9. Start-up 3AUA0000143261 Rev G Original instructions EFFECTIVE: 2023-12-31...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ............... . Use of warnings and notes .
Page 6 6 Table of contents Descriptions of options ............... . . Degree of protection .
Page 7 Requirements tables ............... . . Requirements for ABB motors, P <...
Page 8 Additional requirements for braking applications ....... . . Additional requirements for ABB high-output and IP23 motors ....
Page 9 Table of contents 9 Protecting the contacts of relay outputs ........... . Implementing a motor temperature sensor connection .
Page 10 10 Table of contents 7 Control units of the drive Contents of this chapter ............... . General .
Page 11 Table of contents 11 Fans ....................Replacing a supply module (D7T) cooling fan .
Page 12 12 Table of contents DC fuses ..................Supply module internal DC fuses .
Page 13: Table Of Contents
Table of contents 13 Frame 1×D8T + 2×R8i, IP54 (+B055) ........... Frame 1×D8T + 2×R8i with common motor terminal cubicle (+H359), 1/2 .
Page 14 14 Table of contents Cubicle width 600 mm, bottom cable exit ......... . . Cubicle width 600 mm, top cable exit .
Page 15 Table of contents 15 Selecting and routing the cables of a custom resistor ....... Minimizing electromagnetic interference .
Page 17: Safety Instructions
Safety instructions 17 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start-up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 18: General Safety In Installation, Start-Up And Maintenance
18 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 19 Safety instructions 19 max. • Do not move the module on its wheels for long distances. It can cause damage to the wheels. Also, there is a risk of the module falling over. • Be careful when handling a tall module. The module overturns easily because it is heavy and has a high center of gravity.
Page 20 20 Safety instructions • Before you adjust the drive operation limits, make sure that the motor and all driven equipment can operate throughout the set operation limits. • Before you activate the automatic fault reset or automatic restart functions of the drive control program, make sure that no dangerous situations can occur.
Page 21: Electrical Safety In Installation, Start-Up And Maintenance
Safety instructions 21 Electrical safety in installation, start-up and maintenance Electrical safety precautions ￭ These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 22: Additional Instructions And Notes
There are electromagnetic fields present which can interfere with the function of such devices. This can cause a health hazard. • ABB does not recommend attaching the cabinet by arc welding. If you have to, obey the welding instructions in the drive manuals. Note: •...
Page 23: Printed Circuit Boards
Safety instructions 23 Printed circuit boards WARNING! Use a grounding wristband when you handle printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge. Grounding ￭ These instructions are for all personnel who are responsible for the grounding of the drive.
Page 24: General Safety In Operation
24 Safety instructions General safety in operation These instructions are for all personnel that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Keep the cabinet doors closed when the drive is powered. With the doors open, a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists.
Page 25: Safety In Operation
Safety instructions 25 Before installation, start-up and maintenance work on the drive: • Stop the drive. • Disconnect the motor from the drive with a safety switch or by other means. • If you cannot disconnect the motor, make sure that the motor cannot rotate during work.
Page 27: Introduction To The Manual
Introduction to the manual 27 Introduction to the manual Contents of this chapter This chapter describes the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals. Target audience This manual is intended for people who plan the installation, install, commission and do maintenance work on the drive, or create instructions for the end user of the drive...
Page 28: Use Of Component Designations
28 Introduction to the manual Use of component designations Some device names in the manual include the component designation in brackets (for example, [Q20]). This will help you to identify the components in the circuit diagrams of the drive. Quick installation, commissioning and operation flowchart Task Guidelines for planning the electrical in- Plan the electrical installation and acquire the accessories...
Page 29: Terms And Abbreviations
Type of control unit USCA-02 Adapter for installing F-series option modules onto the UCU control unit. Related documents You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. ACS880-07 (560 to 2800 kW) manuals...
Page 31: Operation Principle And Hardware Description
This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACS880-07 is an air-cooled cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, ABB synchronous reluctance (SynRM) motors and AC induction servomotors.
Page 32: Overview Circuit Diagram Of The Drive
Supply module. Converts alternating current and voltage to direct current and voltage. The module contains an AC input choke. The ACS880-07 has 1…4 supply modules connected in parallel. 12-pulse units have either one or two supply modules per each 6-pulse supply line.
Page 33: 12-Pulse Connection (Option +A004)
Operation principle and hardware description 33 Auxiliary voltage transformers (T21, T101, T111). T21 is standard; T101 and T111 are added whenever required by the options ordered. 12-pulse connection (option +A004) The figure below illustrates the difference between 6-pulse and 12-pulse AC supply connections.
Page 34: Cabinet Line-Up And Layout Examples
34 Operation principle and hardware description Cabinet line-up and layout examples Frame 1×D8T+2×R8i ￭ Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See section Auxiliary control cubicle (ACU) layout (page 42). Incoming cubicle (ICU). Contains the power input cable terminals and switchgear. Supply module cubicle.
Page 35 Operation principle and hardware description 35 Cabinet layout example Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 42). Input cable lead-throughs, PE busbar Input terminals Main switch-disconnector (Q1.1) Grounding (earthing) switch (Q9.1) (optional) AC fuses Main contactor (Q2.1) (optional) Auxiliary voltage switch (Q21) with fuses Incoming cubicle cooling fan Supply module...
Page 36: Frame 2×D7T+2×R8I (12-Pulse Connection, Option +A004)
36 Operation principle and hardware description Frame 2×D7T+2×R8i (12-pulse connection, option +A004) ￭ Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See section Auxiliary control cubicle (ACU) layout (page 42). Incoming cubicle (ICU). Contains the power input cable terminals and switchgear. With option +F259 (grounding switch), there are two incoming cubicles, one for each 6-pulse supply line.
Page 37 Operation principle and hardware description 37 Cabinet layout example Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 42). Input cable lead-throughs, PE busbar Input terminals Main switch-disconnector (Q1.1) AC fuses Main contactors (Q2.1 and Q2.2) (optional) Auxiliary voltage switch (Q21) with fuses Incoming cubicle cooling fans Supply modules.
Page 38: Frame 2×D8T+3×R8I
38 Operation principle and hardware description Frame 2×D8T+3×R8i ￭ Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See section Auxiliary control cubicle (ACU) layout (page 42). Incoming cubicle (ICU). Contains the power input cable terminals and switchgear. Supply module cubicle.
Page 39 Operation principle and hardware description 39 Cabinet layout example Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 42). Input cable lead-throughs, PE busbar Input terminals Main switch-disconnector (Q1.1) Grounding (earthing) switch (Q9.1) (optional) Common AC fuses (installed with optional main contactor) Main contactor (Q2.1) (optional) Auxiliary voltage switch (Q21) with fuses Incoming cubicle cooling fans...
Page 40: Frame 3×D8T+4×R8I (With Main Breaker, Option +F255)
40 Operation principle and hardware description Frame 3×D8T+4×R8i (with main breaker, option +F255) ￭ Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See section Auxiliary control cubicle (ACU) layout (page 42). Incoming cubicle (ICU). Contains the power input cable terminals and switchgear. Supply module cubicle.
Page 41 Operation principle and hardware description 41 Cabinet layout example Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 42). Input cable lead-throughs, PE busbar Input terminals Incoming cubicle cooling fans Main breaker (Q1) (option +F255) Auxiliary voltage switch (Q21) with fuses Grounding (earthing) switch (Q9.1) (optional) Supply module AC fuses Supply modules...
Page 42: Auxiliary Control Cubicle (Acu) Layout
42 Operation principle and hardware description 40 Operation principle and hardware description Auxiliary control cubicle (ACU) layout ￭ Auxiliary control cubicle (ACU) layout A layout example of the auxiliary control cubicle (ACU) is shown below. On the left: A layout example of the auxiliary control cubicle (ACU) is shown below. Swing-out frame closed, detachable mounting plates in place.
Page 43 Operation principle and hardware description 43 Switch (F90) for ground fault monitoring Motor fan starters and contactors (options (item 12) +M602…610) FSO-xx safety functions module (option Terminal blocks (X601) for motor fan connec- +Q972 or +Q973 and other options requiring tions (options +M602…610) FSO-xx) Temperature monitoring relays (options...
Page 44: Overview Of Power And Control Connections (Bcu-X2)
44 Operation principle and hardware description Overview of power and control connections (BCU-x2) The diagram shows the power connections and control interfaces of the drive. SLOT 1...3 SLOT 4 X205 V1T/R… . . . M 3 ~ Drive Supply control unit (A51) Inverter control unit (A41) Option modules can be inserted into slots 1, 2, 3 and 4 as follows: Module type...
Page 45 Operation principle and hardware description 45 Control panel and PC connection Terminal blocks on the inverter control unit. These terminals are optionally wired to terminal block X504 in the auxiliary control cabinet of the drive. Fiber optic link to each inverter module. Similarly, each supply module is connected to the supply control unit by fiber optic cables.
Page 46: Overview Of Power And Control Connections (Ucu-22
46 Operation principle and hardware description Overview of power and control connections (UCU-22…24) The diagram shows the power connections and control interfaces of the drive. XPAN SLOT 1...3 XETH1..4 SLOT 4 XFSO V1T/R… . . . M 3 ~ Drive Supply control unit (A51) Inverter control unit (A41) Option modules can be inserted into slots 1, 2, 3 and 4 as follows:...
Page 47 Operation principle and hardware description 47 Control panel and PC connection Ethernet ports for fieldbus communication (XETH 1…2) and tool communication (XETH 3…4). Not in use. Terminal blocks on the inverter control unit. These terminals are optionally wired to terminal block X504 in the auxiliary control cabinet of the drive.
Page 48: Door Devices
48 Operation principle and hardware description Door devices Label in Eng- Label in local Description lish language READY Ready light (option +G327) Run light (option +G328) FAULT Fault light (option +G329) ENABLE / RUN Run enable signal switch for the supply unit Run enable signal off (starting the supply unit not allowed) Run enable signal on (starting the supply unit allowed).
Page 49: Main Disconnecting Device (Q1.1)
Operation principle and hardware description 49 Main disconnecting device (Q1.1) ￭ Depending on the configuration of the drive, the main disconnecting device of the drive is either a switch-disconnector or a main circuit breaker. Units with a switch-disconnector also have a main contactor. The main disconnecting device switches the main supply to the drive on and off.
