Page 1 — ABB INDUSTRIAL DRIVES ACS880-37 drives (45…400 kW, 60…450 hp) Hardware manual...
Page 3 ACS880-37 drives (45…400 kW, 60…450 hp) Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 9. Start-up 3AXD50000035159 Rev G EFFECTIVE: 2020-03-25...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ................Use of warnings and notes ............... General safety in installation, start-up and maintenance ........Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ..............Measuring the voltage .................
Page 6 6 Table of contents Door switches and lights ................Main disconnecting device (Q1) .............. Other devices on the door ..............Control panel ..................Control by PC tools ................Descriptions of options ................Degree of protection ................Definitions ..................IP22 (UL Type 1) ................IP42 (UL Type 1 Filtered) (option +B054) ..........
Page 7 Availability of du/dt filter and common mode filter by drive type ..... Additional requirements for explosion-safe (EX) motors ......Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ..................Additional requirements for ABB high-output and IP23 motors ......
Page 8 8 Table of contents Selecting the power cables ............... General guidelines ................Typical power cable sizes ..............Power cable types ................Preferred power cable types .............. Alternate power cable types ............... Not allowed power cable types ............Additional guidelines, North America ............Metal conduit ................
Page 9 Table of contents 9 Measuring the insulation of the motor and motor cable ........Compatibility with IT (ungrounded), corner-grounded delta, midpoint-grounded delta and TT systems ..................EMC filter (standard drive, options +E200 or +E202) ........Ground-to-phase varistor ..............Corner-grounded and midpoint-grounded delta systems ......... Attaching the device stickers to the cabinet door ..........
Page 10 10 Table of contents 8 Installation checklist of the drive Contents of this chapter ................Checklist ..................... 9 Start-up Contents of this chapter ................Start-up procedure ................. 10 Fault tracing Contents of this chapter ................LEDs ....................Warning and fault messages ..............11 Maintenance Contents of this chapter ................
Page 11 Table of contents 11 Fuses ....................Replacing fuses (frame R8) ..............Replacing fuses (frame R11) ..............Replacing the DC fuses of the brake chopper (option +D150) ......Control panel ..................Replacing the battery and cleaning ............Control unit ..................Replacing the ZCU-14 control unit battery ..........Memory unit ..................
Page 12 12 Table of contents CE marking ..................Compliance with the European Low Voltage Directive ........Compliance with the European EMC Directive ..........Compliance with the European Machinery Directive ........Compliance with EN 61800-3:2004 + A1:2012 ..........Definitions ..................Category C2 ..................Category C3 ..................
Page 13 Operation principle and hardware description ..........Planning the braking system ..............Selecting the default brake circuit components - ABB chopper and ABB resistor ..Calculating the maximum allowed braking power for a custom duty cycle – ABB chopper and ABB resistor ..............
Page 14 Start-up ..................Technical data ..................Factory-installed brake chopper and resistor types ........Ratings for the factory-installed brake choppers and ABB brake resistors .... Ratings for factory-installed brake choppers and custom resistors ..... DC fuses ..................Terminals and cable entry data of factory-installed chopper/resistor cubicles ..
Page 15: Safety Instructions
Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 16: General Safety In Installation, Start-Up And Maintenance
16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 17: Electrical Safety In Installation, Start-Up And Maintenance
Safety instructions 17 • Before you activate the automatic fault reset or automatic restart functions of the drive control program, make sure that no dangerous situations can occur. These functions reset the drive automatically and continue operation after a fault or supply break. If these functions are activated, the installation must be clearly marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, "THIS MACHINE STARTS AUTOMATICALLY".
Page 18 18 Safety instructions WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Go through these steps before you begin any installation or maintenance work. 1.
Page 19: Measuring The Voltage
Safety instructions 19 ￭ Measuring the voltage Make sure that the voltage between the drive input power terminals (L1, L2, L3) and the grounding (PE) busbar is close to 0 V. L1, L2, L1, L2, L3...
Page 20 nstructions 20 Safety instructions ame R11: Make sure that the voltage of the drive AC busbars between the drive Frame R11: Make sure that the voltage of the drive AC busbars between the drive module dule and the LCL filter and the grounding (PE) busbar are close to 0 V. and the LCL filter and the grounding (PE) busbar are close to 0 V.
Page 21 Safety instructions 21 Make sure that the voltage between the drive DC busbars (+ and -) and the grounding (PE) busbar is close to 0 V. DC-, DC+...
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 recommends not to attach the cabinet by arc welding. If you have to, obey the welding instructions in the drive manuals.
Page 23: Optical Components
Safety instructions 23 Note: • The motor cable terminals of the drive are at a dangerous voltage when the input power is on, regardless of whether the motor is running or not. • When the input power is on, the drive DC bus is at a dangerous voltage. If brake chopper and resistor are in use, they are at a dangerous voltage.
Page 24: General Safety In Operation
24 Safety instructions Note: • You can use power cable shields as grounding conductors only when their conductivity is sufficient. • As the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed protective earth (PE) connection.
Page 25: Additional Instructions For Permanent Magnet Motor Drives
Safety instructions 25 Additional instructions for permanent magnet motor drives ￭ Safety in installation, start-up, maintenance These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
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.
Page 28: Quick Installation, Commissioning And Operation Flowchart
28 Introduction to the manual Quick installation, commissioning and operation flowchart Task Plan the electrical installation and acquire the accessor- Guidelines for planning the electrical installa- ies needed (cables, fuses, etc.). tion (page 85) Check the ratings, required cooling air flow, input power Technical data (page 203) connection, compatibility of the motor, motor connec- tion, and other technical data.
Page 29: Related Manuals
Code Drive hardware manuals and guides Drive/converter/inverter safety instructions Multilingual code: 3AXD50000037978 ACS880-37 drives (45…400 kW, 60…450 hp) hardware manual 3AXD50000035159 ACx-AP-x assistant control panels user’s manual 3AUA0000085685 ACS880 frames R1 to R11 EMC filter and ground-to-phase varistor disconnecting instruc-...
Page 30 07/17/37 drives Manuals and quick guides for I/O extension modules, fieldbus adapter, etc. The code below opens an online listing of the manuals applicable to the product: ACS880-37 (45…400 kW, 60…450 hp) manuals www.abb.com/drives/documents for all manuals on the Internet.
Page 31: Operation Principle And Hardware Description
This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACS880-37 is a low-harmonic, air-cooled, cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance (SynRM) motors.
Page 32: Single-Line Circuit Diagram Of The Drive
32 Operation principle and hardware description ￭ Single-line circuit diagram of the drive Single-line diagram of R8 Auxiliary voltage supply fuses Auxiliary circuit protection switch Switch fuse Line contactor with options +Q951, +Q952, +Q978 Common mode filter (option +E208) du/dt filter (option +E205) or sine filter (option +E206) Auxiliary voltage transformer supplying 24 V and 230/115 V control voltage for, for example, cabinet fan(s), control devices and I/O extension adapter module.
Page 33: Single-Line Diagram Of R11
Operation principle and hardware description 33 Single-line diagram of R11 Main switch-disconnector (switch-disconnector and separate fuses) AC fuses Auxiliary voltage supply fuses Auxiliary circuit protection switch Line contactor inside the drive module. Q2 is controlled by the line-side converter control unit. If Start (Running) command is given to the drive, Q2 is closed and the line-side converter starts to modulate.
Page 34: Block Diagram Of The Drive With Brake Options +D150 And +D151
34 Operation principle and hardware description ￭ Block diagram of the drive with brake options +D150 and +D151 Drive module Line-side converter DC circuit between the line-side converter and motor-side converter Motor-side converter Brake chopper (option +D150) is located in its own cubicle Brake resistor (option +D151) is located in its own cubicle...
Page 35: Line-Side Converter
Operation principle and hardware description 35 ￭ Line-side converter The line-side converter rectifies three-phase AC current to direct current for the intermediate DC link of the drive. The line-side converter is also capable of regenerating, that is, feeding braking energy back into the electrical power network. The following diagram shows the simplified main circuit of the line-side converter.
Page 36: Cabinet Layout
36 Operation principle and hardware description Cabinet layout The layout drawings give an example of the R8 and R11 cabinets. The contents of the cabinet depends on the ordered options. For example: • In the lower power R8 and R11 cabinets with only a few options the “door fan” is replaced with a shroud (basic cabinet without 24 V auxiliary voltage supply, option +E205 du/dt filter and option +E208 common mode filter).
