ABB ACS880-01 drives industrial drives Hardware manual
Below you will find brief information for industrial drives ACS880-01 drives. The ACS880-01 drives are designed for industrial applications and can be used to control a wide range of motors. They offer a variety of features, including: - Built-in safety functions - - - - - - - - - - Easy to use and configure. The ACS880-01 drives are a reliable and efficient solution for your industrial applications.
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ABB industrial drives
Hardware manual
ACS880-01 drives
(0.55 to 250 kW, 0.75 to 350 hp)
List of related manuals
Drive hardware manuals and guides Code (English)
ACS880-01 hardware manual 3AUA0000078093
ACS880-01 quick installation guide for frames R1 to R3 3AUA0000085966
ACS880-01 quick installation guide for frames R4 and R5 3AUA0000099663
ACS880-01 quick installation guide for frames R6 to R9 3AUA0000099689
3AUA0000145446 ACS880-01 drives for cabinet installation (option +P940) supplement
ACS880-01 assembly drawings for cable entry boxes of
IP21 frames R5 to R9
3AUA0000119627
ACS-AP-x assistant control panels user’s manual
Vibration dampers for ACS880-01 drives (frames R4 and
R5, option +C131) installation guide
3AUA0000085685
3AXD50000010497
Vibration dampers for ACS880-01 drives (frames R6 to
R9, option +C131) installation guide
ACS880-01 marine type-approved drives (option +C132) supplement
3AXD50000013389
3AXD50000010521
Drive firmware manuals and guides
ACS880 primary control program firmware manual
Quick start-up guide for ACS880 drives with primary control program
3AUA0000085967
3AUA0000098062
Option manuals and quides
Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.
You can find manuals and other product documents in PDF format on the Internet. See section
Document library on the Internet
on the inside of the back cover. For manuals not available in the
Document library, contact your local ABB representative.
The QR code below opens an online listing of the manuals applicable to this product.
ACS880-01 manuals
2014 ABB Oy. All Rights Reserved.
Hardware manual
ACS880-01 drives
(0.55 to 250 kW, 0.75 to 350 hp)
Table of contents
Safety instructions
Mechanical installation
Electrical installation
Start-up
3AUA0000078093 Rev H
EN
EFFECTIVE: 2014-02-14
Update notice 1
Update notice
The notice concerns the ACS880-01 hardware manuals listed below.
Contents of the notice: New circuit breakers and gG fuse types, changed aR fuses, changed safety data for frame R8. Notice code (EN): 3AUA0000121542 Rev I. Valid: From 2014-08-
11 until revision I of the manual.
Manual code Revision Language
3AUA0000078093
3AUA0000126407
3AUA0000103702
3AUA0000103703
H
H
H
H
English
Dansk
Deutsch
Español
EN
DA
DE
ES
3AUA0000103704
3AUA0000103705
3AUA0000103706
3AUA0000103707
3AUA0000130231
3AUA0000126408
3AUA0000108487
3AUA0000103708
3AUA0000126409
H
H
H
H
H
H
H
H
H
Suomi
Français
Italiano
Nederlands
Poliski
Português
Русский
Svenska
Türkçe
FI
FR
IT
NL
PL
PT
RU
SV
TR
Selecting the power cables
Added: For frame R3 drives with option +B056 (IP55, UL Type 12) and ambient temperature above 39 °C (102 °F), select a cable rated for at least 75 °C maximum permissible temperature of conductor in continuous use.
Protecting the drive and input power cable in short-circuits
Added: You can use these circuit breakers. Fuses must be used with other circuit breakers and with circuit breakers in the USA.