Page 50: Control Panel
50 Operation principle and hardware description Control panel ￭ The ACS-AP-W is the user interface of the drive. It provides the essential controls such as Start/Stop/Direction/Reset/Reference, and the parameter settings for the inverter control program. The control panel can be removed by pulling it forward by the top edge and reinstalled in reverse order.
Page 51: Descriptions Of Options
Operation principle and hardware description 51 Descriptions of options Note: All options are not available for all drive types, are not compatible with some other options, or require additional engineering. Degree of protection ￭ Definitions According to IEC/EN 60529, the degree of protection is indicated by an IP code where the first numeral means protection against ingress of solid foreign objects, and the second numeral protection against ingress of water.
Page 52: Cooling Air Inlet Through Bottom Of Cabinet (Option +C128)
52 Operation principle and hardware description Marine product certifications may require additional wire markings. Refer to section Wire markings (page 54). Cooling air inlet through bottom of cabinet (option +C128) ￭ See section Air inlet through the bottom of the cabinet (option +C128) (page 82).
Page 53: Empty Cubicles On Left (Options +C199
Operation principle and hardware description 53 Empty cubicles on left (options +C199…C201) ￭ The option adds an empty 400, 600 or 800 mm wide cubicle to the left end of the line-up. The cubicle is equipped with blank power cable entries both at the top and the bottom.
Page 54: Output For Motor Space Heater (Option +G313)
54 Operation principle and hardware description • Supplying power for the auxiliary circuits (page 111) • circuit diagrams delivered with drive for the actual wiring. Output for motor space heater (option +G313) ￭ The option contains: • load switch for providing electrical isolation during service •...
Page 55: Additional Wire Markings
Operation principle and hardware description 55 • Main circuit terminals: Connector identifier (eg. "U1") marked on terminal, or on insulating material close to the terminal. Input and output main circuit cables are not marked. • Plug-in connectors of wire sets (except those that require special tools to disconnect) are labeled with connector designation (eg.
Page 56: Top Cable Entry/Exit (Options +H351 And +H353)
56 Operation principle and hardware description provide power and control cable entries at the floor of the cabinet. The entries are equipped with grommets and 360° grounding hardware. For non-UL Listed units, bottom entry/exit is the default cabling arrangement. Top cable entry/exit (options +H351 and +H353) ￭...
Page 57: Connectivity For Wired Remote Monitoring (Option +K496)
Operation principle and hardware description 57 Connectivity for wired remote monitoring (option +K496) ￭ This option provides a gateway to connect the drive to ABB Ability™ via a local Ethernet network. Includes NETA-21 remote monitoring tool and FMBT-21 Modbus/TCP adapter module.
Page 58: L505, +2L505, +L513, +2L513
58 Operation principle and hardware description +L505, +2L505, +L513, +2L513 Option +L505 provides a thermistor relay and a terminal block. The terminal block has connections for the measuring circuit (one to three PTC sensors in series), an output indication of the relay, and an optional external reset button. The relay can be reset either locally or externally, or the reset circuit can be jumpered for automatic reset.
Page 59: Starter For Auxiliary Motor Fan (Options +M600
Operation principle and hardware description 59 The standard Pt100 relay options include two (+2L506), three (+3L506), five (+5L506) or eight (+8L506) relays. By default, the relays are wired internally to digital input DI6 of the drive control unit. The loss of the input is set to trigger an external fault. The options include a terminal block for sensor connection.
Page 60: Type Designation Label
60 Operation principle and hardware description Type designation label The type designation label includes ratings, appropriate markings, a type designation and a serial number, which allow the identification of each unit. A sample label is shown below. Quote the complete type designation and serial number when contacting technical support.
Page 61: Type Designation Key
Operation principle and hardware description 61 Type designation key The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic drive type. The optional selections are given thereafter, separated by plus signs, eg, +E202. Codes preceded by a zero (eg.
Page 62 62 Operation principle and hardware description Code Description Empty 600 mm wide cubicle on left. See section Empty cubicles on left (options C200 +C199…C201) (page 53). Empty 800 mm wide cubicle on left. See section Empty cubicles on left (options C201 +C199…C201) (page 53).
Page 63 Operation principle and hardware description 63 Code Description Common output terminals (for inverter modules mounted in the same cubicle). See section H366 Descriptions of options (page 51). J425 ACS-AP-I control panel (without Bluetooth) K451 FDNA-01 DeviceNet™ adapter module K454 FPBA-01 PROFIBUS DP® adapter module K457 FCAN-01 CANopen®...
Page 64 64 Operation principle and hardware description Code Description M604 Starter for auxiliary motor fan, trip limit 6.3 … 10 A M605 Starter for auxiliary motor fan, trip limit 10…16 A M606 Starter for auxiliary motor fan, trip limit 16…20 A M610 Starter for auxiliary motor fan, trip limit 20…25 A N5000...
Page 65 Operation principle and hardware description 65 Code Description Q982 PROFIsafe with FSO safety functions module and FPNO-21 Ethernet adapter module Q986 FSPS-21 PROFIsafe safety functions module R700 Printed documents in English R701 Printed documents in German R702 Printed documents in Italian R703 Printed documents in Dutch R704...
Page 67: Mechanical Installation
Mechanical installation 67 Mechanical installation Contents of this chapter This chapter tells how to examine the installation site, unpack and examine the delivery and install the drive mechanically.
Page 68: Examining The Installation Site
68 Mechanical installation Examining the installation site Examine the installation site. Make sure that: • The installation site is sufficiently ventilated or cooled to remove heat from the drive. See the technical data. • The ambient conditions of the drive meet the specifications. See the technical data.
Page 69: Moving And Unpacking The Drive
Mechanical installation 69 • drive cabinet line-up • optional modules (if ordered) installed onto the control unit(s) at the factory • appropriate drive and optional module manuals • delivery documents. Make sure that there are no signs of damage. Before attempting installation and operation, see the information on the type designation labels of the drive to verify that the delivery is of the correct type.
Page 70: Lifting The Crate With A Crane
70 Mechanical installation Lifting the crate with a crane WARNING! Obey the local laws and regulations applicable to lifting, such as requirements for planning the lifting, for capacity and condition of lifting equipment, and for training of personnel. Lifting point Optimal position for the lifting sling: as close to the traverse board as possible...
Page 71: Moving The Crate With A Forklift
Mechanical installation 71 Mechanical installation 61 Moving the crate with a forklift Moving the crate with a forklift 750 mm (29.5'') Removing the transport package ￭ Remove the transport package as follows: Undo the screws that attach the wooden parts of the transport crate to each other.
Page 72: Moving The Unpacked Drive Cabinet
62 Mechanical installation Removing the transport package  72 Mechanical installation Remove the transport package as follows: 1. Undo the screws that attach the wooden parts of the transport crate together. Moving the unpacked drive cabinet ￭ 2. Remove the wooden parts. Lifting the cabinet with a crane 3.
Page 73: Moving The Cabinet On Its Back
Mechanical installation 73 Lay the cabinet on the rollers and move it carefully until close to its final location. Remove the rollers by lifting the unit with a crane, forklift, pallet truck or jack. Moving the cabinet on its back WARNING! Do not transport a drive with a sine filter (option +E206) on its back.
Page 74: Attaching The Cabinet To The Floor And Wall Or Roof
74 Mechanical installation Attaching the cabinet to the floor and wall or roof General rules ￭ • The drive must be installed in an upright vertical position. • Leave 400 mm (15.75”) of free space above the basic roof level of the cabinet for cooling.
Page 75: Attaching The Cabinet (Non-Marine Units)
Mechanical installation 75 WARNING! Do not stand or walk on the cabinet roof. Make sure that nothing presses against the roof, side or back plates or door. Do not store anything on the roof while the drive is in operation. Attaching the cabinet (non-marine units) ￭...
Page 76: Alternative 2 - Using The Holes Inside The Cabinet
76 Mechanical installation Alternative 2 – Using the holes inside the cabinet Attach the cabinet to the floor through the bottom fastening holes with size M10…M12 (3/8”…1/2”) bolts. The recommended maximum distance between the front edge fastening points is 800 mm (31.5”). If the back fastening holes are not accessible, attach the top of the cabinet to the wall with L-brackets (not included in the delivery) bolted to the lifting eye/bar holes.
Page 77: Attaching The Cabinet (Marine Units)
Mechanical installation 77 Attaching the cabinet (marine units) ￭ See the dimension drawing delivered with the drive for details of the fastening points. Fasten the cabinet to the floor and roof (wall) as follows: Bolt the unit to the floor through the flat bars at the base of the cabinet using M10 or M12 screws.
Page 78: Joining Cabinet Sections Together
78 Mechanical installation Joining cabinet sections together Wide cabinet line-ups are delivered in multiple sections. The sections must be joined together at the installation site. There is a joining cubicle at the end of a section for this purpose. The screws for joining the sections are in a plastic bag inside the cabinet. Attach the first section to the floor.
Page 79 Mechanical installation 79 Connect the PE (ground) busbars using the M10 bolts included. Tighten to 35…40 N·m (25…30 lbf·ft). If necessary, adjust the connection between two PE busbars with the spacer plates (included in the delivery). Bolt Spring washer Plain washer Self-clinching nut Spacer plate Remove the shroud covering the DC busbars in the joining cubicle.
Page 80 80 Mechanical installation Connect the DC and AC busbars. Tighten the bolts to 55…70 N·m (40…50 lbf·ft). Units with single DC busbars Units with double DC busbars Accessories kit identification: Single DC busbars: 3AXD50000125876 Double DC busbars: 3AXD50000126361 Triple DC busbars (not shown): 3AXD50000126378 Joint piece Plain washer with electroplated zinc coating and blue chromate passivation Spring washer with mechanically sprayed zinc coating...
Page 81 Mechanical installation 81 Units with single AC busbars Units with double AC busbars Accessories kit identification: Single AC busbars: 3AXD50000126392 Double AC busbars: 3AXD50000126408 Triple AC busbars (not shown): 3AXD50000126514 Bolt (M12) Bolt (M12) Joint piece Plain washer with electroplated zinc coating and blue chromate passivation Spring washer with mechanically sprayed zinc coating Nut (M12) WARNING!
Page 82: Miscellaneous
Arc welding ￭ ABB does not recommend attaching the cabinet by arc welding. However, if arc welding is the only option, connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1’6”) of the welding point.