Page 37 Operation principle and hardware description 37 Drive module cubicle, door closed Drive module cubicle, door open Drive control panel Operating buttons and door lights Main switch handle Indicators, for example, V-meter and A-meter UL Type V-meter V-meter switch Main fuses for control devices, IP54 fan with option +B055, transformer with option +B055, V-meter (option +G334), starter for auxiliary motor fan (option +M600) Thermistor and PT100 relays (options +L505, +L506) Buffering module and power supply unit...
Page 38 38 Operation principle and hardware description Swing-out frame open Main contactor Switch fuse (Q1) Internal cabinet fans Auxiliary cooling fan Swing-out frame Terminal block (X504, option +L504) for external control cable connections to the control unit Module cooling fan Input cable connection terminals behind the shroud (bottom entry) PE busbar Cabinet heater (option +G300) Auxiliary voltage transformer (T21) and distribution components...
Page 39: Cabinet Layout Of R11
Operation principle and hardware description 39 ￭ Cabinet layout of R11 IP22 (UL Type 1) IP54 (UL Type 12) option +B055 IP42 (UL Type 1 Filtered) option +B054...
Page 40 40 Operation principle and hardware description Main breaker and power cabling cubicle Drive module cubicle Swing-out frame on the drive module side open Main switch-disconnector (Q1) handle Drive control panel Operating buttons and door lights Indicators, for example, V-meter and A-meter UL Type V-meter V-meter switch Drive module...
Page 41 Operation principle and hardware description 41 Swing-out frame Main fuses for control devices, IP54 fan with option +B055, transformer with option +B055, V-meter (option +G334), starter for auxiliary motor fan (option +M600) Buffering module and power supply unit Terminal blocks X18 and X19 Ground fault monitoring and safety circuit component Optional extension adapters and modules Thermistor and PT100 relays (options +L505, +L506)
Page 42 42 Operation principle and hardware description Swing-out frame Auxiliary voltage transformer (T102) with option +B055 and distribution components Auxiliary voltage transformer (T21) and distribution components Line-side control unit Extraction ramp Auxiliary voltage transformer (T101) with options +B055 and +C128 and distribution components...
Page 43: Brake Chopper Cubicle Option (+D150)
Operation principle and hardware description 43 ￭ Brake chopper cubicle option (+D150) Fuses (F121.1…121.2) Brake chopper module (T121.1) Auxiliary voltage transformer (T121.11) Fan (G121.1)
Page 44: Overview Of Power And Control Connections
44 Operation principle and hardware description Overview of power and control connections The diagram shows the power connections and control interfaces of the drive. ￭ Connection overview of R8 Slot 1 X208 Slot 2 Slot 3 ..
Page 45: Connection Overview Of R11
Operation principle and hardware description 45 ￭ Connection overview of R11 Motor-side converter control unit (drive control unit) Line-side converter control unit Analog and digital I/O extension modules, feedback interface modules and fieldbus communication modules can be inserted into slots 1, 2 and 3. See Type designation key (page 58).
Page 46: External Control Cable Connection Terminals (Other Than Control Unit Terminals)
46 Operation principle and hardware description Terminal blocks for customer connections installed in the drive cabinet. Wiring details are given in Electrical installation. Socket for external line-side converter control Line-side converter DC link Motor-side converter Brake chopper (option +D150) Brake resistors (option +D151) ￭...
Page 47: Connection Terminals Of R11
Operation principle and hardware description 47 Connection terminals of R11 The layout of external control cable connection terminals at the left-hand side of the drive cabinet is shown below. The composition depends on the options selected. Terminals for X250 Line contactor and main switch feedback for customer X506 Thermistor relay or Pt100 relays (option +L505 or +L506) -X969...
Page 48: Door Switches And Lights
48 Operation principle and hardware description Door switches and lights Label in English Label in local language Description READY Ready light (option +G327) Run light (option+G328) FAULT Fault light (option +G329) MAIN CONTACTOR Run enable signal switch for the line-side convert- er with options +Q951, +Q952 and +Q978 OFF-ON Run enable signal off (starting the line-side...
Page 49: Main Disconnecting Device (Q1)
Operation principle and hardware description 49 ￭ Main disconnecting device (Q1) The main disconnecting device switches the main supply to the drive on and off. To disconnect the main supply, turn the switch-disconnector (frame R11) or switch fuse (frame R8) to the 0/OFF position. WARNING! The main disconnecting device does not isolate the input power terminals or V-meter (option +G334) from the power line.
Page 50: Descriptions Of Options
50 Operation principle and hardware description Descriptions of options Note: All options are not available for all drive types, do not coexist with certain other options, or may require additional engineering. Check actual availability with ABB. ￭ Degree of protection...
Page 51: Cooling Air Intake Through Bottom Of Cabinet (Option +C128)
Operation principle and hardware description 51 ￭ Cooling air intake through bottom of cabinet (option +C128) See section Air inlet through the bottom of cabinet (option +C128) (page 79). ￭ UL Listed (option +C129) The cabinet contains the following accessories and features: •...
Page 52: Resistor Braking (Options +D150 And +D151)
52 Operation principle and hardware description ￭ Resistor braking (options +D150 and +D151) See chapter Resistor braking (page 269). ￭ du/dt filter (option +E205) The du/dt filter protects the motor insulating system by reducing the voltage rise speed at the motor terminals. The filter also protects the motor bearings by reducing the bearing currents.
Page 53: Output For Motor Space Heater (Option +G313)
Operation principle and hardware description 53 • Supplying power for the auxiliary circuits (page 102) • 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 54: Bottom Cable Entry/Exit (Options +H350 And +H352)
54 Operation principle and hardware description Option Additional markings +G340 Equipment pin identifiers are marked with snap-on markers (or equivalent) on conductors that (class A3) connect to equipment, terminal blocks or detachable plug-type connectors, or are part of the wiring between power modules. Plug-type connector identifications are marked on labels near the connectors.
Page 55: Thermal Protection With Ptc Relays (Options +L505, +2L505, +L513, +2L513, +L536, +L537)
Operation principle and hardware description 55 ￭ Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513, +L536, +L537) PTC thermistor relay options are used for overtemperature supervision of motors equipped with PTC sensors. When the motor temperature rises to the thermistor wake-up level, the resistance of the sensor increases sharply.
Page 56: Thermal Protection With Pt100 Relays (Options +Nl506, +Nl514)
56 Operation principle and hardware description • FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option +L537+Q971) for ACS880 drives user's manual (3AXD50000027782 [English]) • circuit diagrams delivered with the drive for the actual wiring. ￭ Thermal protection with Pt100 relays (options +nL506, +nL514) Pt100 temperature monitoring relays are used for overtemperature supervision of motors equipped with Pt100 sensors.
Page 57: Description
Operation principle and hardware description 57 up to four fan connections (eg. option +4M602), while the highest current rating only allows one (eg. +M610). For more information, refer to ACS880-X7 single drives ordering information (3AXD10000052815, available on request). Description The output for the auxiliary fan is wired from the 3-phase supply voltage to terminal block X601 through a motor starter switch and a contactor.
Page 58: Type Designation Key
Type designation key The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (for example, ACS880-37- 0650A-3). The optional selections are given thereafter, separated by plus signs, for example, +E202.
Page 59 Operation principle and hardware description 59 Code Description C180 Seismic design. See section Seismic design (option +C180) (page 51). Empty 400 mm wide cubicle on right. See section Empty cubicles on right (options C196 +C196…C198) (page 51). Empty 600 mm wide cubicle on right. See section Empty cubicles on right (options C197 +C196…C198) (page...
Page 60 60 Operation principle and hardware description Code Description G340 Additional wire markings. See section Wire markings (page 53). G342 Cabling Supply cabling direction down. See section Bottom cable entry/exit (options +H350 and H350 +H352) (page 54). H351 Supply cabling direction up. See section Top cable entry/exit (options +H351 and +H353) (page 54).
Page 61 Operation principle and hardware description 61 Code Description L521 FSE-31 pulse encoder interface module L525 FAIO-01 analog I/O extension module L526 FDIO-01 digital I/O extension module L536 FPTC-01 thermistor protection module L537 FPTC-02 ATEX-certified thermistor protection module Starter for auxiliary motor fan (see section Descriptions of options (page 50)) M600...