Drive type
ACS880-01-
Frame size
ABB miniature circuit breaker ABB moulded case circuit breaker (Tmax)
Type kA
1)
Type kA
1)
U
N
= 230 V
04A6-2
06A6-2
07A5-2
10A6-2
16A8-2
R1
R1
R1
R1
R2
S 203 M/P-B/C 6
S 203 M/P-B/C 6
S 203 M/P-B/C 16
S 203 M/P-B/C 16
S 203 M/P-B/C 20
5
5
5
5
5
-
-
-
-
-
-
-
-
-
-
2 Update notice
Drive type
ACS880-01-
032A-3
038A-3
045A-3
061A-3
072A-3
087A-3
105A-3
145A-3
03A3-3
04A0-3
05A6-3
07A2-3
09A4-3
12A6-3
017A-3
025A-3
24A3-2
031A-2
046A-2
061A-2
075A-2
087A-2
115A-2
145A-2
170A-2
206A-2
274A-2
U
N
= 400 V
02A4-3
169A-3
206A-3
246A-3
293A-3
363A-3
430A-3
U
N
= 500 V
02A1-5
03A0-5
03A4-5
R4
R5
R5
R6
R2
R3
R3
R4
R1
R1
R1
R2
R1
R1
R1
R1
R6
R7
R7
R8
R8
R9
R9
R1
R1
R1
R5
R5
R6
R6
R2
R3
R4
R4
R7
R7
R8
Frame size
ABB miniature circuit breaker ABB moulded case circuit breaker (Tmax)
Type kA
1)
Type kA
1)
S 203 M/P-B/C 32
S 203 M/P-B/C 50
5
5
-
-
-
-
S 803 S-B/C 75
S 803 S-B/C 80
S 803 S-B/C 125
S 803 S-B/C 125
10
10
10
10
-
-
1SDA067918R1
1SDA067918R1
-
-
65
65
-
-
-
-
-
-
-
-
-
-
1SDA067918R1
1SDA068555R1
1SDA068555R1
1SDA054141R1
1SDA054141R1
65
65
65
65
65
S 203 M/P-B/C 6
S 203 M/P-B/C 6
S 203 M/P-B/C 6
S 203 M/P-B/C 10
S 203 M/P-B/C 13
S 203 M/P-B/C 13
S 203 M/P-B/C 20
S 203 M/P-B/C 25
S 203 M/P-B/C 32
S 203 M/P-B/C 50
S 203 M/P-B/C 63
S 803 S-B/C 63
S 803 S-B/C 75
S 803 S-B/C 125
S 803 S-B/C 125
-
-
-
-
-
-
-
-
S 803 S-B/C 6
S 803 S-B/C 6
S 803 S-B/C 6
10
10
10
-
5
5
5
10
5
5
5
5
5
5
5
5
-
-
-
-
-
-
-
10
10
10
-
-
-
-
-
-
-
-
-
-
-
-
-
1SDA067918R1
1SDA067918R1
1SDA068555R1
1SDA068555R1
1SDA068555R1
1SDA054141R1
1SDA054365R1
1SDA054420R1
1SDA054420R1
1SDA054420R1
-
-
-
-
65
65
65
-
-
-
-
-
-
-
-
-
-
-
-
65
65
65
65
65
65
65
-
-
-
Update notice 3
Drive type
ACS880-01-
240A-5
260A-5
361A-5
414A-5
U
N
= 690 V
07A3-7
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
042A-7
040A-5
052A-5
065A-5
077A-5
096A-5
124A-5
156A-5
180A-5
04A8-5
05A2-5
07A6-5
11A0-5
014A-5
021A-5
027A-5
034A-5
049A-7
061A-7
084A-7
098A-7
R5
R5
R5
R5
R5
R5
R5
R5
R6
R6
R7
R7
R4
R4
R5
R5
R8
R8
R9
R9
R2
R2
R3
R3
R1
R1
R1
R1
Frame size
ABB miniature circuit breaker ABB moulded case circuit breaker (Tmax)
Type kA
1)
Type kA
1)
S 803 S-B/C 10
S 803 S-B/C 13
10
10
-
-
-
-
S 803 S-B/C 13
S 803 S-B/C 20
S 803 S-B/C 25
S 803 S-B/C 32
10
10
10
10
-
-
-
-
-
-
-
-
S 803 S-B/C 50
S 803 S-B/C 63
S 803 S-B/C 63
S 803 S-B/C 75
S 803 S-B/C 125
S 803 S-B/C 125
-
-
10
10
10
10
10
10
-
-
-
-
-
-
1SDA067918R1
1SDA067918R1
1SDA068555R1
1SDA068555R1
65
65
65
65
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1SDA068555R1
1SDA054141R1
1SDA054420R1
1SDA054420R1
1SDA054420R1
1SDA054420R1
65
65
65
65
65
65
R5
R6
R6
R7
S 803 S-B/C 13
S 803 S-B/C 20
S 803 S-B/C 25
S 803 S-B/C 32
S 803 S-B/C 50
S 803 S-B/C 63
S 803 S-B/C 63
S 803 S-B/C 80
S 803 S-B/C 80
S 803 S-B/C 125
S 803 S-B/C 125
-
4
4
4
4
4
4
4
4
4
3
3
-
1SDA067915R1
1SDA067915R1
1SDA067915R1
1SDA067916R1
1SDA067916R1
1SDA067916R1
1SDA067916R1
1SDA067917R1
1SDA054069R1
1SDA067917R1
1SDA054069R1
1SDA067918R1
1SDA054070R1
1SDA067918R1
1SDA054070R1
1SDA068555R1
1SDA054071R1
35
20
35
20
35
35
18
35
20
18
18
18
18
18
18
18
18
4 Update notice
Drive type
ACS880-01-
119A-7
142A-7
174A-7
210A-7
271A-7
Frame size
R7
R8
R8
R9
R9
ABB miniature circuit breaker ABB moulded case circuit breaker (Tmax)
Type kA
1)
Type kA
1)
1SDA068555R1
1SDA054071R1
20
35
-
-
-
-
1SDA068555R1
1SDA054071R1
1SDA054141R1
1SDA054365R1
1SDA054420R1
20
35
35
35
35
1)
Maximum allowed rated conditional short-circuit current (IEC 61439-1) of the electrical power network
Ratings
Added:
Drive type
ACS880-
01-
Frame size
Input rating
I
1N
A
Max. current
I
max
A
NEMA RATINGS
Output ratings
Light-overload use
I
Ld
A kW
P
Ld hp
Heavy-duty use
I
Hd
A kW
P
Hd hp
U
N
= 575 V
174A-7
1)
271A-7
2)
R8
R9
180
271
274
411
180
271
132
200
200
250
144
242*
110
160
150
250
1)
The drive can deliver 192 A continuously with no overload.