Page 83: Air Outlet Duct On The Cabinet Roof (Option +C130)
Mechanical installation 83 Air inlet area Support the plinth of the cabinet all round. The air duct must be able to supply a sufficient volume of cooling air. See technical data for the minimum air flow values. Top cable entry adapter and joining cubicles have no air inlet. WARNING! Make sure that the incoming air is sufficiently clean.
Page 84: Calculating The Required Static Pressure Difference
The required pressure in the exit air duct is then 1.5…2 · 17 Pa = 26…34 Pa below the pressure in the room. Lifting lugs and bars Certificate of conformity ￭ The certificate is available in ABB Library at www.abb.com/drives/documents (document number 3AXD10001061361).
Page 85: Declarations Of Conformity
Mechanical installation 85 Declarations of conformity ￭...
Page 86 86 Mechanical installation...
Page 87 Mechanical installation 87 Declaration of Conformity Supply of Machinery (Safety) Regulations 2008 Manufacturer: ABB Oy Address: Hiomotie 13, 00380 Helsinki, Finland. Phone: +358 10 22 11 declare under our sole responsibility that the following products: Lifting bars, identified with material codes...
Page 88 Supply of Machinery (Safety) Regulations 2008. Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland Helsinki, 28 May 2021 Signed for and on behalf of:...
Page 89: Guidelines For Planning The Electrical Installation
Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
Page 90: Selecting The Supply Transformer
90 Guidelines for planning the electrical installation Selecting the supply transformer Basic guidelines ￭ Define the apparent power of the transformer. You can use this rule of thumb: (kVA) = 1.32 × sum of the motor shaft power (kW) Define the nominal voltage for the transformer secondary winding according to the nominal input voltage of the drive.
Page 91 Guidelines for planning the electrical installation 91 Medium voltage network Three-winding transformer 12-pulse drive No grounding of transformer secondary windings is permitted No load unbalance between transformer secondary windings is permitted Large 6-pulse drives (possible sources of harmonics) No (or only minimal) voltage distortion in medium voltage network is permitted. a.
Page 92: Selecting The Supply Disconnecting Device
Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.
Page 93: Requirements Tables
Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound ≤...
Page 94: Requirements For Abb Motors, P
96). Motor type Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW IEC 315 ≤ frame size <...
Page 95: Requirements For Non-Abb Motors, P
1) These are typical values. The network topology and grounding, drive type, cable type, cable length, and motor type have an effect on the phase-to-phase and phase-to-ground voltages of the motor. For motor dimensioning and selection, refer to IEC 60034-18-41, IEC 60034-18-42 and IEC/TC 60034-25. For more information, contact ABB.
Page 96: Requirements For Non-Abb Motors, P
1) These are typical values. The network topology and grounding, drive type, cable type, cable length, and motor type have an effect on the phase-to-phase and phase-to-ground voltages of the motor. For motor dimensioning and selection, refer to IEC 60034-18-41, IEC 60034-18-42 and IEC/TC 60034-25. For more information, contact ABB. Abbreviations Abbr.
Page 97: Additional Requirements For Explosion-Safe (Ex) Motors
The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: •...
Page 98: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
For motor dimensioning and selection, refer to IEC 60034-18-41, IEC 60034-18-42 and IEC/TC 60034-25. For more information, contact ABB. Additional data for calculating the rise time and the peak line-to-line voltage The diagrams below show the relative peak line-to-line voltage and rate of change of voltage as a function of the motor cable length.
Page 99: Additional Note For Sine Filters
Guidelines for planning the electrical installation 99 Û du/dt ------------ - (1/ s) l (m) du/dt ------------ - (1/ s) Û l (m) Drive with d u /d t filter Drive without d u /d t filter Motor cable length Û...
Page 100: Selecting The Power Cables
Make sure that the cable can enter the cabinet through the cable entry plate. Refer to the dimension drawings of the drive delivery or technical data in the drive hardware manual. For special cable entry solutions, consult ABB. Make sure that there is sufficient space to install the cable(s) and cable lugs to the terminals.
Page 101: Power Cable Types
Guidelines for planning the electrical installation 101 Power cable types ￭ Preferred power cable types This section shows the preferred cable types. Make sure that the selected cable type also complies with local/state/country electrical codes. Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar-...
Page 102: Not Allowed Power Cable Types
102 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Yes with motors up to 100 kW (135 hp). A potential equalization between the frames of motor and driven equipment is required.
Page 103: Grounding Requirements
Guidelines for planning the electrical installation 103 Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient.
Page 104: Additional Grounding Requirements - Iec
￭ Only use shielded control cables. Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable also for the pulse encoder signals. Use one individually shielded pair for each signal. Do not use common return for different analog signals.
Page 105: Signals In Separate Cables
Relay cable ￭ The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel to drive cable ￭ Use EIA-485, Cat 5e (or better) cable with male RJ-45 connectors. The maximum length of the cable is 100 m (328 ft).
Page 106: The Motor Cable
106 Guidelines for planning the electrical installation The following figure illustrates the cable routing guidelines with an example drive. min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min.
Page 107: Situations And Against Thermal Overload
The drive protects the motor cable and motor in a short-circuit situation when: • the motor cable is sized correctly • the motor cable type complies with the motor cable selection guidelines by ABB • the cable length does not exceed the allowed maximum length specified for the drive •...
Page 108: Protecting The Motor Against Overload Without Thermal Model Or Temperature Sensors
108 Guidelines for planning the electrical installation Protecting the motor against overload without thermal model or ￭ temperature sensors Motor overload protection protects the motor against overload without using motor thermal model or temperature sensors. Motor overload protection is required and specified by multiple standards including the US National Electric Code (NEC) and the common UL/IEC 61800-5-1 standard in conjunction with UL/IEC 60947-4-1.
Page 109: Implementing The Safe Torque Off Function
Guidelines for planning the electrical installation 109 Implementing the Safe torque off function See chapter The Safe torque off function (page 307). Implementing the Prevention of unexpected start-up function You can order the drive with a Prevention of unexpected start-up (POUS) function. The POUS function disables the control voltage of the power semiconductors of the drive (inverter) output stage.
Page 110: Implementing The Functions Provided By The Fso Safety Functions Module
110 Guidelines for planning the electrical installation Implementing the functions provided by the FSO safety functions module You can order the drive with an FSO-12 safety functions module (option +Q973) or FSO-21 safety functions module (option +Q972). An FSO module enables the implementation of functions such as Safe brake control (SBC), Safe stop 1 (SS1), Safe stop emergency (SSE), Safely limited speed (SLS) and Safe maximum speed (SMS).
Page 111: Supplying Power For The Auxiliary Circuits
Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during...
Page 112: Implementing The Control Of A Contactor Between Drive And Motor
112 Guidelines for planning the electrical installation Implementing the control of a contactor between drive and motor Implementing the control of the output contactor depends on the motor control mode and stopping method selected. When you select the DTC motor control mode and the motor ramp stop mode, use this operation sequence to open the contactor: Give a stop command to the drive.
Page 113: Implementing A Motor Temperature Sensor Connection
Guidelines for planning the electrical installation 113 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode Implementing a motor temperature sensor connection WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: •...
Page 114: Connecting A Motor Temperature Sensor To The Drive Through An Option Module
114 Guidelines for planning the electrical installation Connecting a motor temperature sensor to the drive through an ￭ option module This table shows: • option module types that you can use for the motor temperature sensor connection • insulation or isolation level that each option module forms between its temperature sensor connector and other connectors •...
Page 115: Electrical Installation
Electrical installation 115 Electrical installation Contents of this chapter This chapter contains instructions on the wiring of the drive. Warnings WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
Page 116: Measuring The Insulation Resistance Of The Motor And Motor Cable
Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.
Page 117: Checking The Settings Of Transformers T21, T101 And T111
Electrical installation 117 Checking the settings of transformers T21, T101 and T111 Check the tap settings of all auxiliary voltage transformers. Transformer T21 is standard equipment; T101 and T111 are present depending on drive configuration. The voltage settings of transformers T21 and T101 are made at terminal blocks T21_X1/X2 and T101_X1/X2 respectively.
Page 118: T21 And T101 Tap Settings (690 V Units)
118 Electrical installation T21 and T101 tap settings (690 V units) ￭ T21_X1 T21_X2 T101_X1 T101_X2 690 V 230 V 660 V 600 V 575 V 540 V 525 V...
Page 119: T111 Tap Settings
Electrical installation 119 T111 tap settings ￭ 3~ input 3~ output 3~ input 3~ output Tap settings Terminals Supply Terminals 400 V 320/340 V voltage A1– B1– C1– (50 Hz) (60 Hz) 690 V A1, B1, C1 a1, b1, c1 a2, b2, c2 660 V A1, B1, C1...
Page 120: Connecting The Control Cables
120 Electrical installation Connecting the control cables See chapter Control units of the drive (page 143) for the default I/O connections of the inverter unit (with the ACS880 primary control program). The default I/O connections can be different with some hardware options. See the circuit diagrams delivered with the drive for the actual wiring.
Page 121 Electrical installation 121 If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the peeled part. Be careful not to cut the conductors or the grounding wire. • Turn the conductive side of the shield inside out over the insulation. •...
Page 122: Routing The Control Cables Inside The Cabinet
122 Electrical installation Routing the control cables inside the cabinet Use the existing trunking in the cabinet where possible. Use sleeving if cables are laid against sharp edges. When running cables to or from a swing-out frame, leave enough slack at the hinge to allow the frame to open fully. Connecting control cabling Connect the conductors to the appropriate terminals.
Page 123: Connecting The Motor Cables (Units Without Common Motor Terminal Cubicle Or Sine Output Filter)
Electrical installation 123 The drawing below represents the grounding of the control cabling when connecting to a terminal block inside the cabinet. The grounding is done in the same way when connecting directly to a component such as the control unit. Connecting the motor cables (units without common motor terminal cubicle or sine output filter) On units without a common motor terminal cubicle or a sine output filter, the motor...
Page 124: Motor Connection Diagram (Without Option +H366)
124 Electrical installation Motor connection diagram (without option +H366) ￭ All parallel-connected inverter modules are to be cabled separately to the motor. 360° grounding must be used at the cable entries. Inverter unit cubicle(s) The recommended cable types are given in the technical data. WARNING! The cabling from all inverter modules to the motor must be physically identical considering cable type, cross-sectional area, and length.
Page 125: Procedure
Electrical installation 125 Bridging busbars Inverter unit cubicle(s) The recommended cable types are given in the technical data. WARNING! The bridging can carry the nominal output of one inverter module. In case of three parallel modules, make sure that the load capacity of the bridging is not exceeded.