Page 62 62 Operation principle and hardware description Code Description Q963 Emergency stop (category 0) with safety relays, by activating the Safe torque off function Q964 Emergency stop (category 1) with safety relays, by activating the Safe torque off function Q965 Safely-limited speed with FSO-21 and encoder Q971 ATEX-certified safe disconnection function Q972...
Page 63: Mechanical Installation
Mechanical installation 63 Mechanical installation Contents of this chapter This chapter describes the mechanical installation procedure of the drive. 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.
Page 64: Necessary Tools
64 Mechanical installation Do not install the drive on an elevated platform or a recess. The module extraction/installation ramp included with the drive is only suitable for a height difference of 50 mm maximum (ie. the standard plinth height of the drive). Necessary tools The tools required for moving the unit to its final position, fastening it to the floor and wall and tightening the connections are listed below:...
Page 65: Moving And Unpacking The Drive
Mechanical installation 65 Moving and unpacking the drive Move the drive in its original packaging to the installation site as shown below to avoid damaging the cabinet surfaces and door devices. When you are using a pallet truck, check its load capacity before you move the drive. The drive cabinet is to be moved in the upright position.
Page 66 66 Mechanical installation 1088 Lifting the transport package with slings. Lifting points Lifting the transport package with forklift...
Page 67: Moving The Drive In Its Packaging - Frame R11
Mechanical installation 67 ￭ Moving the drive in its packaging – Frame R11 Lifting the crate with a forklift WARNING! Incorrect lifting can cause danger or damage. Obey the local laws and regulations applicable to lifting, such as requirements for planning the lift, for capacity and condition of lifting equipment, and for training of personnel.
Page 68: Lifting The Crate With A Crane
68 Mechanical installation Lifting the crate with a crane WARNING! Incorrect lifting can cause danger or damage. Obey the local laws and regulations applicable to lifting, such as requirements for planning the lift, 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 69: Moving The Crate With A Forklift
Mechanical installation 69 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: 1. Undo the screws that attach the wooden parts of the transport crate to each other. 2.
Page 70: Moving The Unpacked Drive Cabinet
Removing the transport package  Remove the transport package as follows: 70 Mechanical installation 1. Undo the screws that attach the wooden parts of the transport crate together. 2. Remove the wooden parts. ￭ Moving the unpacked drive cabinet 3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws.
Page 71: Moving The Cabinet On Rollers
Mechanical installation 71 Moving the cabinet on rollers WARNING! Do not move marine versions (option +C121) on rollers. 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 the drive with a sine filter (option +E206) on its back.
Page 72: Final Placement Of The Cabinet
72 Mechanical installation Final placement of the cabinet Move the cabinet into its final position with a slate bar (spud bar). Place a piece of wood between the edge of the cabinet and the bar to protect the cabinet frame.
Page 73: Installing The Ip54 Roof (Option +B055)
Mechanical installation 73 Installing the IP54 roof (option +B055) If the roof of an IP54 cabinet is delivered in a separate package, install the roof as follows. ￭ Frame R8 1. Undo the lifting eye screws and remove the lifting eyes. 2.
Page 74: Frame R11
74 Mechanical installation ￭ Frame R11 1. Undo the lifting eye screws and remove the lifting eyes. 2. To remove the top front profile of the cabinet, undo the mounting screws. Undo the back mounting screws. 3. Install the roof. 4.
Page 75: Attaching The Cabinet To The Floor And Wall Or Roof
Mechanical installation 75 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 76: Attaching The Cabinet (Non-Marine Units)
76 Mechanical installation ￭ Attaching the cabinet (non-marine units) Alternative 1 – Clamping 1. Insert the clamps (included) into the twin slots along the front and rear edges of the cabinet frame body and fasten them to the floor with a bolt. The recommended maximum distance between the clamps in the front edge is 800 mm (31.5”).
Page 77: Alternative 2 - Using The Holes Inside The Cabinet
Mechanical installation 77 Alternative 2 – Using the holes inside the cabinet 1. Attach the cabinet to the floor through the bottom fastening holes with M10 to M12 (3/8” to 1/2”) bolts. The recommended maximum distance between the front edge fastening points is 800 mm (31.5”).
Page 78: Attaching The Cabinet (Marine Units)
78 Mechanical installation ￭ 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: 1. Bolt the unit to the floor through the flat bars at the base of the cabinet using M10 or M12 screws.
Page 79: 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 80: Air Outlet Duct On The Cabinet Roof (Option +C130)
80 Mechanical installation 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 81 Mechanical installation 81 Example The cabinet has 3 exit openings of 315 mm diameter. The rated air flow of the cabinet is 4650 m /h =1.3 m = 3 · 0.315 · π / 4 = 0.234 m = 1.3 / 0.234 = 5.5 m/s = 0.5 ·...
Page 82: Lifting Lugs And Bars
82 Mechanical installation Lifting lugs and bars ￭ Certificate of conformity The certificate is available in ABB Library at www.abb.com/drives/documents (document number 3AXD10001061361). ￭ Declaration of Conformity...
Page 83 Mechanical installation 83...
Page 85: Guidelines For Planning The Electrical Installation
The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
Page 86: Examining The Compatibility Of The Motor And Drive
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 87 Guidelines for planning the electrical installation 87 This table shows the requirements when an ABB motor is in use. Motor Nominal AC supply Requirement for type voltage Motor insula- ABB du/dt and common mode filters, insulated N-end tion system motor bearings <...
Page 88 88 Guidelines for planning the electrical installation This table shows the requirements when a non-ABB motor is in use. Motor Nominal AC supply Requirement for type voltage Motor insula- ABB du/dt and common mode filters, insulated N-end tion system motor bearings <...
Page 89: Availability Of Du/Dt Filter And Common Mode Filter By Drive Type
The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: •...
Page 90: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
90 Guidelines for planning the electrical installation Nominal AC supply Requirement for voltage Motor insulation system ABB du/dt and common mode filters, insulated N- end motor bearings < 100 kW or frame 100 kW < P < 350 kW or size <...
Page 91: Additional Note For Sine Filters
Guidelines for planning the electrical installation 91 Û du/dt ------------ - (1/μs) Û du/dt ------------ - (1/μs) l (m) l (m) Drive with du/dt filter Drive without du/dt filter Motor cable length Û Relative peak line-to-line voltage (du/dt)/U Relative du/dt value Note: Û...
Page 92: Typical Power Cable Sizes
92 Guidelines for planning the electrical installation fault current during the disconnection time of the protective device. The cross-sectional area of the protective conductor can either be selected from the table below or calculated according to 543.1 of IEC 60364-5-54. This table shows the minimum cross-sectional area of the protective conductor related to the phase conductor size according to IEC/UL 61800-5-1 when the phase conductor and the protective conductor are made of the same metal.
Page 93: Alternate Power Cable Types
Guidelines for planning the electrical installation 93 Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or armored) cable with three phase conductors and symmetrically constructed PE conductor and a shield (or armor) Symmetrical shielded (or armored) cable with three phase conductors and a shield (or armor), and separ- ate PE conductor/cable...
Page 94: Not Allowed Power Cable Types
￭ Additional guidelines, North America ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor(s). Due to the variety of application needs, metallic and non-metallic conduit can be used. ABB prefers the use of metallic conduit.
Page 95: Metal Conduit
Guidelines for planning the electrical installation 95 Wiring method Notes 1) 2) Conduit - Metallic Electrical metallic tubing: Type EMT Prefer symmetrical shielded VFD cable. Use separate conduit run for each motor. Rigid metal conduit: Type RMC Do not run input power wiring and motor wiring in the Liquid-tight flexible metal electrical conduit: Type LFMC same conduit.
Page 96: Selecting The Control Cables
￭ Relay cable The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. ￭ Control panel to drive cable Use EIA-485 with male RJ-45 connector, cable type Cat 5e or better. The maximum permitted...
Page 97: Pc Tool Cable
Guidelines for planning the electrical installation 97 ￭ PC tool cable Connect the Drive composer PC tool to the drive through the USB port of the control panel. Use a USB Type A (PC) - Type Mini-B (control panel) cable. The maximum length of the cable is 3 m (9.8 ft).
Page 98: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable
98 Guidelines for planning the electrical installation Input power cabling Motor cabling Conduit ￭ Continuous motor cable shield/conduit or enclosure for equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...