2)
The power rating is as per NEC Table 42.1. However, the drive can be used for a typical 4pole motor rated to 300 hp meeting NEMA MG 1 Table 12-11 minimum efficiency standard
(EPAct efficiency electrical motors) if motor full load current is not more than 271 A.
aR fuses (frames R1 to R9)
Changed:
Drive type
ACS880-
01-
U
N
= 230 V
031A-2
046A-2
061A-2
075A-2
Min. shortcircuit current
1)
(A)
160
280
300
380
Ultrarapid (aR) fuses (one fuse per phase)
Input current
(A)
A A
2 s V
Fuse
Manufacturer
31.0
46
61
75
63
80
125
125
1450
2550
8500
3700
690
690
690
690
Bussmann
Bussmann
Bussmann
Bussmann
Type
170M1565
170M1566
170M1568
170M3813
Type
IEC 60263
000
000
000
1
Update notice 5
Drive type
ACS880-
01-
087A-2
115A-2
145A-2
170A-2
206A-2
274A-2
U
N
= 400 V
087A-3
Min. shortcircuit current
1)
(A)
380
500
700
1000
1280
1810
105A-3
145A-3
169A-3
206A-3
480
700
700
1280
246A-3
293A-3
363A-3
430A-3
U
N
= 500 V
077A-5
1280
1520
1810
2620
3010
096A-5
124A-5
156A-5
180A-5
480
700
700
1280
240A-5
260A-5
361A-5
414A-5
U
N
= 690 V
042A-7
1280
1520
1810
2620
3010
049A-7
061A-7
084A-7
098A-7
280
280
480
700
119A-7
142A-7
174A-7
210A-7
271A-7
700
700
1000
1280
1610
1610
Ultrarapid (aR) fuses (one fuse per phase)
Input current
(A)
A A
2 s V
Fuse
Manufacturer
87
115
145
170
206
274
87
105
145
169
206
246
293
363
430
77
96
124
156
180
240
260
361
414
42
49
61
84
98
119
142
174
210
271
160
200
250
315
350
7500
15000
28500
46500
68500
690
690
690
690
690
450 105000 690
160
200
250
315
350
16000
15000
28500
46500
68500
690
690
690
690
690
450 105000 690
500 145000 690
630 275000 690
700 405000 690
160
200
250
315
315
400
16000
15000
28500
46500
46500
74000
690
690
690
690
690
690
450 105000 690
630 275000 690
700 405000 690
80
80
125
160
200
200
250
315
400
2550
2550
8500
16000
15000
15000
28500
46500
74000
690
690
690
690
690
690
690
690
690
500 145000 690
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Type
170M3814
170M3815
170M3816
170M3817
170M3818
170M5809
170M1569
170M3815
170M3816
170M3817
170M3818
170M5809
170M5810
170M5812
170M5813
170M1569
170M3815
170M3816
170M3817
170M3817
170M5808
170M5809
170M5812
170M5813
170M1566
170M1566
170M1568
170M1569
170M3815
170M3815
170M3816
170M3817
170M5808
170M5810
Type
IEC 60263
1
1
1
1
1
2
2
2
1
2
2
000
1
1
1
2
2
1
2
2
000
1
1
1
1
1
1
1
000
000
000
000
2
2
6 Update notice
gG fuses (frames R1 to R9)
Check on the fuse time-current curve to ensure the operating time of the fuse is below 0.5 seconds. Obey the local regulations.