Page 126 126 Electrical installation Remove the screws holding the front cover plate. Lift the cover plate somewhat to release it. Disconnect the wiring at the top of the fan carriage. Remove the two screws at the bottom of the fan carriage. WARNING! Before you proceed, make sure the two screws holding the top of the inverter module are in place.
Page 127 Electrical installation 113 Electrical installation 127...
Page 128: Connecting The Motor Cables
128 Electrical installation Connecting the motor cables Refer to the drawings below. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Do the steps in section Electrical safety precautions (page 21) before you start the work.
Page 129 Electrical installation 129 360° grounding detail...
Page 130: Installing The Fan Carriage Of An Inverter Module
130 Electrical installation Installing the fan carriage of an inverter module (If the inverter module was removed completely instead of only the fan carriage, proceed to section Installing an inverter module (page 207)). The installation of the fan carriage is the removal procedure in reverse. See section Removing the fan carriage of an inverter module (page 125).
Page 131: Connecting An External Brake Resistor Assembly
Electrical installation 131 Grommet Cut the cables to suitable length. Strip the cables and conductors. Twist the cable screens into bundles and connect the bundles to the PE busbar in the cubicle. Connect any separate ground conductors/cables to the PE busbar in the cubicle. Refer to section Use of fasteners in cable lug connections (page 135).
Page 132: Connecting The Input Power Cables
132 Electrical installation Connecting the input power cables Connection diagram, 6-pulse units ￭ Fuses or other protection means for short-circuit protection of the cable. Grounding of the cable shield at the cable entry (360-degree grounding). Additional information: • See the technical data for the dimensions of the cable entries, and the dimensions and tightening torques of the terminals.
Page 133: Layout Of The Input Cable Connection Terminals And Cable Entries
Electrical installation 133 Layout of the input cable connection terminals and cable entries ￭ The location and dimensions of the busbars are visible in the dimensional drawings delivered with the drive. Alternatively, see the example dimension drawings in the manual. Connection procedure ￭...
Page 134 134 Electrical installation Attach the conductive sleeves to the cable shields with cable ties. Tie up the unused conductive sleeves with cable ties. Connect the twisted shields of the cables to the PE busbar of the cabinet. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals. (With 12-pulse connection, the terminals are 1L1, 1L2 and 1L3 for one 6-pulse supply line, 2L1, 2L2 and 2L3 for the other.) See Use of fasteners in cable lug...
Page 135: Use Of Fasteners In Cable Lug Connections
Electrical installation 135 Use of fasteners in cable lug connections Use the bolts, nuts and washers delivered with the drive. Install all the fasteners in the correct order. See the figure below. Tighten the cable lug to the torque specified for the connection.
Page 136: Panel Bus (Control Of Several Units From One Control Panel)
136 Electrical installation USB connected Stop Start Loc/Rem Start Stop Loc/Rem Panel bus (control of several units from one control panel) One control panel (or PC) can be used to control several drives (or inverter units, supply units etc.) by constructing a panel bus. This is done by daisy-chaining the panel connections of the drives.
Page 137 Electrical installation 137 With twin connectors in the control panel holder:...
Page 138 138 Electrical installation With FDPI-02 modules and BCU control unit:...
Page 139: Installing Option Modules
Electrical installation 139 Installing option modules Mechanical installation of I/O extension, fieldbus adapter and pulse ￭ encoder interface modules See hardware description for the available slots for each module. Install the option modules as follows: WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 140 140 Electrical installation Attach the FSO module onto slot 3 of the BCU control unit [A41] with four screws. Torque the FSO module electronics grounding screw to 0.8 N·m (7.1 lbf·in). 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.
Page 141: Wiring Of Option Modules
Electrical installation 141 Wiring of option modules ￭ See the applicable optional module manual for specific installation and wiring instructions.
Page 143: Control Units Of The Drive
Control units of the drive 143 Control units of the drive Contents of this chapter This chapter • describes the connections of the control unit(s) used in the drive, • contains the specifications of the inputs and outputs of the control unit(s). General The drive utilizes either BCU-x2 control units or UCU-22…24 control units.
Page 144: Bcu Layout
144 Control units of the drive BCU layout Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface, field-...
Page 145 Control units of the drive 145 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XD24 +24 V output (for digital inputs) XDIO XETH Ethernet port – Not in use XPOW External power input XRO1...
Page 146: Default I/O Diagram Of The Supply Control Unit (Bcu-X2)
146 Control units of the drive Default I/O diagram of the supply control unit (BCU-x2) The diagram below shows the default I/O connections on the supply control unit (A51), and describes the use of the connections in the supply unit. Under normal circumstances, the factory-made wiring should not be changed.
Page 147 Control units of the drive 147 Terminal Description Temp fault (0 = overtemperature) Run enable (1 = run enable) MCB feedback (0 = main contactor/breaker open) Auxiliary circuit breaker fault Not in use by default. Can be used for eg. earth fault monitoring. Reset (0 ->...
Page 148 148 Control units of the drive Terminal Description X205 Memory unit connection 1) Must be set to ON when the supply unit is the first or last unit on the drive-to-drive (D2D) link. On intermediate units, set termination to OFF. 2) Default use of the signal in the control program.
Page 149: Default I/O Diagram Of The Inverter Control Unit (Bcu)
Control units of the drive 149 Default I/O diagram of the inverter control unit (BCU) The table below describes the use of the connections in the inverter unit. Under normal circumstances, the factory-made wiring should not be changed. The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …...
Page 150 150 Control units of the drive Terminal Description Stop (0) / Start (1) Forward (0) / Reverse (1) Reset Acceleration & deceleration select Constant speed 1 select (1 = on) Not in use by default. DIIL Run enable XDIO Digital input/outputs DIO1 Output: Ready DIO2...
Page 151 Control units of the drive 151 Terminal Description X205 Memory unit connection 1) 0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use. 1 = Acceleration/deceleration ramps defined by parameters 23.14/23.15 in use. 2) Constant speed 1 is defined by parameter 22.26. 3) The DIIL input is configured to stop the unit when the input signal is removed.
Page 152 152 Control units of the drive The diagram below shows the default I/O connections on the inverter control unit (A41). XRO1…XRO3 XSTO SGND DIIL XD24 +24VD +24VD AI1+ AI1- AI2+ AI2- AGND AGND Fault If necessary, you can connect a safety device (for example, a safety relay) to the XSTO terminal. Refer to chapter The Safe torque off function.
Page 153: Ucu-22
Control units of the drive 153 UCU-22…24 layout Description I/O terminals SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. For F-type modules with USCA-02 adapter. SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection. For F-type modules with USCA-02 adapter.
Page 154 154 Control units of the drive Description Analog input XRO4 XD24 XPOW Analog output XCAN Not in use XRO3 XCAN TERM CAN bus termination switch XDIO Digital input XDIO Digital input/output XRO2 XD2D Drive-to-drive link XD24 +24 V output (for digital input) XRO1 XETH1 Ethernet ports for fieldbus, internal switch...
Page 155 Control units of the drive 155 Description XFSO Not in use Environmental Humidity and temperature measurements sensors (1) XFSO...
Page 156: Default I/O Diagram Of The Supply Control Unit (Ucu-22
156 Control units of the drive Default I/O diagram of the supply control unit (UCU-22…24) The diagram below shows the default I/O connections on the supply control unit (A51), and describes the use of the connections in the supply unit. Under normal circumstances, the factory-made wiring should not be changed.
Page 157 Control units of the drive 157 Terminal Description Norm. closed XRO3: MCB ctrl (Energized = Closes main contactor/breaker.) COM3 Common 250 V AC / 30 V DC, 2 A Norm. open XRO4 Relay output 4 Norm. closed XRO4: Not supported COM4 Common 250 V AC / 30 V DC, 2 A...
Page 158 158 Control units of the drive Terminal Description Analog inputs, reference voltage output 10 V DC, R +VREF 1…10 kohm -VREF -10 V DC, R 1…10 kohm AGND Ground AI1+ Not in use by default. 0(2)…10 V, R > 200 kohm AI1- AI2+ Not in use by default.
Page 159: Default I/O Diagram Of The Inverter Control Unit (Ucu-22
Control units of the drive 159 Default I/O diagram of the inverter control unit (UCU-22…24) The table below describes the use of the connections in the inverter unit. Under normal circumstances, the factory-made wiring should not be changed. The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …...
Page 160 160 Control units of the drive Terminal Description Norm. closed XRO3: Fault (-1) (Energized = No fault) COM3 Common 250 V AC / 30 V DC, 2 A Norm. open XRO4 Relay output 4 Norm. closed XRO4: Not supported COM4 Common 250 V AC / 30 V DC, 2 A Norm.
Page 161 Control units of the drive 161 Terminal Description Analog inputs, reference voltage output 10 V DC, R +VREF 1…10 kohm -VREF -10 V DC, R 1…10 kohm AGND Ground AI1+ Speed reference. 0(2)…10 V, R > 200 kohm AI1- AI2+ Not in use by default.
Page 162 162 Control units of the drive The diagram below shows the default I/O connections on the inverter control unit (A41). XRO1…XRO4 COM1 COM2 COM3 COM4 XSTO SGND STO1 STO2 DIIL XD24 +24VD +24VD AI1+ AI1- AI2+ AI2- AGND AGND Fault If necessary, you can connect a safety device (eg, a safety relay) to the XSTO terminal.
Page 163: Additional Information On The Connections
Use a shielded twisted-pair cable for data, and another pair or a wire for signal ground (nominal impedance 100…165 ohm, for example Belden 9842). For the best immunity, ABB recommends high quality cable. Keep the cable as short as possible. Avoid unnecessary loops and parallel runs near power cables such as motor cables.
Page 164: Safe Torque Off (Xsto, Xsto Out)
The BCU control unit has an on-board data logger that collects real-time data from the power modules to help fault tracing and analysis. The data is stored onto the SDHC memory card inserted into the SD CARD slot and can be analyzed by ABB service personnel.
Page 165: Connector Data
Control units of the drive 165 Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) Maximum tightening torque 0.45 N·m (4 lbf·in) 24 V (±10%) DC, 2 A (BCU) 19…32 V DC, 2.9 A (UCU-22…24) External power input.
Page 166 166 Control units of the drive Reference voltage for analog inputs Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) +VREF and -VREF (XAI:1 and XAI:2) Maximum tightening torque 0.45 N·m (4 lbf·in) 10 V ±1% and -10 V ±1%, R 1…10 kohm load Maximum output current: 10 mA...