Page 99: Implementing Thermal Overload And Short-Circuit Protection
Guidelines for planning the electrical installation 99 Implementing thermal overload and short-circuit protection ￭ Protecting the drive and input power cable in short-circuits The drive is equipped with internal AC fuses (1) as standard. The fuses restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive. Protect the input cable with fuses or circuit breaker (2) according to local safety regulations, appropriate input voltage and the rated current of the drive (see the technical data).
Page 100: Protecting The Motor Against Thermal Overload
100 Guidelines for planning the electrical installation ￭ Protecting the motor against thermal overload According to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary.
Page 101: Implementing The Prevention Of Unexpected Start-Up Function
Guidelines for planning the electrical installation 101 • use an ATEX-certified Ex motor • order an ATEX-certified thermistor protection module for the drive (option +L357), or acquire and install an ATEX-compliant protection relay • do the necessary connections. For a cabinet-installed drives, an ATEX-certified motor thermal protection function is also available (option +L513+Q971, or +L514+Q971).
Page 102: Implementing The Power-Loss Ride-Through Function
￭ Implementing a bypass connection An order-based engineered bypass connection is available from ABB. For more information, see Bypass connection for ACS880-07, -17, -37 (40...1200 A) option description (3AXD50000048959 [English]).
Page 103: Using Power Factor Compensation Capacitors With The Drive
￭ 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 maintenance work on the drive.
Page 104: Implementing A Motor Temperature Sensor Connection
104 Guidelines for planning the electrical installation or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system. Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs.
Page 105: Connecting Motor Temperature Sensor To The Drive Via An Option Module
Guidelines for planning the electrical installation 105 1. If there is double or reinforced insulation between the sensor and the live parts of the motor: You can connect the sensor directly to the analog/digital input(s) of the drive. See the control cable connection instructions. 2.
Page 106 106 Guidelines for planning the electrical installation Option module Temperature sensor Temperature sensor insulation type requirement Type Insulation/Isolation Pt100, Pt1000 FIO-11 Galvanic isolation between sensor Reinforced insulation connector and other connectors (in- cluding drive control unit connector) FEN-xx Galvanic isolation between sensor Reinforced insulation connector and other connectors (in- cluding drive control unit connector)
Page 107: Electrical Installation
Electrical installation 107 Electrical installation Contents of this chapter This chapter gives instructions on the wiring 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 or maintenance work.
Page 108: Measuring The Insulation 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 109: Corner-Grounded And Midpoint-Grounded Delta Systems
Electrical installation 109 WARNING! Do not install the drive with the ground-to-phase varistor connected to a system that the varistor is not suitable for. If you do, the varistor circuit can be damaged. ￭ Corner-grounded and midpoint-grounded delta systems WARNING! Do not install the drive on a 525…690 V corner-grounded or midpoint-grounded delta system.
Page 110: Connecting The Power Cables
110 Electrical installation Connecting the power cables ￭ Connection diagram Connection diagram of frame R8 Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor. See General guidelines (page 91).
Page 111: Connection Diagram Of Frame R11
Electrical installation 111 Note: If there is a symmetrically constructed grounding conductor on the motor cable in addition to the conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor ends. Do not use an asymmetrically constructed motor cable.
Page 112: Layout Of Power Cable Connection Terminals And Cable Entries
112 Electrical installation ￭ Layout of power cable connection terminals and cable entries The layout of power cable connection terminals and cable entries of the standard drive are shown below. Note: You have to remove the “door fan” to gain access to the cable terminals and entries (see page 158).
Page 113: Frame R11
Electrical installation 113 Frame R11 Strain relief Power cable entries. Conductive sleeve under the grommet. Control cable entry with EMI conductive cushions. PE terminal Input power cable terminals L1, L2 and L3 Motor cable terminals U2, V2, W2...
Page 114: Layout Of Power Cable Connection Terminals (Option +C129)
114 Electrical installation Layout of power cable connection terminals (option +C129) This figure shows the layout of the power cable connection terminals of frame R8. Power cable entries Strain relief Ground bar Input cable power connection terminals L1, L2 and L3 Motor cable connection terminals U2, V2, W2 This figure shows the layout of the power cable connection terminals of frame R11.
Page 115: External Resistor Cable Connection Terminals And Cable Entries
Electrical installation 115 External resistor cable connection terminals and cable entries External brake resistor cables are connected directly to the brake chopper (option +D150) terminals in the brake chopper cubicle. The delivery drawings show the location of the terminals and entries. ￭...
Page 116 116 Electrical installation 5. Prepare the ends of the cables. WARNING! Apply grease to stripped aluminum conductors before attaching them to non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions. Aluminum-aluminum contact can cause oxidation in the contact surfaces. 6. If fire insulation is used, make an opening in the mineral wool sheet according to the diameter of the cable.
Page 117: Connection Procedure (North America)
Electrical installation 117 8. Attach the conductive sleeves to the cable shields with cable ties. 9. Tie up the unused conductive sleeves with cable ties. 10. Connect the twisted shields of the motor cables to the ground bar and the phase conductors to the U2, V2 and W2 terminals.
Page 118 118 Electrical installation 3. For R8 bottom entry of cables: • If there is a mounting plate above the fan, loosen the four screws and pull out the plate. Unplug the connectors and remove the plate. • If there is no mounting plate, but a shroud above the fan, undo the four screws and remove the shroud.
Page 119 Electrical installation 119 10. Drives with external brake resistors (option +D150 and no +D151): • Run the power cables from the brake resistor to the brake copper cubicle including the grounding cable. • Connect the ground cable to the ground bar at the bottom of the cabinet. •...
Page 120: Grounding The Motor Cable Shield At The Motor End
120 Electrical installation ￭ Grounding the motor cable shield at the motor end For minimum radio-frequency interference, ground the cable shield 360 degrees at the cable entry of the motor terminal box. Connecting the control cables See chapter Control units of the drive for the default I/O connections of the drive control unit (with the ACS880 primary control program).
Page 121 Electrical installation 121 5. For bottom entry: Route the cables of these options to the connection terminals at the right-hand side of the cabinet as shown below. For top entry, see step 7. Terminal Option X250 Main switch feedback and line contactor feedback with options +Q951, +Q952 or +Q978 for customer X506 Thermistor relay or Pt100 relays (option +L505 or +L506)
Page 122 122 Electrical installation 6. Drives with swing-out frame: Open the swing-out frame (a). Marine drives (option +C121): To open the swing-out frame, undo the three M6 screws on the left side of the swing-out frame. Drives without swing-out frame: Remove the shroud (b).
Page 123: Frame R11
Electrical installation 123 7. Route the cables to the control unit (a) and additional terminal block X504 (option +L504) and to options +QXXX, +MXXX, +L505 and +L506 as shown below. Bottom entry Top entry X504 +QXXX +MXXX +L505 +L506 Frame R11 1.
Page 124 124 Electrical installation 5. Bottom entry: Route the cables of these options to the connection terminals at the left-hand side of the cabinet as shown below. Terminal Option X250 Main switch and line contactor feedback for customer X506 Thermistor relay or Pt100 relays (option +L505 or +L506) X601 Starter for auxiliary motor fan (options +M600…+M605) X951...
Page 125 Electrical installation 125 6. Bottom entry: Route the cables to the control unit (a), additional terminal block X504 (option +L504) as shown below. X504 Top entry: Route the control cables to the control unit (a) and additional terminal block X504 (option +L504) as shown below (standard cabinet and option +B054 with blue color;...
Page 126 126 Electrical installation +B055 X504...
Page 127: Connecting The External Control Cables To The Drive Control Unit
Electrical installation 127 ￭ Connecting the external control cables to the drive control unit See chapter Control units of the drive for the default I/O connections of the drive control 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 128 128 Electrical installation A PC (with eg, the Drive composer PC tool) can be connected as follows: 1. Connect an ACx-AP-x control panel to the unit either • by inserting the control panel into the panel holder or platform, or •...
Page 129: Installing Option Modules
Electrical installation 129 Installing option modules ￭ Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface modules 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Insert the module carefully into its position on the control unit. 3.
Page 130: Installation Of An Fso-Xx Safety Functions Module Onto Zcu-14
130 Electrical installation ￭ Installation of an FSO-xx safety functions module onto ZCU-14 WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work.