Added:
Drive type
ACS880-
01…
Min. shortcircuit current
1)
A
Input current gG fuses (one fuse per phase)
Fuse
A A A
2 s V Manufacturer Type IEC size
U
N
= 230 V
170A-2
206A-2
274A-2
U
N
= 400 V
169A-3
206A-3
246A-3
293A-3
363A-3
430A-3
U
N
= 500 V
156A-5
180A-5
240A-5
260A-5
361A-5
414A-5
U
N
= 690 V
098A-7
119A-7
142A-7
174A-7
210A-7
271A-7
3300
5500
7000
3300
5500
6400
7800
9400
10200
3300
5500
6400
7000
10200
10200
1700
2200
3200
5500
7000
7000
170
206
274
98
119
142
174
210
271
156
180
240
260
361
414
169
206
246
293
363
430
250 600000 500
315 710000 500
400 1100000 500
250 600000 500
315 710000 500
355 920000 500
425 1300000 500
500 2000000 500
630 2800000 500
250 600000 500
315 710000 500
355 920000 500
400 1100000 500
630 2800000 500
630 2800000 500
160 240000 690
200 350000 690
250 700000 690
315 850000 690
400 1300000 690
400 1300000 690
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
OFAF0H250
OFAF1H315
OFAF2H400
OFAF0H250
OFAF1H315
OFAF1H355
OFAF2H425
OFAF2H500
OFAF3H630
OFAF0H250
OFAF1H315
OFAF1H355
OFAF2H400
OFAF3H630
OFAF3H630
OFAA1GG160
OFAA1GG200
OFAA1GG250
OFAA2GG315
OFAA3GG400
OFAA3GG400
1
2
0
1
3
3
1
2
0
1
2
3
0
1
2
1
2
1
1
3
3
Update notice 7
Quick guide for selecting between gG and aR fuses
Added and changed:
Drive type
ACS880-
01…
Cable type Supply transformer minimum apparent power S
N
(kVA)
Copper Aluminium Maximum cable legth
mm
2 mm
2
with gG fuses
10 m 50 m 100 m
Maximum cable legth with aR fuses
10 m 100 m 200 m
U
N
= 230 V
087A-2
115A-2
145A-2
170A-2
206A-2
274A-2
U
N
= 400 V
087A-3
105A-3
145A-3
169A-3
206A-3
246A-3
293A-3
363A-3
430A-3
U
N
= 500 V
077A-5
096A-5
124A-5
156A-5
180A-5
240A-5
260A-5
361A-5
414A-5
U
N
= 690 V
098A-7
119A-7
142A-7
174A-7
210A-7
271A-7
3×35
3×50
3×95
3×120
3×150 3×240
2×(3×95) 2×(3×120)
3×35
3×50
3×95
3×120
3×50
3×70
3×95
3×150
3×150 3×185
2×(3×70) 2×(3×95)
2×(3×95) 2×(3×120)
2×(3×120) 2×(3×185)
2×(3×150) 2×(3×240)
3×35
3×50
3×95
3×120
3×70
3×70
3×120
3×150
3×150 3×240
2×(3×70) 2×(3×95)
2×(3×70) 2×(3×95)
2×(3×120) 2×(3×185)
2×(3×150) 2×(3×240)
3×50
3×70
3×95
3×120
3×185
3×240
3×70
3×70
3×120
3×150
3×70
3×95
3×120
3×185
2×(3×95)
2×(3×120
36
48
64
93
158
198
48
63
82
160
269
311
380
459
499
60
78
103
200
335
388
425
621
621
141
183
267
452
584
584
39
52
70
104
194
229
49
65
85
170
298
335
411
502
547
61
80
105
209
362
410
452
669
666
143
187
275
476
608
605
-
-
-
-
-
-
52
68
88
187
357
393
478
591
641
63
83
108
224
411
456
512
763
747
146
192
286
515
654
640
14
19
28
36
40
57
34
34
48
62
73
99
106
150
174
42
42
60
77
77
108
123
187
217
58
58
83
106
134
183
15
21
30
39
45
62
35
35
50
65
78
103
111
159
186
43
43
62
80
80
112
128
196
229
59
59
85
109
136
187
84
117
135
208
246
46
45
65
84
84
111
118
173
205
38
37
53
69
-
-
-
-
-
-
60
60
87
112
139
193
8 Update notice
Electrical power network specification
Changed:
Rated conditional short-circuit current (IEC 61439-1)
100 kA when protected by fuses given in the fuse tables
EAC marking
The drive has EAC certification. EAC marking is required in Russia, Belarus and
Kazakhstan.