Page 167 Control units of the drive 167 Safe torque off connection (XSTO) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) Maximum tightening torque 0.45 N·m (4 lbf·in) Input voltage range: -3…30 V DC Logic levels: "0" < 5 V, "1" > 17 V. Note: For the unit to start, both connections must be “1”.
Page 168: Bcu Ground Isolation Diagram
168 Control units of the drive BCU ground isolation diagram ￭ XPOW +24VI +24VI +VREF -VREF AGND AI1+ AI1- AI2+ AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO SGND XSTO OUT...
Page 169: Ucu-22
Control units of the drive 169 UCU-22…24 ground isolation diagram ￭ XPOW XD2D X485 XCAN XETH1 XETH2 XETH3 XETH4 XPAN XRO1-XRO4 COM1 … COM4 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO XSTO OUT Power supply ground *The maximum common mode voltage between each AI input and AGND is ±30 V **Ground selector (DICOM=DIOGND) settings DICOM=DIOGND: ON...
Page 171: Installation Checklist
Installation checklist 171 Installation checklist Contents of this chapter This chapter contains a checklist for the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
Page 172 172 Installation checklist Make sure that … If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground-to-phase varistor) the electrical installation instructions. There is an adequately sized protective earth (ground) conductor(s) between the drive and the switchboard, the conductor is connected to correct terminal, and the terminal is tightened to the correct torque.
Page 173: Start-Up
Start-up 173 Start-up Contents of this chapter This chapter contains the start-up and switch-off procedures of the drive. Start-up procedure The tasks which are needed in certain cases only are marked with underlining, and option codes are given in brackets. Default device designations (if any) are given in brackets after the name, for example “main switch-disconnector [Q1]”.
Page 174 ABB recommends to set the operating temperatures of the relay, typically for example, as follows: • 120…140 °C when only tripping is in use •...
Page 175 Start-up 175 Action Setting up the inverter unit parameters, and performing the first start Set up the inverter control program. See the appropriate start-up guide and/or firmware manual. There is a separate start-up guide only for some control programs. Make sure that parameter 95.09 Switch fuse controller is set to Disabled. Drives with a brake chopper (option +D150): See chapter Resistor braking (page 333).
Page 176: Switching Off The Drive
176 Start-up Switching off the drive Stop the motor. Turn the Run enable switch (S21) to the off (0) position to deactivate the Run enable signal and to switch the main contactor/breaker off.
Page 177: Fault Tracing
Fault tracing 177 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. Control unit LEDs (BCU-x2) Color Indication BATT OK Green Battery voltage of the real-time clock is OK (higher than 2.8 V). When the LED is not lit, •...
Page 178: Control Unit Leds (Ucu-22
178 Fault tracing Control unit LEDs (UCU-22…24) Indication Green Battery voltage of the real-time clock is sufficient (higher than 2.5 V). Battery voltage is below 2.5 V, the battery is missing or the control unit is not powered. Green Internal voltage is sufficient. FAULT Control program indicates that the equipment is faulty.
Page 179: Maintenance
Maintenance 179 Maintenance Contents of this chapter This chapter contains maintenance instructions. Handling fiber optic cables WARNING! Obey these instructions. If you ignore them, damage to the equipment can occur. • Handle the fiber optic cables with care. • When you disconnect the fiber optic cables, always hold the connector, not the cable.
Page 180: Maintenance Intervals
180 Maintenance Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. For ABB Service offering, refer to www.abb.com/drivesservices or consult your local ABB Service representative (www.abb.com/searchchannels). Description of symbols ￭ Action Description...
Page 181: Recommended Maintenance Intervals After Start-Up
Maintenance 181 Recommended maintenance intervals after start-up ￭ Years from start-up Component … Cooling Supply and inverter module main cooling fans Supply and inverter modules: circuit board compartment fan Sine filter (option +E206) cool- ing fan Door fan Other cabinet cooling fans (50 Other cabinet cooling fans (60 Batteries Control panel battery...
Page 182 • Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.
Page 183: Cabinet
Maintenance 183 Cabinet Cleaning the interior of the cabinet ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
Page 184: Cleaning The Door Air Inlets (Ip22 And Ip42)
184 Maintenance Cleaning the door air inlets (IP22 and IP42) ￭ Check the dustiness of the air inlet meshes. If the dust cannot be removed by vacuum cleaning from outside through the grating holes with a small nozzle, proceed as follows: Stop the drive and do the steps in section Electrical safety precautions (page 21) before you start the work.
Page 185: Replacing The Inlet Door Filters (Ip54)
Maintenance 185 Replacing the inlet door filters (IP54) ￭ Stop the drive and do the steps in section Electrical safety precautions (page 21) before you start the work. Remove the fasteners at the top of the grating. Lift the grating and pull it away from the door. Remove the air filter mat.
Page 186: Fans
See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB-specified spare parts. Replacing a supply module (D7T) cooling fan ￭...
Page 187: Replacing A Supply Module (D8T) Or Inverter Module (R8I) Cooling Fan
If the connectors are not compatible, replace the connector at the end of the fan kit cable. Use the connector in the old fan kit, or order a suitable connector from ABB. Stop the drive and do the steps in section Electrical safety precautions (page 21) before you start the work.
Page 188: Replacing The Circuit Board Compartment Fan
188 Maintenance Remove the shroud in front of the fan (if any). Remove the screws holding the front cover plate. Lift the cover plate somewhat to release it. Disconnect the fan wiring. Remove the unit below the fan. Remove the screws of the fan unit. Pull out the fan unit.
Page 189 Maintenance 189 Disconnect the fan cable. Remove the four M3 (5.5 mm) nuts which hold the fan. Remove the fan from the fan holder. Put the fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder. Install and tighten the four nuts removed earlier.
Page 190: Replacing The Cooling Fan In The Auxiliary Control Cubicle
190 Maintenance 11. Align and push the fan holder into the module. 12. Install and tighten the two M4×12 (T20) screws. Replacing the cooling fan in the auxiliary control cubicle ￭ WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 191: Replacing The Roof Fan (Ip54/Ul Type 12)
Maintenance 191 Remove the fastening screws (a) and finger guard (b) of the fan. Install the new fan in reverse order. Make sure that the arrow indicating the air flow direction points up. Replacing the roof fan (IP54/UL type 12) ￭...
Page 192: Replacing The Common Motor Terminal Cubicle Fan
192 Maintenance Different roof fan models Replacing the common motor terminal cubicle fan ￭ WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. Fan attached to the cabinet door Stop the drive and do the steps in section Electrical safety precautions (page 21) before you start the work.
Page 193: Floor Fan (With Options +C128 And +H353)
Maintenance 193 Floor fan (with options +C128 and +H353) Stop the drive and do the steps in section Electrical safety precautions (page 21) before you start the work. Open the cabinet door. Remove the finger guard. Disconnect the fan wiring. Remove the fastening screws.
Page 194: Supply And Inverter Modules
If the connectors are not compatible, replace the connector in the new module. Use the connector in the old module, or order suitable connector from ABB. Refer to +V112 connector replacement guide for ACS880-x04 R8i/D8T/D7T module change (3AXD50001060015 [English]).
Page 195 Maintenance 195 Remove the shroud. Unplug the plug connector on top of the module (a), and the plug connector and fiber optic connector in front of the module (b). Remove the lower support bracket of the module. Remove the fastening bolts of the DC busbars (a) and the DC busbars carefully. Do not drop anything inside the module.
Page 196 196 Maintenance...
Page 197: Replacing A Frame D8T Supply Module
Maintenance 197 Replacing a frame D8T supply module ￭ Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. See Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). WARNING! Only qualified electricians are allowed to do this work. Read and obey the complete safety instructions of the drive.
Page 198 198 Maintenance WARNING! Use extreme caution when maneuvering the supply module. It is heavy and has a high center of gravity. Ignoring the following instructions can cause physical injury, or damage to the equipment. • Use the required personal protection equipment: safety shoes with metal toe cap, protective gloves, etc.
Page 199 If the connectors are not compatible, replace the connector in the new module. Use the connector in the old module, or order suitable connector from ABB. Refer to +V112 connector replacement guide for ACS880-x04 R8i/D8T/D7T module change (3AXD50001060015 [English]).
Page 200 Maintenance 165 200 Maintenance...
Page 201 166 Maintenance Maintenance 201...
Page 202: Removing An Inverter Module
202 Maintenance Removing an inverter module ￭ Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. See Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). WARNING! Obey the safety instructions of the drive. If you ignore them, injury or...
Page 203 Maintenance 203 WARNING! Use extreme caution when maneuvering the inverter module. It is heavy and has a high center of gravity. Ignoring the following instructions can cause physical injury, or damage to the equipment. • Use the required personal protection equipment: safety shoes with metal toe cap, protective gloves, etc.
Page 204 204 Maintenance Detach the terminal block [X50] at the top of the module. Detach the DC busbars from the module. Make note of the order and position of the screws and washers. Detach the wiring connected to the terminals on the front of the module (including fiber optic cabling).
Page 205 Electrical installation 109 Maintenance 205...
Page 206 206 Maintenance 110 Electrical installation...
Page 207: Installing An Inverter Module
If the connectors are not compatible, replace the connector in the new module. Use the connector from the old module, or order suitable connector from ABB. Refer to Connector replacement guide, auxiliary power supply for ACS880-104 R8i, ACS880-304 D8T and D7T...
Page 208 208 Maintenance for ACS880-104 R8i with +C183, ACS880-304 D8T with +C183 (3AXD50001060022 [English]). If you replace a module with a new one, make sure that the new module has the same type code as the old one. Make sure there are no tools, debris or any other foreign objects in the cubicle. If not already in place, attach the module extraction/installation ramp (included) to the base of the cabinet so that the tabs on the mounting bracket enter the slots on the ramp.
Page 209: Cleaning The Heatsink
Maintenance 209 Cleaning the heatsink ￭ The drive 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! Use the required personal protective equipment.
Page 210: Resuming Normal Operation
If the control unit is powered from the faulty module, connect the control unit to another 24 V DC power supply. ABB strongly recommends using an external power supply with supply/rectifier units consisting of parallel-connected modules.
Page 211 Maintenance 211 Stop the drive and do the steps in section Electrical safety precautions (page 21) before you start the work. Remove the shrouding above the module bay (in front of the DC fuses). Remove the DC fuses and the busbar assembly connecting the fuses to the inverter module.