Page 131: Safety Functions Module Fso-Xx Beside The Zcu-14 Control Unit
Electrical installation 131 7. Connect the other end of the data cable to connector X110 on the FSO-xx. 8. To complete the installation, refer to the instructions in the user’s manual delivered with the FSO-xx. ￭ Safety functions module FSO-xx beside the ZCU-14 control unit 1.
Page 132: Installation Of An Fsps-21 Safety Functions Module
132 Electrical installation ￭ Installation of an FSPS-21 safety functions module Install safety functions module FSPS-21 onto the drive control unit as described in its user's manual.
Page 133: Control Units Of The Drive
Control units of the drive 133 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 ZCU-1x control units.
Page 134: Layout
134 Control units of the drive ZCU-12 layout Description Analog inputs Analog outputs X202 Digital inputs X208 XDIO Digital input/outputs XD24 Digital input interlock (DIIL) and +24 V output X205 XD2D Drive-to-drive link XPOW External power input XRO1 Relay output RO1 XRO2 Relay output RO2 X203...
Page 135: Layout
Control units of the drive 135 ZCU-14 layout Description XPOW External power input Analog inputs XRO1 Analog outputs XD2D Drive-to-drive link XRO2 XRO1 Relay output RO1 XRO2 Relay output RO2 XRO3 Relay output RO3 XRO3 XD24 Digital input interlock (DIIL) and +24 V output XDIO Digital input/outputs XPOW...
Page 136: Default I/O Diagram Of The Drive Control Unit (Zcu-1X)
136 Control units of the drive Default I/O diagram of the drive control unit (ZCU-1x) Relay outputs XRO1…XRO3 Ready 250 V AC / 30 V DC Running 250 V AC / 30 V DC Faulted(-1) 250 V AC / 30 V DC Fault External power input XPOW...
Page 137 Control units of the drive 137 Notes: The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (24…12 AWG). The torque is 0.5 N·m (5 lbf·in). Current [0(4)…20 mA, R = 100 ohm] or voltage [0(2)…10 V, R >...
Page 138: Additional Information On The Connections
138 Control units of the drive Additional information on the connections ￭ External power supply for the control unit (XPOW) The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW. Using an external supply is recommended if •...
Page 139: Diil Input
(nominal impedance 100 to 165 ohm, for example Belden 9842) for the wiring. For best immunity, ABB recommends high quality cable. Keep the cable as short as possible. Avoid unnecessary loops and parallel runs near power cables such as motor cables.
Page 140: Safe Torque Off (Xsto)
140 Control units of the drive ZCU-12 ZCU-14 Termination ON Termination OFF Termination ON ￭ Safe torque off (XSTO) See chapter The Safe torque off function (page 253). Note: The XSTO input only acts as a true Safe torque off input on the inverter control unit. De-energizing the IN1 and/or IN2 terminals of other units (supply, DC/DC converter, or brake unit) will stop the unit but not constitute a true safety function.
Page 141: Connector Data
Control units of the drive 141 Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 2.5 mm 24 V (±10%) DC, 2 A External power input. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3) 250 V AC / 30 V DC, 2 A Protected by varistors +24 V output (XD24:2 and XD24:4)
Page 142 142 Control units of the drive Analog outputs AO1 and AO2 (XAO) Connector pitch 5 mm, wire size 2.5 mm 0…20 mA, R < 500 ohm load Frequency range: 0…300 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range XD2D connector Connector pitch 5 mm, wire size 2.5 mm Physical layer: RS-485...
Page 143: Zcu-1X Ground Isolation Diagram
Control units of the drive 143 ￭ ZCU-1x ground isolation diagram XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- channels ±30 V AI2+ AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2...
Page 145: Installation Checklist Of The Drive
Installation checklist of the drive 145 Installation checklist of the drive Contents of this chapter This chapter contains a checklist of the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person.
Page 146 146 Installation checklist of the drive Make sure that … The cooling air flows freely in and out of the drive. If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground- to-phase varistor).
Page 147: Start-Up
Start-up 147 Start-up Contents of this chapter This chapter contains the start-up procedure 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 148 148 Start-up Action Safety WARNING! Obey the safety instructions during the start-up procedure. See chapter Safety instruc- tions (page 15). Checks/Settings with no voltage connected Ensure that the disconnector of the supply transformer is locked to the off (0) position, ie. no voltage is, and cannot be connected to the drive inadvertently.
Page 149 Start-up 149 Action Setting up the line-side converter parameters The line-side converter control program parameters are set at the factory. Normally, there is no need to change them at the start-up. For more information on the line-side converter control parameters, see ACS880 primary control program firmware manual (3AUA0000085967 [English]) or ACS880 IGBT supply control program firmware manual (3AUA0000131562 [English]).
Page 151: Fault Tracing
Fault tracing 151 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs Where Color When the LED is lit Control panel POWER Green Control unit is powered and +15 V is supplied to the control mounting platform panel FAULT...
Page 153: Maintenance
This chapter contains preventive maintenance instructions. Maintenance intervals The table below shows the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels).
Page 154 Note: • Maintenance and component replacement intervals are based on the assumption that the equipment is op- erated 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 mainten- ance intervals for certain components.
Page 155: Cabinet
Maintenance 155 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 or maintenance work.
Page 156: Replacing The Inlet Door Filters (Ip54)
156 Maintenance ￭ Replacing the inlet door filters (IP54) 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Remove the fasteners at the top of the grating. 3. Lift the grating and pull it away from the door. 4.
Page 157: Cleaning The Heatsink
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.
Page 158: Replacing The Cabinet "Door Fan
158 Maintenance ￭ Replacing the cabinet “door fan” WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work.
Page 159: Replacing The Internal Cabinet Cooling Fans (Frame R8)
Maintenance 159 ￭ Replacing the internal cabinet cooling fans (frame R8) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work.
Page 160 160 Maintenance...
Page 161: Replacing The Drive Module Main Fan (Frame R8)
Maintenance 161 ￭ Replacing the drive module main fan (frame R8) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work.
Page 162 162 Maintenance 5. Undo the mounting screws of the fan cassette. 6. Pull the fan cassette out. 7. Undo the mounting screws of the fan(s). The finger guard of the fan is attached by the same screws and is removed at the same time. Keep the finger guard for reuse. 8.
Page 163: Replacing The Lcl Filter Module Fan (Frame R11)
Maintenance 163 ￭ Replacing the LCL filter module fan (frame R11) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work.
Page 164: Replacing The Auxiliary Cooling Fan Of The Drive Module (Frame R8)
164 Maintenance ￭ Replacing the auxiliary cooling fan of the drive module (frame R8) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work.
Page 165: Replacing The Auxiliary Cooling Fans Of The Drive Module (Frame R11)
Maintenance 165 ￭ Replacing the auxiliary cooling fans of the drive module (frame R11) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Fan in the front panel: 1.
Page 166 166 Maintenance 4. To open the swing-out frame, undo the M10 bolts from top and bottom (4 pcs). The fan locates in the bottom part of drive module circuit board compartment. 5. Undo the mounting screw of the fan cassette. 6.
Page 167: Frame R8: Replacing The Ip54 (Ul Type 12) Roof Fan And Chopper (Option +D150) Cubicle Fan G101.2
Maintenance 167 ￭ Frame R8: Replacing the IP54 (UL Type 12) roof fan and chopper (option +D150) cubicle fan G101.2 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1.
Page 168: Frame R11 With Options +B055 And +C128: Replacing The Roof Fan
168 Maintenance ￭ Frame R11 with options +B055 and +C128: Replacing the roof fan WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work.
Page 169: Frame R11 With Option +B055: Replacing The Roof Fan
Maintenance 169 ￭ Frame R11 with option +B055: Replacing the roof fan WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work.
Page 170: Replacing The Sine Filter Cooling Fan
170 Maintenance 4. Unscrew fan mounting screws (4 pcs). 5. Slide the fan out. 6. Install the new fan in reverse order. ￭ Replacing the sine filter cooling fan For replacing the cooling fans of NSINxxx-x sine filters, see Sine filters hardware manual (3AXD50000016814 [English]).
Page 171: Replacing The Drive Module (Frame R8)
• torque wrench with an extension bar • lifting chains. A lifting device is available from ABB with order code 3AXD50000047447. ￭ Replacing the drive module (frame R8) WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 172 172 Maintenance 6. For drives with option +C121: Undo the three M6 screws on the left side of the swing-out frame. All drives: Undo the two M6 screws on the right side of the swing-out frame and open the swing-out frame or remove the shroud and four shroud fixing brackets if there is no swing-out frame.