Safety data (SIL, PL)
Changed:
Frame
SIL SC
IEC 61508 and EN/IEC 61800-5-2
PFH
(1/h) d
HFT SFF
(%)
Lifetime
(Years)
U
N
= 500 V
R8 3 3 3.84E-09 (3.84 FIT) 1 95.04
20
PFD
(T1 = 2a)
1.56E-4
5
Table of contents
1. Safety instructions
2. Introduction to the manual
3. Operation principle and hardware description
4. Mechanical installation
6
5. Planning the electrical installation
Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . . . 59
Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . . . 60
Additional data for calculating the rise time and the peak line-to-line voltage . . . . . . 61
7
Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . . . 71
Protecting the drive and the input power and motor cables against thermal overload . . . 72
Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . . . . . 74
Switching the motor power supply from drive to direct-on-line . . . . . . . . . . . . . . . . . . 77
Switching the motor power supply from direct-on-line to drive . . . . . . . . . . . . . . . . . . 77
6. Electrical installation
AI1 and AI2 as Pt100 and KTY84 sensor inputs (XAI, XAO) . . . . . . . . . . . . . . . . . . 102
8
Wiring I/O extension, fieldbus adapter and pulse encoder interface modules . . . . . . . . 111
7. Installation checklist
8. Start-up
9. Fault tracing
10. Maintenance
9
11. Technical data
IP55 (UL Type 12) drive types -274A-2, 293A-3, -260A-5, -302A-5 and -174A-7 . . 148
IP55 (UL Type 12) types -0430A-3, -0414A-5 and -0271A-7 . . . . . . . . . . . . . . . . . . 150
10
12. Dimension drawings
13. Safe Torque off function
11
14. Resistor braking
15. Common mode, du/dt and sine filters
Further information
12
Safety instructions 13
1
Safety instructions
What this chapter contains
This chapter contains the safety instructions which you must obey when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, motor or driven equipment. Read the safety instructions before you work on the unit.
Use of warnings
Warnings caution you about conditions which can result in serious injury or death and/or damage to the equipment and advise on how to avoid the danger. The following warning symbols are used in this manual:
Electricity warning warns of hazards from electricity which can cause physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by electricity, which can result in physical injury and/or damage to the equipment.
Electrostatic sensitive devices warning warns of electrostatic discharge which can damage the equipment.
14 Safety instructions
Safety in installation and maintenance
Electrical safety
These warnings are intended for all who work on the drive, motor cable or motor.
WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:
• Only qualified electricians are allowed to install and maintain the drive.
• Never work on the drive, motor cable or motor when main power is applied.
After disconnecting the input power, always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive, motor or motor cable.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:
• voltage between drive input phases L1, L2 and L3 and the frame is close to 0 V
• voltage between terminals UDC+ and UDC- and the frame is close to 0 V.
• Do not work on the control cables when power is applied to the drive or to the external control circuits. Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off.
• Do not make any insulation or voltage withstand tests on the drive.
• Do not connect the drive to a voltage higher than what is marked on the type designation label. Higher voltage can activate the brake chopper and lead to brake resistor overload, or activate the overvoltage controller what can lead to motor rushing to maximum speed.
Note:
• The motor cable terminals on the drive are at a dangerously high voltage when the input power is on, regardless of whether the motor is running or not.
• The DC terminals (UDC+, UDC-) carry a dangerous DC voltage (over 500 V) when internally connected to the intermediate DC circuit.
• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the terminals of relay outputs (XRO1, XRO2 and XRO3).
• The Safe torque off function does not remove the voltage from the main and auxiliary circuits. The function is ineffective against deliberate sabotage or misuse.
Safety instructions 15
Grounding
These instructions are intended for all who are responsible for the grounding of the drive.
WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction:
• Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and interference.
• Make sure that grounding conductors are adequately sized as required by safety regulations.
• In a multiple-drive installation, connect each drive separately to protective earth (PE).
• Where EMC emissions must be minimized, make a 360° high frequency grounding of cable entries in order to suppress electromagnetic disturbances.
In addition, connect the cable shields to protective earth (PE) in order to meet safety regulations.
• Do not install d drive with EMC filter options +E200 or +E202 on an ungrounded power system or a high-resistance-grounded (over 30 ohms)
.
Note:
• Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations.
• Standard EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed protective earth connection and
• a cross-section of the protective earthing conductor of at least 10 mm
2
Cu or 16 mm
2
Al, or
• automatic disconnection of the supply in case of discontinuity of the protective earthing conductor, or
• a second protective earthing conductor of the same cross-sectional area as the original protective earthing conductor.
16 Safety instructions
Permanent magnet motor drives
These are additional warnings concerning permanent magnet motor drives.
WARNING! Ignoring the instructions can cause physical injury or death, or damage to the equipment:
• Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.
Before installation and maintenance work on the drive:
• Stop the motor.
• Ensure that there is no voltage on the drive power terminals according to step
1 or 2, or if possible, according to the both steps.
1. Disconnect the motor from the drive with a safety switch or by other means. Check by measuring that there is no voltage present on the drive input or output terminals (L1, L2, L3, U/T1, V/T2, W/T3, UDC+, UDC-).
2. Ensure that the motor cannot rotate during work. Make sure that no other system, like hydraulic crawling drives, is able to rotate the motor directly or through any mechanical connection like felt, nip, rope, etc. Check by measuring that there is no voltage present on the drive input or output terminals (L1, L2, L3, U/T1, V/T2, W/T3, UDC+, UDC-). Ground the drive output terminals temporarily by connecting them together as well as to the
PE.