Page 212: Returning The Module
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. Reforming the capacitors The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more.
Page 213: Fuses
Maintenance 213 Fuses Checking and replacing the DC fuses of a D7T supply module ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves.
Page 214: Checking And Replacing The Dc Fuses Of A D8T Supply Module
214 Maintenance Checking and replacing the DC fuses of a D8T supply module ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves.
Page 215 Maintenance 215 Without options +C129 and +C134...
Page 216: Control Panel
216 Maintenance With options +C129 and +C134 Control panel Refer to ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels user’s manual (3AUA0000085685 [English]).
Page 217: Control Units
Maintenance 217 Control units BCU control unit types ￭ There are three variants of the BCU control unit used in ACS880 drives: BCU-02, BCU-12 and BCU-22. These have a different number of converter module connections (2, 7 and 12 respectively) but are otherwise identical. The three BCU types are interchangeable as long as the number of connections is sufficient.
Page 218: Ucu Control Unit Types
218 Maintenance Dispose of the old battery according to local disposal rules or applicable laws. Set the real-time clock. UCU control unit types ￭ Different variants of the UCU control units are used in ACS880 drives: UCU-22…24. These have a different number of converter module connections but are otherwise identical.
Page 219: Replacing The Ucu Control Unit Battery
Maintenance 219 Replacing the UCU control unit battery ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
Page 220: Replacing The Microsdhc Memory Card (Ucu-22
220 Maintenance Replacing the microSDHC memory card (UCU-22…24) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
Page 221: Functional Safety Components
Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information.
Page 223: Technical Data
The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table. Input Output ratings rat- No-overload use Light-overload use Heavy-duty use ACS880-07-… = 400 V, 6-pulse connection 1140A-3 1047 1140 1490 – 1072 –...
Page 224 224 Technical data Input Output ratings rat- No-overload use Light-overload use Heavy-duty use ACS880-07-… 1760A-3+A004 1617 1760 2120 1000 – 1219 1690 – 1316 – 2210A-3+A004 2030 2210 2880 1200 – 1531 2122 1200 – 1653 – 2610A-3+A004 2397 2610...
Page 225: Definitions
Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.
Page 226: Switching Frequency Derating
For a more accurate derating, use the DriveSize PC tool. Switching frequency derating Switching frequencies other than default can require output current derating. Contact ABB for more information. Output frequency derating Motor operation above 150 Hz can require type-specific output current derating. Contact ABB for more information.
Page 227: Frame Sizes And Power Module Types
Technical data 227 Frame sizes and power module types Supply module(s) used Inverter modules used ACS880-07-… Frame size Type Type = 400 V, 6-pulse connection 1140A-3 1×D8T + 2×R8i ACS880-304-0980A-3+A018 ACS880-104-0640A-3 1250A-3 2×D8T + 2×R8i ACS880-304-0650A-3+A018 ACS880-104-0640A-3 1480A-3 2×D8T + 2×R8i...
Page 228: Fuses
228 Technical data Supply module(s) used Inverter modules used ACS880-07-… Frame size Type Type = 690 V, 12-pulse connection 0800A-7+A004 2×D7T + 2×R8i ACS880-304-0410A-7+A018 ACS880-104-0410A-7 0950A-7+A004 2×D8T + 2×R8i ACS880-304-0570A-7+A018 ACS880-104-0530A-7 1160A-7+A004 2×D8T + 2×R8i ACS880-304-0570A-7+A018 ACS880-104-0600A-7 1450A-7+A004 2×D8T + 3×R8i...
Page 229 Technical data 229 Ultrarapid (aR) fuses at supply module input Bussmann (IEC/UL) Mersen/Ferraz Shawmut (IEC only) Input Rated current Clearing Clearing I ACS880-07-… Rated Rated current t at at rated voltage voltage Type Type 660 V voltage 1070A-5 1600 170M6419...
Page 230: Dc Fuses
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. DC fuses at inverter module input ACS880-07-… Manufacturer Type = 400 V, 6-pulse connection...
Page 231: Supply Module Internal Dc Fuses
Technical data 231 DC fuses at inverter module input ACS880-07-… Manufacturer Type 1450A-7 1000 2150000 1250 Bussmann 170M6548 1650A-7 1100 2800000 1250 Bussmann 170M6549 1950A-7 1100 2800000 1250 Bussmann 170M6549 2300A-7 1100 2800000 1250 Bussmann 170M6549 2600A-7 1100 2800000 1250...
Page 232: Dimensions And Weights
Measured from the base plate of 1500 15.75 the cabinet top. > 400 mm (15.75 in.) Losses, cooling data and noise Air flow Noise Typical power loss ACS880-07-… /min dB(A) = 400 V, 6-pulse connection 1140A-3 4290 2525 18751 1250A-3 5720...
Page 233 Technical data 233 Air flow Noise Typical power loss ACS880-07-… /min dB(A) 1320A-5+A004 5720 3367 21590 1450A-5+A004 5720 3367 24243 1580A-5+A004 5720 3367 27336 1800A-5+A004 7150 4208 30016 1980A-5+A004 7150 4208 33285 = 690 V, 6-pulse connection 0800A-7 4290 2525...
Page 234: Sine Output Filter Data
Sine output filters are available as option +E206. The table below shows the types and technical data of the filters and filter cubicles used in drives. The standard filters listed require no current derating. For availability of sine output filters for other types, contact your local ABB representative. Sine filter(s) used...
Page 235: Typical Power Cable Sizes
Technical data 235 Typical power cable sizes The tables below give the current carrying capacity ( I ) and typical size for copper Lmax and aluminum cables with PVC or XLPE insulation. A correction factor K = 0.70 is used. Time const.
Page 236: Terminal And Cable Entry Data For The Power Cables
236 Technical data Terminal and cable entry data for the power cables The locations and sizes of the cable entries are shown in the dimension drawings delivered with the drive, and the dimension drawing examples in this manual. Busbar terminal material: Tin-plated copper. Terminal data for the motor cables ￭...
Page 237: Terminal Data For The Supply And Inverter Control Units
50/60 Hz, variation ± 5% of nominal frequency Imbalance Max. ± 3% of nominal phase-to-phase input voltage Short-circuit withstand ACS880-07-2610A-3, ACS880-07-2600A-7 and ACS880-07-2860A-7 without strength, standard IEC grounding/earthing switch (ie. without option +F259): supply unit variant Rated peak withstand current ( I...
Page 238: Motor Connection Data
Note: Longer cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and character- istics. Contact ABB for more information. Also note that a sine filter (optional) at the drive output also causes a voltage decrease.
Page 239: Ambient Conditions
Installation site altitude 0…2000 m (0…6562 ft) above sea level. For alti- tudes over 2000 m, con- tact ABB. Output derated above 1000 m (3281 ft). Air temperature 0 … +40 °C -40 … +70 °C -40 …...
Page 240: Transportation
Storage conditions The table below specifies the storage conditions for the drive. Store the drive in its package. ABB recommends seaworthy package (option +P912) if the drive is in long-term storage. The storage conditions must also comply with the environmental...
Page 241: Colors
Technical data 241 Colors RAL Classic 7035, RAL Classic 9017. Materials Drive ￭ Refer to Recycling instructions and environmental information for ACS880 cabinet-installed drives and multidrive modules (3AXD50000153909 [English]). Packaging of drive ￭ • Plywood • Wood • PET (strapping) •...
Page 242: Disposal
Substances of Concern In articles as such or in complex objects (Products) established under the Waste Framework Directive (2008/98/EC). For further information, contact your local ABB distributor or consult European Chemicals Agency's SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located.
Page 243: Markings
Technical data 243 Standard Information Enclosure and environmental protection EN 60529:1991 + A2:2013 + AC:2019 Degrees of protection provided by enclosures (IP code) IEC 60529:1989 + Amd1:1999 + Amd2:2013 + Cor1:2019 UL 50: 12th edition Enclosures for Electrical Equipment, Non-Environmental Consider- ations UL 50E: 1st edition Enclosures for Electrical Equipment, Environmental Considerations...
Page 244: Emc Compliance (Iec/En 61800-3)
Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of Conformity is available from https://library.abb.com. WEEE mark At the end of life the product should enter the recycling system at an appropriate collection point and not placed in the normal waste stream.
Page 245: Category C3
Technical data 245 The drive is installed according to the instructions given in the hardware manual. Maximum motor cable length is 100 meters (328 ft). WARNING! The drive may cause radio interference if used in a residential or domestic environment. The installer is required to take measures to prevent interference, in addition to the requirements for CE compliance listed above, if necessary.
Page 246 246 Technical data Medium voltage network Equipment Neighboring network Supply transformer Point of measurement Static screen Low voltage Drive Equipment (victim) An EMC plan for preventing disturbances is drawn up for the installation. A template is available in Technical guide No. 3 EMC compliant installation and configuration for a power drive system (3AFE61348280 [English]).
Page 247: Ul And Csa Checklist
The fuses are listed elsewhere in this chapter. • The drive provides motor overload protection. The protection is not enabled when the drive leaves the ABB factory. For enabling the protection, see the firmware manual. • The drive overvoltage category according to IEC 60664-1 is III, except for auxiliary power connections (fan, control, heating, lighting, cooling unit pump etc) which are of category II.
Page 248: Tightening Torques
248 Technical data Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Electrical connections ￭ Size Torque Strength class 0.5 N·m (4.4 lbf·in) 4.6...8.8 1 N·m (9 lbf·in) 4.6...8.8 4 N·m (35 lbf·in) 9 N·m (6.6 lbf·ft) 22 N·m (16 lbf·ft) 42 N·m (31 lbf·ft)
Page 249: Disclaimers
ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of...
Page 251: Dimensions
Not all possible configurations are presented. For information on unlisted configurations, contact ABB. • The data given is preliminary. ABB reserves the right to modify the design at any time without notice. Consult ABB for up-to-date, drive-specific information. The tables are followed by selected dimension drawing examples.
Page 252: Dimension Tables
252 Dimensions Dimension tables ￭ 1×D8T + 2×R8i – 6-pulse connection 1800 1800 2100 2100 2100 2100 2400 2400 1000 2800 2800 1000 3100 3100 2600 2600 2900 2900 2900 2900 3200 3200 1000 3600 3600 1000 3900 3900 4200 4200 2300 + 2400 4700...