Page 173 Maintenance 173 10. Unplug the connector and remove the fan or remove the shroud if there is no fan.
Page 174 174 Maintenance 11. Loosen the four M5 screws and remove the plastic shroud. 12. For drives with bottom entry: Undo the four M6 combi screws and remove the plastic shroud. 13. For drives with bottom entry or exit: Remove the connection terminal subassembly: Undo the screws or nuts: •...
Page 175 Maintenance 175 17. For drives with brake chopper (option +D150): Undo the two M10 nuts and bend the two power cables down so that they do not disturb the module replacement. Bottom exit from module Bottom exit with +E208 or +E205...
Page 176 176 Maintenance Top exit 18. Undo the four M6 combi screws and remove the plastic air guide. 19. Loosen the four M6 combi screws, unplug the connector, lift the fan up a bit and remove the fan plate. 20. For easier removal of the module, undo the four M6 combi screws, disconnect the wires of the thermal switch and remove the plastic air guide.
Page 177 Maintenance 177 22. Unplug the wires and connectors of X504 mounting plate. 23. Undo the four M8 Serpress® nuts.
Page 178 178 Maintenance 24. Undo the two M6 self-tapping screws in the bottom left side of the cabinet and remove the module slide extension rails. 25. Install the extension rails at the end of the sliding bars. 26. Slide the drive module towards the end of the sliding bars. 27.
Page 179 Maintenance 179 31. Place X504 mounting plate to the new module and attach the M5 combi screws. 32. Install the new module in reverse order.
Page 180: Replacing The Drive And Lcl Filter Modules (Frame R11)
180 Maintenance Replacing the drive and LCL filter modules (frame R11) ￭ Required tools • installation ramp • set of screw drivers • torque wrench with an extension bar • lifting chains. ￭ Safety WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 181 Maintenance 181 • Make sure that the module does not topple over when you move it on the floor: Open the support legs by pressing each leg a little down (1, 2) and turning it aside. Whenever possible attach the module also with chains. Do not tilt the drive module. It is heavy and its center of gravity is high.
Page 182: Replacing The Drive Module (Frame R11)
182 Maintenance ￭ Replacing the drive module (frame R11) Replacing the drive module requires preferably two persons. 1. Stop the drive (if running) and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Open the cabinet doors.
Page 183 Maintenance 183 3. For drives with option +C121: Undo the two module attaching screws (3a). Undo the M6 screws and remove the three supports (3b). Undo the five M6 screws on the left side of the swing-out frame (3c). 3a: Combi screw M10 3b: M6 3c: M6...
Page 184 184 Maintenance 4. To open the module section swing-out frame, undo the M10 bolts from top and bottom (4 pcs). 5. Loosen the two M6 screws of the air baffle and push it to the left. (Not for drives with option +C128.) 6.
Page 185 Maintenance 185 9. Disconnect all cables from line-side converter control unit (from terminal X2, INU STO connector and the fiber optic cables from the V8, V13, V2 and V7 connectors). The connections between the line-side converter control unit and drive are shown below. The drive control unit remains in its place when you remove the drive module.
Page 186 186 Maintenance 10. Loosen the M4 screws, lift the plastic shroud of the DC busbars up and remove it. 11. Disconnect the input power cabling busbars from the drive module busbar terminals. For drives with option +D150, disconnect the DC busbars also.
Page 187 Maintenance 187 12. Disconnect the output power cabling and PE busbars from the drive module busbar terminals. Hex screw Hex screw...
Page 188 188 Maintenance 13. To disconnect the drive module from the LCL filter module: • (13a) Remove the shroud. • (13b) Remove the bolts that connect the power busbars. • (13c) Remove the attaching bolt. • (13d) Remove the shroud. • (13e) Remove the bolts.
Page 189 Maintenance 189 16. Adjust the extraction ramp to the correct height and attach it to the cabinet base with the two mounting screws of the support bracket that was removed. 17. For drives with marine construction (option +C121): Remove the bolts that attach the drive module to the cabinet frame at the lower part.
Page 190 190 Maintenance 21. Undo the bolts that attach drive module from back to the cabinet frame. Combi screw M4 Combi screw M8 Combi screw M10 22. Attach the lifting lugs of the module to be removed to the cabinet lifting lug with chains. 23.
Page 191: Replacing The Lcl Filter Module
Maintenance 191 24. Before the module back wheels reach the attaching hook on the floor, open also the back support legs of the drive module by pressing each leg a little downwards and turning it aside. Close the legs when the module back wheels have passed the attaching hook.
Page 192 192 Maintenance 6. Undo the 5 bolts that attach LCL filter module from back and from the right to the cabinet frame. 7. Attach the lifting lugs of the module to be removed to the cabinet lifting lug with chains.
Page 193: Capacitors
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. ￭...
Page 194 194 Maintenance 3. Remove the fuse replacement handle. 4. Remove the shroud. 5. Remove the top mounting plate. 6. Pull out the fuses with the fuse handle and replace them with the new fuses. 7. Reinstall the mounting plate, shroud and fuse handle.
Page 195: Replacing Fuses (Frame R11)
Maintenance 195 ￭ Replacing fuses (frame R11) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.
Page 196 196 Maintenance...
Page 197: Replacing The Dc Fuses Of The Brake Chopper (Option +D150)
Maintenance 197 ￭ Replacing the DC fuses of the brake chopper (option +D150) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.
Page 198: Control Panel
198 Maintenance Control panel ￭ Replacing the battery and cleaning See ACx-AP-x assistant control panels user’s manual [3AUA0000085685 (English)]. Control unit ￭ Replacing the ZCU-14 control unit battery WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 199: Replacing The Memory Unit Of The Motor-Side Converter Control Unit (Frame R8)
Maintenance 199 After power-up, the drive scans the memory unit. If a different control program or different parameter settings are detected, they are copied to the drive. This can take several minutes. Replacing the memory unit of the motor-side converter control unit (frame R8) WARNING! Obey the safety instructions of the drive.
Page 200 200 Maintenance 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Open the cabinet door and swing-out frame or remove the shroud if there is no swing-out frame. The control unit is located behind swing-out frame or shroud. 3.
Page 201: Replacing The Memory Unit Of The Motor-Side Converter Control Unit (Frame R11)
Maintenance 201 Replacing the memory unit of the motor-side converter control unit (frame R11) 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Open the cabinet doors. The control unit is located on the module-side swing-out frame. For the location, see also section Cabinet layout (page 36).
Page 202: Replacing The Memory Unit Of The Line-Side Converter Control Unit (Frame R11)
202 Maintenance Replacing the memory unit of the line-side converter control unit (frame R11) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.
Page 203: Technical Data
The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described in section Definitions (page 205). ￭ IEC ratings Output ratings Input Nominal ratings Light-overload current Heavy-duty use Drive type Frame size ACS880-37-… = 400 V 0105A-3 0145A-3 0169A-3 0206A-3...
Page 204: Ul (Nec) Ratings
204 Technical data Output ratings Input Nominal ratings Light-overload current Heavy-duty use Drive type Frame size ACS880-37-… 0293A-3 0363A-3 0442A-3 0505A-3 0585A-3 0650A-3 = 500 V 0101A-5 0124A-5 0156A-5 0180A-5 0260A-5 0361A-5 0414A-5 0460A-5 0503A-5 = 690 V 0174A-7 0210A-7...
Page 205: Definitions
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 206: Altitude Derating
1 percentage point for every added 100 m (328 ft). For example, the derating factor for 1500 m (4921 ft) is 0.95. For altitudes above 2000 m (6562 ft), contact ABB. If surrounding air temperature is below +40 °C (+104 °F), the derating can be reduced by 1.5 percentage points for every 1 °C (1.8 °F) reduction in temperature.
Page 207: Deratings For Special Settings In The Drive Control Program
Ex motor, sine filter, low noise The ratings in these cases are given in the table below: • drive is used with an ABB motor for explosive atmospheres (Ex) and EX motor in parameter 95.15 Special HW settings is enabled •...
Page 208 208 Technical data Output ratings for special settings Ex motor (ABB Ex motor) ABB sine filter Low noise mode Light- Heavy- Light- Heavy- Light- Heavy- Drive type Nominal use duty duty Nominal use duty duty Nominal use duty duty ACS880-37-…...