Safety instructions 17
General safety
These instructions are intended for all who install and service the drive.
WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:
• Handle the unit carefully.
• For frame sizes R6 to R9: Lift the drive using the lifting eyes of the unit. Do not tilt the drive. The drive is heavy and its center of gravity is high.
An overturning unit can cause physical injury.
• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors, remain hot for a while after disconnection of the electrical supply.
• Ensure that debris from borings and grindings does not enter the drive when installing. Electrically conductive debris inside the unit may cause damage or malfunction.
• Ensure sufficient cooling.
• Do not attach the drive by riveting or welding.
18 Safety instructions
Printed circuit boards
WARNING! Ignoring the following instructions can cause damage to the printed circuit boards:
• Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily. The printed circuit boards contain components sensitive to electrostatic discharge.
Safe start-up and operation
General safety
These warnings are intended for all who plan the operation of the drive or operate the drive.
WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:
• Before you connect voltage to the drive, make sure that the drive covers are on. Keep the covers on during the operation.
• Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line.
• Do not activate any automatic fault reset functions of the drive control program if dangerous situations can occur. When activated, these functions will reset the drive and resume operation after a fault.
• The maximum number of drive power-ups is five in ten minutes. Too frequent power-ups can damage the charging circuit of the DC capacitors.
• Make sure that any safety circuits (for example, emergency stop and Safe
torque off) are validated in start-up. See chapter
validation instructions.
Note:
• If an external source for start command is selected and it is ON, the drive will start immediately after an input voltage break or fault reset unless the drive is configured for 3-wire (a pulse) start/stop.
• When the control location is not set to local, the stop key on the control panel will not stop the drive.
Safety instructions 19
Permanent magnet motor drives
WARNING! Do not run the motor over the rated speed. Motor overspeed leads to overvoltage which may damage or explode the capacitors in the intermediate circuit of the drive.
20 Safety instructions
Introduction to the manual 21
2
Introduction to the manual
What this chapter contains
This chapter describes the manual. It contains a flowchart of steps for checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals.
Target audience
This manual is intended for people who plan the installation, install, start-up, use and service the drive. Read the manual before working on the drive. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.
The manual is written for readers worldwide. Both SI and imperial units are shown.
Contents of the manual
This manual contains the instructions and information for the basic drive configuration. The chapters of the manual are briefly described below.
gives safety instructions for the installation, start up, operation and
maintenance of the drive.
introduces the manual.
Operation principle and hardware description
describes how to install the basic drive mechanically.
Planning the electrical installation
contains instructions for the motor and cable selection, protections and cable routing.
22 Introduction to the manual
gives instructions on wiring the drive.
contains a list for checking the mechanical and electrical installation of the drive.
describes the start-up procedure of the drive.
describes the fault tracing of the drive.
contains preventive maintenance instructions.
contains the technical specifications of the drive, eg, the ratings, sizes
and technical requirements, provisions for fulfilling the requirements for CE and other markings.
contains dimension drawings of the drives and auxiliary
components.
describes the Safe torque off function of the drive and gives instructions on its implementing.
describes selection, protection and wiring of brake choppers and
resistors. The chapter also contains technical data.
Common mode, du/dt and sine filters
describes selection external filters for the drive.
Related manuals
on the inside of the front cover.
Categorization by frame size and option code
The instructions, technical data and dimension drawings which concern only certain drive frame sizes are marked with the symbol of the frame size (R1, R2, etc.). The frame size is marked on the type designation label.
The instructions and technical data which concern only certain optional selections are marked with option codes (such as +E200). The options included in the drive can be identified from the option codes visible on the type designation label. The option
selections are listed in section
Introduction to the manual 23
Quick installation, start-up and operating flowchart
Task
Plan the electrical installation and acquire the accessories needed (cables, fuses, etc.).
Check the ratings, required cooling air flow, input power connection, compatibility of the motor, motor connection, and other technical data.
See
Planning the electrical installation
(page
)
Check the installation site.
(page
Unpack and examine the units (only intact units may be started up).
Examine that all necessary optional modules and equipment are present and correct.
Mount the drive.
If the drive has been non-operational for more than one year, the converter
DC link capacitors need to be
)
Route the cables.
Check the insulation of the supply cable, the motor and the motor cable.
Connect the power cables.
Connect the control cables.
(page
)
(page
Checking the insulation of the assembly
(page
)
(page
),
Check the installation.
Start the drive up.
)
Operate the drive: start, stop, speed control etc.