Page 253 Dimensions 253 2×D7T + 2×R8i – 12-pulse connection (option +A004), without grounding switch (no option +F259) 2000 2000 2200 2200 2300 2300 2500 2500 1000 3000 3000 1000 3200 3200 2800 2800 3000 3000 3100 3100 3300 3300 1000 3800 3800 1000 4000...
Page 254 254 Dimensions 2×D7T + 2×R8i – 12-pulse connection (option +A004), with grounding switch (option +F259) 2200 2200 2500 2500 1000 3200 3200 3000 3000 3300 3300 1000 4000 4000 2400 + 2400 4800 2500 + 2400 4900 1000 3400 + 2400 5800 3400 3400...
Page 255 Dimensions 255 2×D8T + 2×R8i – 6-pulse connection, 400/500 V 2200 2200 2400 2400 2500 2500 2700 2700 1000 3200 3200 1000 3400 3400 3400 3400 3600 3600 2400 + 3600 6000 2600 + 3600 6200 3700 3700 3900 3900 2500 + 3600 6100 2700 + 3600...
Page 256 256 Dimensions 2×D8T + 2×R8i – 12-pulse connection (option +A004), without grounding switch (no option +F259) 2200 2200 2400 2400 2500 2500 2700 2700 1000 3200 3200 1000 3400 3400 3400 3400 3600 3600 3700 3700 3900 3900 1000 3400 + 1200 4600 1000 3600 + 1200...
Page 257 (ICU) ule cubicle ule cubicle (ACU) entry cubicle 2600 2800 3000 3200 3400 1) 600 mm with ACS880-07-2610-3 with top cable exit, otherwise 400 mm. 3×D8T + 4×R8i Common Auxiliary Incoming Adapter for Supply Inverter Inverter Line-up motor ter-...
Page 258 4600 3000+1400 4400 3400+1400 4800 1) Units with option +F259 (grounding switch), +C129 (UL Listed) or +C134 (CSA approved) only. 2) 600 mm with ACS880-07-2610-3+A004 with top cable exit, otherwise 400 mm. 4×D8T + 4×R8i 3400 3400 3600 3600 3800...
Page 259 4000 + 600 4600 1000 4200 + 600 4800 1) 1000 mm with UL/CSA, otherwise 600 mm. 2) 400 mm with non-UL/CSA ACS880-07-2600A-7 with bottom cable exit, otherwise 600 mm. 4×D8T + 5×R8i - 12-pulse connection 3600 3600 3800 3800...
Page 260: Weights
260 Dimensions Weights ￭ The table below lists the approximate basic weights. Weight Frame size 1×D8T + 2×R8i 1470 3240 2×D7T + 2×R8i 1710 3770 2×D8T + 2×R8i (6-pulse) 1770 3900 2×D8T + 2×R8i (12-pulse) 1870 4120 2×D8T + 3×R8i (6-pulse) 1920 4230 2×D8T + 3×R8i (12-pulse)
Page 261: Dimension Drawing Examples
Dimensions 261 Dimension drawing examples ￭ Frame 2×D7T + 2×R8i, 12-pulse (+A004)
Page 262: Frame 1×D8T + 2×R8I (Ip22)
262 Dimensions Frame 1×D8T + 2×R8i (IP22)
Page 263: Frame 1×D8T + 2×R8I, Ip54 (+B055)
Dimensions 263 Frame 1×D8T + 2×R8i, IP54 (+B055)
Page 264: Frame 1×D8T + 2×R8I With Common Motor Terminal Cubicle (+H359), 1/2
264 Dimensions Frame 1×D8T + 2×R8i with common motor terminal cubicle (+H359), 1/2...
Page 265: Frame 1×D8T + 2×R8I With Common Motor Terminal Cubicle (+H359), 2/2
Dimensions 265 Frame 1×D8T + 2×R8i with common motor terminal cubicle (+H359), 2/2...
Page 266: Frame 1×D8T + 2×R8I With Brake Choppers And Resistors (+D150 +D151), 1/2
266 Dimensions Frame 1×D8T + 2×R8i with brake choppers and resistors (+D150 +D151), 1/2...
Page 267: Frame 1×D8T + 2×R8I With Brake Choppers And Resistors (+D150 +D151), 2/2
Dimensions 267 Frame 1×D8T + 2×R8i with brake choppers and resistors (+D150 +D151), 2/2...
Page 268: Frame 1×D8T + 2×R8I With Sine Output Filter (+E206), 1/2
268 Dimensions Frame 1×D8T + 2×R8i with sine output filter (+E206), 1/2...
Page 269: Frame 1×D8T + 2×R8I With Sine Output Filter (+E206), 2/2
Dimensions 269 Frame 1×D8T + 2×R8i with sine output filter (+E206), 2/2...
Page 270: Frame 2×D8T + 2×R8I, 12-Pulse (+A004) With Grounding Switch (+F259)
270 Dimensions Frame 2×D8T + 2×R8i, 12-pulse (+A004) with grounding switch (+F259)
Page 271: Frame 2×D8T + 3×R8I, 1/2
Dimensions 271 Frame 2×D8T + 3×R8i, 1/2...
Page 272: Frame 2×D8T + 3×R8I, 2/2
272 Dimensions Frame 2×D8T + 3×R8i, 2/2...
Page 273: Frame 2×D8T + 3×R8I With Common Motor Terminal Cubicle (+H359), 1/2
Dimensions 273 Frame 2×D8T + 3×R8i with common motor terminal cubicle (+H359), 1/2...
Page 274: Frame 2×D8T + 3×R8I With Common Motor Terminal Cubicle (+H359), 2/2
274 Dimensions Frame 2×D8T + 3×R8i with common motor terminal cubicle (+H359), 2/2...
Page 275: Frame 2×D8T + 3×R8I With Top Entry / Top Exit (+H351/+H353), 1/2
Dimensions 275 Frame 2×D8T + 3×R8i with top entry / top exit (+H351/+H353), 1/2...
Page 276: Frame 2×D8T + 3×R8I With Top Entry/Top Exit, 2/2
276 Dimensions Frame 2×D8T + 3×R8i with top entry/top exit, 2/2...
Page 277: Frame 3×D8T + 4×R8I, 1/2
Dimensions 277 Frame 3×D8T + 4×R8i, 1/2...
Page 278: Frame 3×D8T + 4×R8I, 2/2
278 Dimensions Frame 3×D8T + 4×R8i, 2/2...
Page 279: Frame 3×D8T + 4×R8I With Common Motor Terminal Cubicle (+H359), 1/2
Dimensions 279 Frame 3×D8T + 4×R8i with common motor terminal cubicle (+H359), 1/2...
Page 280: Frame 3×D8T + 4×R8I With Common Motor Terminal Cubicle (+H359), 2/2
280 Dimensions Frame 3×D8T + 4×R8i with common motor terminal cubicle (+H359), 2/2...
Page 281: Frame 3×D8T + 4×R8I With Top Entry / Top Exit (+H351/+H353), 1/2
Dimensions 281 Frame 3×D8T + 4×R8i with top entry / top exit (+H351/+H353), 1/2...
Page 282: Frame 3×D8T + 4×R8I With Top Entry / Top Exit (+H351/+H353), 2/2
282 Dimensions Frame 3×D8T + 4×R8i with top entry / top exit (+H351/+H353), 2/2...
Page 283: Frame 4×D8T + 5×R8I (6-Pulse) With Top Entry/Exit, Ul Listed (+C129), 1/2
Dimensions 283 Frame 4×D8T + 5×R8i (6-pulse) with top entry/exit, UL Listed (+C129), 1/2...
Page 284: Frame 4×D8T + 5×R8I (6-Pulse) With Top Entry/Exit, Ul Listed (+C129), 2/2
284 Dimensions Frame 4×D8T + 5×R8i (6-pulse) with top entry/exit, UL Listed (+C129), 2/2...
Page 285: Dimensions Of Empty Cubicles (Options +C199, +C200, +C201)
Dimensions 285 Dimensions of empty cubicles (options +C199, +C200, +C201) ￭ IP22/IP42...
Page 286: Ip54
286 Dimensions IP54...
Page 287: Location And Size Of Input Terminals
Dimensions 287 Location and size of input terminals Note: See the dimension tables as to which incoming cubicles are used with which drive type and options. 400 mm, bottom cable entry ￭ 400 mm, top cable entry ￭...
Page 288: Mm, Without Main Breaker, Bottom Cable Entry (Including 12-Pulse Units With Grounding Switch)
288 Dimensions 600 mm, without main breaker, bottom cable entry (including 12-pulse ￭ units with grounding switch) 600 mm, without main breaker, top cable entry (including 12-pulse ￭ units with grounding switch)
Page 289: 600 Mm, 12-Pulse Units Without Grounding Switch, Bottom Cable Entry
Dimensions 289 600 mm, 12-pulse units without grounding switch, bottom cable entry ￭ 600 mm, 12-pulse units without grounding switch, top cable entry ￭...
Page 290: 600 Mm, With Main Breaker, Bottom Cable Entry
290 Dimensions 600 mm, with main breaker, bottom cable entry ￭ 600 mm, with main breaker, top cable entry ￭...
Page 291: 1000 Mm (Ul/Csa), Top Cable Entry
Dimensions 291 1000 mm (UL/CSA), top cable entry ￭...
Page 292: 1000 Mm (Ul/Csa), Bottom Cable Entry
292 Dimensions 1000 mm (UL/CSA), bottom cable entry ￭ Location and size of output terminals Units without common motor terminal cubicle ￭...
Page 293: Inverter Module Cubicle With Two R8I Modules, Bottom Cable Exit
Dimensions 293 Inverter module cubicle with two R8i modules, bottom cable exit...
Page 294: Inverter Module Cubicle With Two R8I Modules, Top Cable Exit
294 Dimensions Inverter module cubicle with two R8i modules, top cable exit...
Page 295: Inverter Module Cubicle With Three R8I Modules, Bottom Cable Exit
Dimensions 295 Inverter module cubicle with three R8i modules, bottom cable exit...
Page 296: Inverter Module Cubicle With Three R8I Modules, Top Cable Exit
296 Dimensions Inverter module cubicle with three R8i modules, top cable exit...
Page 297: Brake Chopper Cubicle
Dimensions 297 Brake chopper cubicle...