Page 209 High speed mode Selection High speed mode of parameter 95.15 Special HW settings improves control performance at high output frequencies. ABB recommends it to be selected with output frequency of 120 Hz and above. This table gives the drive module ratings for 120 Hz output frequency and the maximum output frequency for the drive ratings when High speed mode in parameter 95.15 Special...
Page 210 Heavy- Nominal use Nominal use duty use duty use duty use duty use ACS880-37-… 0330A-7 0370A-7 0430A-7 Output frequency Maximum output frequency with High speed mode Nominal voltage of the drive Continuous rms output current. No overload capability at 40 °C (104 °F) Typical motor power in no-overload use.
Page 211: Fuses (Iec)
Technical data 211 Fuses (IEC) The drive is equipped with aR fuses listed below as standard. Input cur- Ultrarapid (aR) fuses (one fuse per phase) Drive type rent ACS880-37-… Manufacturer Type Size = 400 V 0105A-3 8250 Bussmann 170M3814D 0145A-3...
Page 212 212 Technical data Input cur- Ultrarapid (aR) fuses (one fuse per phase) Drive type rent ACS880-37-… Manufacturer Type Size = 400 V 0105A-3 0145A-3 0169A-3 0206A-3 0293A-3 160000 Mersen SC32AR69V500TF 0363A-3 315000 Mersen SC32AR69V630TF 0442A-3 442000 Mersen SC32AR69V700TF 0505A-3 660000...
Page 213: Fuses (Ul)
The fuses must be of the “non-time delay” type. Obey local regulations. Fuse (one fuse per phase) Drive type Input current UL class / ACS880-37-… Manufacturer Type Size = 400 V 0105A-3...
Page 214: Dimensions And Weights
214 Technical data Note: • See also Implementing thermal overload and short-circuit protection (page 99). • Fuses with higher current rating than the recommended ones must not be used. Fuses with lower current rating can be used. • 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.
Page 215: Free Space Requirements
Technical data 215 Height Width Depth Weight Frame size IP22/42 IP54 0180A-5 2145 84.45 2315 91.14 23.62 25.43 0260A-5 2145 84.45 2315 91.14 23.62 25.43 0302A-5 2145 84.45 2315 91.14 23.62 25.43 0361A-5 2145 84.45 2315 91.14 23.62 25.43 0414A-5 2145 84.45 2315...
Page 216: Cooling Data, Noise
This table shows typical heat dissipation values, required air flow and noise at the nominal ratings of the drive. The heat loss values can vary depending on product configuration, voltage, cable conditions, motor efficiency and power factor. To obtain more accurate values for given conditions, use ABB DriveSize tool (http://new.abb.com/drives/softwaretools/drivesize). Air flow...
Page 217: 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 the drive. Cooling data Sine filter(s) used Drive type Heat dissipation Air flow ACS880-37-… Type /h (ft /min) = 400 V 0105A-3 B84143V0130S230 0.63...
Page 218: Typical Cable Sizes
The table below gives copper and aluminum cable types with concentric copper shield for nominal current. For drawings of the terminals, see chapter Dimension drawings (page 231). Drive type Frame Cu cable size Al cable size Cu cable size size ACS880-37-… AWG/kcmil = 400 V 0105A-3 3×50 3×70 0145A-3 3×95 3×120 0169A-3 3×120...
Page 219: Tightening Torques
Technical data 219 Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. ￭ Electrical connections Size Torque Note 0.5 N·m (4.4 lbf·in) Strength class 4.6...8.8 1 N·m (9 lbf·in) Strength class 4.6...8.8 4 N·m (35 lbf·in) Strength class 8.8 9 N·m (6.6 lbf·ft)
Page 220: Iec
Electrical power network specification Voltage (U ACS880-37-xxxxx-3 drives: 380…415 VAC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage level. 3 ~ 400 V AC. ACS880-37-xxxxx-5 drives: 380…500 VAC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage levels.
Page 221 Technical data 221 Short-circuit cur- The drive is suitable for use on a circuit capable of delivering not more than 100,000 rent protection rms symmetrical amperes at 600 V maximum when the input cable is protected with T (CSA C22.2 No. 14- class fuses.
Page 222: Motor Connection Data
222 Technical data Motor connection data Motor types Asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors, ABB synchronous reluctance (SynRM) motors Voltage (U 0 to U , 3-phase symmetrical, This is indicated in the type designation label as typical output voltage level as 3 ~ 0…U...
Page 223: Auxiliary Circuit Power Consumption
Technical data 223 Operation Storage Transportation installed for stationary in the protective package in the protective package Contamination IEC/EN 60721-3-3:2002: IEC 60721-3-1:1997 IEC 60721-3-2:1997 Classification of environ- Chemical gases: Class Chemical gases: Class mental conditions - Part 3- 3: Classification of groups Solid particles: Class 1S3 Solid particles: Class 2S2 of environmental paramet-...
Page 224: Materials
IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must...
Page 225: Applicable Standards
Technical data 225 Applicable standards The drive complies with the standards below. The compliance with the European Low Voltage Directive is verified according to standard EN 61800-5-1. European electrical safety requirements product standards EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety requirements – electrical, thermal and energy IEC 60146-1-1:2009 Semiconductor converters –...
Page 226: Ce Marking
226 Technical data EAC (Eurasian Conformity) mark Product complies with the technical regulations of the Eurasian Customs Union. EAC mark is required in Russia, Belarus and Kazakhstan. RCM mark Product complies with Australian and New Zealand requirements specific to EMC, telecommunica- tions and electrical safety.
Page 227: Compliance With En 61800-3:2004 + A1:2012
Technical data 227 Compliance with EN 61800-3:2004 + A1:2012 ￭ Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes.
Page 228: Category C4
228 Technical data WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network. ￭ Category C4 The drive complies with the C4 category with these provisions: 1.
Page 229: Ul And Csa Checklist
Canadian Electrical Code). Obey also any other applicable local or provincial codes. Note: Circuit breakers must not be used without fuses in the USA. For suitable circuit breakers, contact your local ABB representative. WARNING! The opening of the branch-circuit protective device may be an indication that a fault current has been interrupted.
Page 230: Disclaimers
ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized...
Page 231: Dimension Drawings
Dimension drawings 231 Dimension drawings Contents of this chapter This chapter contains example dimension drawings.
Page 232: R8 Ip22 (Ul Type 1) And Option +B054 (Ip42 [Ul Type 1 Filtered])
232 Dimension drawings R8 IP22 (UL Type 1) and option +B054 (IP42 [UL Type 1 Filtered])
Page 233: R8 Ip54 (Ul Type 12, Option +B055), Option +C129
Dimension drawings 233 R8 IP54 (UL Type 12, option +B055), option +C129...
Page 234: R8 Ip22 (Ul Type 1) And Ip42 (Ul Type 1 Filtered, Option +B054): Options +D150, +D151
234 Dimension drawings R8 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +D150, +D151...
Page 235: R8 Ip22 (Ul Type 1) And Ip42 (Ul Type 1 Filtered, Option +B054): Option +E206
Dimension drawings 235 R8 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +E206...
Page 236: R8 Ip22 (Ul Type 1): Option +E202
236 Dimension drawings R8 IP22 (UL Type 1): option +E202...
Page 237: R11 Ip22 (Ul Type 1) And Ip42 (Ul Type 1 Filtered, Option +B054)
Dimension drawings 237 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054)
Page 238: R11 Ip54 (Ul Type 12, Option +B055)
238 Dimension drawings R11 IP54 (UL Type 12, option +B055)
Page 239: R11 Ip22 (Ul Type 1) And Ip42 (Ul Type 1 Filtered, Option +B054): Options +C129, +H350, +H352
Dimension drawings 239 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +C129, +H350, +H352...
Page 240: R11 Ip54 (Ul Type 12, Option +B055): Option +C128
240 Dimension drawings R11 IP54 (UL Type 12, option +B055): option +C128...
Page 241: R11 Ip54 (Ul Type 12, Option +B055): Option +C129
Dimension drawings 241 R11 IP54 (UL Type 12, option +B055): option +C129...