ACS880 quick start-up guide,
firmware manual
24 Introduction to the manual
Terms and abbreviations
Explanation Term/
Abbreviation
EMC
EMI
EMT
FAIO-01
FDIO-01
FIO-01
FIO-11
FCAN-01
FCNA-01
FDNA-01
FECA-01
FEPL-01
FENA-01
FENA-11
FLON-01
FPBA-01
FEN-01
FEN-11
FEN-21
FEN-31
FDCO-01
FSO-11
Frame (size)
IGBT
I/O
ZCON
ZCU
ZGAB
ZGAD
ZINT
ZMU
R1…R9
Electromagnetic compatibility
Electromagnetic interference
Electrical metallic tubing
Optional analog I/O extension module
Optional digital /O extension module
Optional digital I/O extension module
Optional analog I/O extension module
Optional FCAN-01 CANopen adapter module
Optional ControlNet™ adapter module
Optional DeviceNet™ adapter module
Optional EtherCAT adapter module
Optional Ethernet POWERLINK adapter module
Optional Ethernet/IP™ and Modbus/TCP and PROFINET adapter module
Optional dual port Ethernet/IP™ and Modbus/TCP and PROFINET adapter module
Optional LonWorks® adapter module
Optional PROFIBUS DP adapter module
Optional TTL incremental encoder interface module
Optional TTL absolute encoder interface module
Optional resolver interface module
Optional HTL incremental encoder interface module
Optional optical DDCS communication adapter module
Optional functional safety module
Physical size of the drive
Insulated gate bipolar transistor; a voltage-controlled semiconductor type widely used in inverters due to their easy controllability and high switching frequency.
Input/Output
Control board in which the control program runs.
Control board built in a housing. The external I/O control signals are connected to the control unit, or optional I/O extensions mounted on it.
Brake chopper adapter board in frames R8 to R9
Gate driver adapter board in frames R6 to R9
Main circuit board
The memory unit attached to the control unit of the drive
Frame size designation of the drive
Operation principle and hardware description 25
Operation principle and hardware description
3
What this chapter contains
This chapter briefly describes the operation principle and construction of the drive.
Product overview
The ACS880-01 is a drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors).
26 Operation principle and hardware description
Main circuit
The main circuit of the drive is shown below.
L1
L2
L3
ACS880-01
1 2 3
4
T1/U
T2/V
T3/W
R- UDC+ UDC-
R+
1 Rectifier. Converts alternating current and voltage to direct current and voltage.
2 DC link. DC circuit between rectifier and inverter.
3 Inverter. Converts direct current and voltage to alternating current and voltage.
4 Brake chopper. Conducts the surplus energy from the intermediate DC circuit of the drive to the brake resistor when necessary. The chopper operates when the DC link voltage exceeds a certain maximum limit. The voltage rise is typically caused by deceleration (braking) of a high inertia motor. User obtains and installs the brake resistor when needed.
Operation principle and hardware description 27
Layout (IP21, UL Type 1)
The components of the standard IP21 drive are shown below (view of frame R5).
4
4
6
1
5
3 Cable entry box
4 Four fastening points at the back of the unit
5 Heatsink
2
6
3
28 Operation principle and hardware description
Layout (IP55, option +B056)
The components of the IP55 drive (option +B056) are shown below (view of frame
R4).
3
3
5
1
1 Control panel behind the control panel cover
3 Four fastening points at the back of the unit
4 Heatsink
4
2
5
Operation principle and hardware description 29
Layout (UL Type 12, option +B056)
The components of the UL Type 12 drive (option +B056) are shown below (view of frame R6).
5
3
3
6
4
2
1
1 Control panel behind the control panel cover
3 Four fastening points at the back of the drive
4 Heatsink
6 Hood (included in frames R4 to R7)
5
Layout (IP20 – UL Open Type, option +P940)
See ACS880-01 drives for cabinet installation (option + P940) supplement
(3AUA0000145446 [English]).
30 Operation principle and hardware description
Overview of power and control connections
The diagram shows the power connections and control interfaces of the drive.
FXX
Slot 1
1
X208
X13
7
PE
L1
L2
L3
FXX
4
FXXX
..... .....
.......... ..........
X12
......
......
Slot 2
5
2
PE
L1
Slot 3
3
L2
L3
R-
6
...
...
U/T1
V/T2
UDC+
R+
W/T3
UDC-
8
M
3 ~
1
2
3
Analog and digital I/O extension modules, feedback interface modules and fieldbus communication modules can be inserted into slots 1, 2 and 3. See section
4 Memory unit, see page
5 Connector for safety functions modules, see page
Default I/O connection diagram
(page
Control unit (ZCU-12) connection data
).
7 See section
8 du/dt, common mode or sine filter (optional), see page
.
Operation principle and hardware description 31
External control connection terminals
The layout of external control connection terminals of the drive is shown below.