Page 298: Sine Filter Cubicle, 1000 Mm, Bottom Cable Exit
298 Dimensions Sine filter cubicle, 1000 mm, bottom cable exit...
Page 299: Sine Filter Cubicle, 1000 Mm, Top Cable Exit
Dimensions 299 Sine filter cubicle, 1000 mm, top cable exit...
Page 300: Units With Common Motor Terminal Cubicle (+H359)
300 Dimensions Units with common motor terminal cubicle (+H359) ￭ Cubicle width 300 mm, bottom cable exit...
Page 301: Cubicle Width 300 Mm, Top Cable Exit
Dimensions 301 Cubicle width 300 mm, top cable exit...
Page 302: Cubicle Width 400 Mm, Bottom Cable Exit
302 Dimensions Cubicle width 400 mm, bottom cable exit...
Page 303: Cubicle Width 400 Mm, Top Cable Exit
Dimensions 303 Cubicle width 400 mm, top cable exit...
Page 304: Cubicle Width 600 Mm, Bottom Cable Exit
304 Dimensions Cubicle width 600 mm, bottom cable exit...
Page 305: Cubicle Width 600 Mm, Top Cable Exit
Dimensions 305 Cubicle width 600 mm, top cable exit...
Page 307: The Safe Torque Off Function
The Safe torque off function 307 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description WARNING! In case of parallel-connected drives or dual-winding motors, the STO must be activated on each drive to remove the torque from the motor.
Page 308: Chinery (Safety) Regulations
308 The Safe torque off function Standard Name IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards – Immunity requirements for equipment intended to perform functions in a safety-related system (functional safety) in industrial locations IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC requirements –...
Page 309: Wiring
For more information, see the module documentation. Cable types and lengths ￭ • ABB recommends double-shielded twisted-pair cable. • Maximum cable lengths: • 300 m (1000 ft) between activation switch [K] and drive control unit •...
Page 310: Dual-Channel Connection With Internal Power Supply (Bcu-X2)
310 The Safe torque off function Dual-channel connection with internal power supply (BCU-x2) ￭ XSTO +24 V SGND XSTO OUT STO IN (X52) 24VDC CH1 SGND GND CH1 24VDC CH2 SGND GND CH2 STO IN (X52) STO OUT (X51) 24VDC CH1 24VDC CH1 GND CH1 GND CH1...
Page 311: Dual-Channel Connection With Internal Power Supply (Ucu-22
The Safe torque off function 311 Dual-channel connection with internal power supply (UCU-22…24) ￭ XSTO +24 V SGND STO1 STO2 XSTO OUT STO IN (X52) OUT1 24VDC CH1 SGND GND CH1 24VDC CH2 OUT2 SGND GND CH2 STO IN (X52) STO OUT (X51) 24VDC CH1 24VDC CH1...
Page 312: Single-Channel Connection Of Activation Switch (Bcu-X2)
312 The Safe torque off function Single-channel connection of activation switch (BCU-x2) ￭ +24 V SGND Note: • Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL classi- fication is given. • Pay special attention to avoiding any potential failure modes for the wiring. For example, use shielded cable.
Page 313: Multiple Drives
The Safe torque off function 313 Multiple drives ￭ Internal power supply (example, drives with ZCU-xx and BCU-x2) XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * Terminal designation may vary depending on drive type...
Page 314: Internal Power Supply (Example, Drives With Ucu-22
314 The Safe torque off function Internal power supply (example, drives with UCU-22…24) XSTO +24 V SGND STO1 STO2 XSTO SGND STO1 STO2 XSTO SGND STO1 STO2 Drive Control unit Activation switch...
Page 315: External Power Supply (Example, Drives With Zcu-Xx And Bcu-X2)
The Safe torque off function 315 External power supply (example, drives with ZCU-xx and BCU-x2) 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * Terminal designation may vary depending on drive type...
Page 316: External Power Supply (Example, Drives With Ucu-22
316 The Safe torque off function External power supply (example, drives with UCU-22…24) 24 V DC XSTO +24 V SGND STO1 STO2 XSTO SGND STO1 STO2 XSTO SGND STO1 STO2 Drive Control unit Activation switch...
Page 317: Operation Principle
The Safe torque off function 317 Operation principle The Safe torque off activates (the activation switch is opened, or safety relay contacts open). The STO inputs of the drive control unit de-energize. The control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).
Page 318: Start-Up Including Validation Test
318 The Safe torque off function Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed at initial start-up of the safety function after any changes related to the safety function (circuit boards, wiring, components, settings, replacement of inverter module, etc.)
Page 319 The Safe torque off function 319 Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...
Page 320: Use
320 The Safe torque off function Open the activation switch, or activate the safety functionality that is wired to the STO connection. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).
Page 321 The Safe torque off function 321 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. •...
Page 322: Maintenance
If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 318). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...
Page 323: Perfect Proof Test Procedure
The Safe torque off function 323 Perfect proof test procedure ￭ Action WARNING! Obey the safety instructions. If you ignore them, injury or death, or damage to the equip- ment can occur. Test the operation of the STO function. If the motor is running, it will stop during the test. •...
Page 324: Fault Tracing
See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.
Page 325: Safety Data
The Safe torque off function 325 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and applies only if both STO channels are used.
Page 326 326 The Safe torque off function...
Page 327: Terms And Abbreviations
The Safe torque off function 327 • The STO is a type B safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) • The STO does not activate when requested • A fault exclusion on the failure mode “short circuit on printed circuit board”...
Page 328: Tüv Certificate
IEC 61508-6 Dangerous failure rate (per hour) of the diagnostics function of Diag_d λ IEC 61508-6 Safe failure rate (per hour) of the diagnostics function of STO Diag_s TÜV certificate ￭ The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
Page 329: Declarations Of Conformity
+358 10 22 11 declare under our sole responsibility that the following products: Frequency converters and frequency converter components ACS880-04, -14, -34 (frames nxR8i) ACS880-04XT, -04FXT ACS880-07, -17, -37, -107 ACS880-104 ACS880 multidrives ACS880-104LC ACS880-07CLC, -07LC, -17LC, -37LC, -107LC ACS880 liquid-cooled multidrives...
Page 330 330 The Safe torque off function ACS880-07, -17, -37, -07CLC, -07LC, -17LC, -37LC, ACS880 multidrives and ACS880 liquid- cooled multidrives: Prevention of unexpected start-up (option codes +Q950; +Q957), Emergency stop (option codes +Q951; +Q952; +Q963; +Q964; +Q978; +Q979), Safely-limited speed (option codes +Q965; Q966) are in conformity with all the relevant safety component requirements of EU Machinery Directive 2006/42/EC, when the listed safety functions are used for safety component functionality.
Page 331 +358 10 22 11 declare under our sole responsibility that the following products: Frequency converters and frequency converter components ACS880-04, -14, -34 (frames nxR8i) ACS880-04XT, -04FXT ACS880-07, -17, -37, -107 ACS880-104 ACS880 multidrives ACS880-104LC ACS880-07CLC, -07LC, -17LC, -37LC, -107LC ACS880 liquid-cooled multidrives...
Page 332 332 The Safe torque off function ACS880-07, -17, -37, -07CLC, -07LC, -17LC, -37LC, ACS880 multidrives and ACS880 liquid- cooled multidrives: Prevention of unexpected start-up (option codes +Q950; +Q957), Emergency stop (option codes +Q951; +Q952; +Q963; +Q964; +Q978; +Q979), Safely-limited speed (option codes +Q965; Q966)
Page 333: Resistor Braking
Resistor braking 333 Resistor braking Contents of this chapter This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the related technical data. Operation principle The brake chopper handles the extra energy generated by motor during a quick deceleration.
Page 334: Factory-Installed Brake Choppers And Resistors
The following brake choppers (option +D150) and resistors (+D151) are available for the drive as factory-installed. It is also possible to use option +D150 with a custom resistor assembly. ACS880-07 type Brake chopper type (+D150) Brake resistor type (+D151) ACS880-07-0990A-3 2 ×...
Page 335: Technical Data
Resistor braking 335 Technical data Ratings of chopper/resistor combinations ￭ Duty Cycle Duty Cycle (10/60 s) (1/5 min) brmax brcont Chopper(s) Resistors (ohm) (kW) (kW) (kW) (kW) 2 × 400 V NBRA-659 SAFUR180F460 2 × (2 × 400 V 2 × NBRA-659 1090 SAFUR180F460) 3 ×...
Page 336: Safur Resistor Data
336 Resistor braking SAFUR resistor data ￭ The following SAFUR resistors are available separately. Rcont Type IPxx SAFUR125F500 3600 IP00 SAFUR210F575 4200 10.5 IP00 SAFUR200F500 5400 13.5 IP00 SAFUR180F460 6000 15.0 IP00 Nominal voltage Resistance Short energy pulse that the resistor assembly will withstand each 400 seconds Continuous power (heat) dissipation of the resistor when placed correctly.
Page 337: Planning The Braking System
Resistor braking 337 Planning the braking system Verifying the load capacity of the braking equipment ￭ Calculate the maximum power generated by the motor during braking ( P Ensure that the maximum power rating of the braking equipment is equal to or greater than P The P values specified in the ratings table are for the reference braking cycle...
Page 338: Selecting And Routing The Cables Of A Custom Resistor
338 Resistor braking Braking energy transferred during any ten minute period must be less than or equal to the energy transferred during the reference braking cycle (1/9 min). The maximum braking power for a custom braking cycle ( P ) must not exceed the rated maximum value P brmax The rules as equations:...
Page 339: Maximum Cable Length
Resistor braking 339 Maximum cable length The maximum length of the resistor cable(s) is 50 m (164 ft). Selecting the installation location for the brake resistors ￭ Protect the open (IP00) brake resistors against contact. Install the brake resistor in a place where it cools effectively.
Page 340: Electrical Installation Of Custom Brake Resistors
340 Resistor braking Electrical installation of custom brake resistors Connection diagram ￭ Brake chopper cubicle t° Brake resistor cubicle Connection procedure ￭ WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 341: Brake System Start-Up
any separate PE conductor (if present). • At the chopper end of the cable, 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 Resistor braking 341 resistance must be higher than 1 Mohm.
Page 342: Maintenance
342 Resistor braking Maintenance Replacing the brake resistor cabinet fan ￭ WARNING! Wear protective gloves and long sleeves. Some parts have sharp edges. Stop the drive and do the steps in section Electrical safety precautions (page 21) before you start the work. Remove any shrouding in front of the cooling fans.
Page 343 Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/contact-centers.

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