Page 242: R11 Ip54 (Ul Type 12, Option +B055): Options +C129, +H350, +H352
242 Dimension drawings R11 IP54 (UL Type 12, option +B055): options +C129, +H350, +H352...
Page 243: R11 Ip22 (Ul Type 1) And Ip42 (Ul Type 1 Filtered, Option +B054): Option +D150
Dimension drawings 243 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +D150...
Page 244: R11 Ip22 (Ul Type 1) And Ip42 (Ul Type 1 Filtered, Option +B054): Options +D150, +D151
244 Dimension drawings R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +D150, +D151...
Page 245: R11 Ip22 (Ul Type 1) And Ip42 (Ul Type 1 Filtered, Option +B054): Option +E206
Dimension drawings 245 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +E206...
Page 246: R11 Ip22 (Ul Type 1): Option +E202
246 Dimension drawings R11 IP22 (UL Type 1): option +E202...
Page 247: Location And Size Of Power Cable Connection Terminals
Dimension drawings 247 Location and size of power cable connection terminals ￭ R8 input and motor cable terminal dimensions – bottom entry and exit...
Page 248: R8 Input And Motor Cable Terminal Dimensions - Top Entry And Exit (Options +H351 And +H353)
248 Dimension drawings ￭ R8 input and motor cable terminal dimensions – top entry and exit (options +H351 and +H353)
Page 249: R8 Input And Motor Cable Terminals
Dimension drawings 249 ￭ R8 input and motor cable terminals ￭ R11 input and motor cable terminal dimensions – bottom entry and exit...
Page 250: R11 Input And Motor Cable Terminal Dimensions - Top Entry And Exit (Options +H351 And +H353)
250 Dimension drawings ￭ R11 input and motor cable terminal dimensions – top entry and exit (options +H351 and +H353) ￭ R11 input cable terminals...
Page 251: R11 Motor Cable Terminals
Dimension drawings 251 ￭ R11 motor cable terminals ￭ Terminals for connecting external resistors ￭ Sine filter (+E206) cubicle, 400 mm: motor cable terminals...
Page 252: Sine Filter (+E206) Cubicle, 600 Mm: Motor Cable Terminals
252 Dimension drawings ￭ Sine filter (+E206) cubicle, 600 mm: motor cable terminals ￭ Sine filter (+E206) cubicle, 1000 mm: motor cable terminals...
Page 253: The Safe Torque Off Function
The Safe torque off function 253 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 254: Compliance With The European Machinery Directive
254 The Safe torque off function Standard Name IEC 60204-1:2016 Safety of machinery – Electrical equipment of machines – Part 1: General requirements EN 60204-1:2006 + A1:2009 + AC:2010 IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards – Im- munity requirements for equipment intended to perform functions in a safety-related system (functional safety) in industrial locations IEC 61326-3-1:2017...
Page 255: Wiring
The Safe torque off function 255 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Activation switch In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC.
Page 256: Single Acs880-37 Drive, Internal Power Supply
256 The Safe torque off function ￭ Single ACS880-37 drive, internal power supply Dual-channel connection +24 V SGND UDC+ UDC– Drive Control unit Control logic To motor Activation switch * "OUT1" with ZCU-12 control unit Single-channel connection +24 V SGND Note: •...
Page 257: Multiple Drives
The Safe torque off function 257 ￭ Multiple drives Internal power supply XSTO +24 V SGND XSTO SGND XSTO SGND Drive/Inverter unit Control unit Activation switch * Terminal designation may vary depending on drive/inverter unit type...
Page 258: External Power Supply
258 The Safe torque off function External power supply 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive/Inverter unit Control unit Activation switch * Terminal designation may vary depending on drive/inverter unit type...
Page 259: Operation Principle
The Safe torque off function 259 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.
Page 260: Start-Up Including Acceptance Test
260 The Safe torque off function Start-up including acceptance 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 an acceptance test. The acceptance test must be performed •...
Page 261 The Safe torque off function 261 Action Test the operation of the STO function when the motor is running. • Start the drive and make sure the motor is running. • Open the STO circuit. The motor should stop. The drive generates an indication if one is defined for the 'running' state in parameter 31.22 (see the firmware manual).
Page 262: Use
262 The Safe torque off function 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs.
Page 263: Maintenance
If any wiring or component change is needed after start up, or the parameters are restored, do the test given in section Acceptance test procedure (page 260). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...
Page 264: 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 265: Safety Data
The Safe torque off function 265 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. MTTF SIL/ Frame size...
Page 266: Tüv Certificate
Mission time: the period of time covering the intended use of the safety function/device. After the mission time elapses, the safety device must be replaced. Note that any T values given cannot be regarded as a guarantee or warranty. ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
Page 267: Declaration Of Conformity
The Safe torque off function 267 ￭ Declaration of conformity...
Page 268 268 The Safe torque off function...
Page 269: Resistor Braking
Planning the braking system ￭ Selecting the default brake circuit components - ABB chopper and ABB resistor 1. Calculate the maximum power generated by the motor during braking and define the braking cycle.
Page 270: Calculating The Maximum Allowed Braking Power For A Custom Duty Cycle - Abb Chopper And Abb Resistor
Braking time within the custom duty cycle in seconds Maximum braking power allowed for 40 seconds every 600 seconds. See the value in the ratings br,max of the ABB choppers and resistors. (The ABB resistor does not withstand the 60-second cycle of the brake chopper.) ￭...
Page 271: Selecting Custom Resistors
Resistor braking 271 Selecting custom resistors If you use other than ABB resistor, 1. make sure that the resistance of the custom resistor is greater or equal than the resistance of the default resistor in the ratings of the custom resistors:...
Page 272: Calculating The Maximum Allowed Braking Power For A Custom Duty Cycle - Abb Chopper And Custom Resistor
272 Resistor braking ￭ Calculating the maximum allowed braking power for a custom duty cycle – ABB chopper and custom resistor The maximum allowed braking power for the customer braking cycle must meet both of the conditions 1 and 2 below.
Page 273: Selecting And Routing Brake Resistor Cables
IGBT semiconductors of the brake chopper. Note: ABB has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling. The customer must consider the EMC compliance of the complete installation.
Page 274: Placing The Brake Resistors
274 Resistor braking ￭ Placing the brake resistors Install the resistors outside the drive in a place where they are able to cool effectively. Arrange the cooling of the resistor in a way that • no danger of overheating is caused to the resistor or nearby materials, and •...
Page 275: Electrical Installation Of Custom Brake Resistors
Resistor braking 275 Electrical installation of custom brake resistors ￭ Connection diagram t° NBRA brake chopper Brake resistor ￭ Measuring the insulation of the resistor circuit WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 276: Connection Procedure
276 Resistor braking 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Make sure that the resistor cable is connected to the resistor, and disconnected from the chopper output terminals R+ and R-. 3.
Page 277: Technical Data
10 seconds every 60 seconds and 1 minute every 5 minutes. For calculating the maximum allowed braking power with a custom duty cycle, see the braking system planning instructions for factory-installed brake chopper and ABB resistor. Duty cycle...
Page 278: Ratings For Factory-Installed Brake Choppers And Custom Resistors
DC voltage at which chopper stops conducting br,off The airflow is required for cooling the chopper. ￭ DC fuses This table shows DC fuses for brake chopper protection. Fuses Drive type ACS880-37- Manufacturer Type = 400 V 0105A-3 Bussmann 170M5142 0145A-3...
Page 279: Terminals And Cable Entry Data Of Factory-Installed Chopper/Resistor Cubicles
Resistor braking 279 Fuses Drive type ACS880-37- Manufacturer Type 0505A-3 Bussmann 170M8635 0585A-3 Bussmann 170M8635 0650A-3 Bussmann 170M8635 = 500 V 0101A-5 Bussmann 170M5142 0124A-5 Bussmann 170M5142 0156A-5 Bussmann 170M5142 0180A-5 Bussmann 170M5142 0260A-5 Bussmann 170M8635 0302A-5 Bussmann 170M8635 0361A-5...
Page 281 Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.

ABB ACS880-37 Hardware Manual

1 Safety Instructions

2 Introduction to the Manual

3 Operation Principle and Hardware Description

4 Mechanical Installation

5 Guidelines for Planning the Electrical Installation

6 Electrical Installation

7 Control Units of the Drive

8 Installation Checklist of the Drive

9 Start-Up

10 Fault Tracing

11 Maintenance

12 Technical Data

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Summary of Contents for ABB ACS880-37