X202
X205
X203
X12
X208
X13
XPOW
X204
XAI
XRO1
J1, J2
XAO XD2D XRO2
XSTO XDI
J3, J6
XDIO XD24 XRO3
Description
XPOW External power input
XAI Analog inputs
XAO Analog outputs
XD2D Drive-to-drive link
XRO1 Relay output 1
XRO2 Relay output 2
XRO3 Relay output 3
XD24 Start interlock connection
(DIIL) and +24 V output
XDIO Digital input/outputs
XDI Digital inputs
XSTO Safe torque off connection
X12
X13
Connector for safety functions modules (optional)
Control panel connection
X202 Option slot 1
X203 Option slot 2
X204 Option slot 3
X205 Memory unit connection
X208 Auxiliary cooling fan connection
J1, J2 Voltage/Current selection jumpers (J1, J2) for analog inputs
J3, J6 Drive-to-drive link termination jumper (J3), common digital input ground selection jumper (J6)
32 Operation principle and hardware description
Control panel
The control panel can be removed by pulling it forward from the top edge and reinstalled in reverse order. For the use of the control panel, see the firmware manual or ACS-AP assistant control panels user’s manual (3AUA0000085685 [English]).
Control panel mounting platform cover
In deliveries without control panel (option + 0J400) the control panel mounting platform is covered. The indication LEDs on the platform are visible through the protective cover.
Control panel door mounting kits
Door mounting kits for the control panel are available. For more information see
DPMP-01 mounting platform installation guide (3AUA0000100140 [English]) or
DPMP-02 mounting platform installation guide (3AUA0000136205 [English].
Operation principle and hardware description 33
Type designation label
The type designation label includes an IEC and NEMA rating, appropriate markings, a type designation and a serial number, which allow identification of each unit. The type designation label is located on the front cover. An example label is shown below.
1
4
3
2
5
No. Description
1
2 Frame size
3 Ratings in the supply voltage range
4 Valid markings
5 Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial number so that there are no two units with the same number.
Type designation key
The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration, eg, ACS880-01-
12A6-3 The optional selections are given thereafter, separated by plus signs, eg,
+L519. The main selections are described below. Not all selections are available for all types. For more information, refer to ACS880-01 Ordering Information
(3AXD10000014923), available on request.
CODE DESCRIPTION
Basic codes
2
3
01 When no options are selected: Wall mounted drive, IP21 (UL Type 1), ACS-AP-I assistant control panel, no EMC filter, DC choke, ACS880 primary control program,
Safe torque off function, cable entry box, brake chopper in frames R1 to R4, coated boards, printed multilingual quick guides and CD containing all manuals.
Size
xxxx
Refer to the rating tables, page
Voltage range
208…240 V
380…415 V
34 Operation principle and hardware description
CODE
5
7
DESCRIPTION
380…500 V
525…690 V
Option codes (plus codes)
Degree of protection
B056 IP55 (UL Type 12)
Construction
C131
C132
Vibration dampers for frames R4 to R9 in wall installations. Not needed in cabinet installations.
Marine type approved drive. Requires option +C131 in wall installations for frames
R4 to R9. Includes common mode filter for frames R6 to R9.
Resistor braking
D150 Brake chopper for frame R5 and up.
Filters
E200
E201
EMC filter for second environment TN (grounded) system, category C3.
E202
EMC filter for second environment IT (ungrounded) system, category C3. Available for 380…500 V frames R6 to R9.
EMC filter for first environment TN (grounded) system, category C2.
Cable entry box
H358 UK cable entry box
Control panel
0J400 No control panel. Includes control panel holder cover. Note: You need at least one loose control panel to be able to commission the drive.
Fieldbus adapters
K451 FDNA-01 DeviceNet™ adapter module
K452
K454
FLON-01 LonWorks® adapter module
FPBA-01 PROFIBUS DP adapter module
K457
K458
K462
K469
K470
K473
FCAN-01 CANopen adapter module
FSCA-01 RS-485 adapter module
FCNA-01 ControlNet™ adapter module
FECA-01 EtherCAT adapter module
FEPL-01 Ethernet POWERLINK adapter module
FENA-11 high performance Ethernet/IP™, Modbus/TCP and PROFINET adapter module
I/O extensions and feedback interfaces
L500 FIO-11 analog I/O extension module
L501
L502
FIO-01 digital I/O extension module
FEN-31 HTL incremental encoder interface module
L503
L508
FDCO-01 optical DDCS communication adapter module
FDCO-02 optical DDCS communication adapter module
Operation principle and hardware description 35
CODE
L515
L516
L517
L518
L525
L526
DESCRIPTION
FEA-03 I/O extension adapter
FEN-21 resolver interface module
FEN-01 TTL incremental encoder interface module
FEN-11 absolute encoder interface module
FAIO-01 analog I/O extension module
FDIO-01 digital I/O extension module
Control program
N7502 Enables setting of synchronous reluctance motor parameters in the drive control program.
Specialties
P904 Extended warranty
P940 Drive without front covers and cable entry box. Includes control panel. Note: With option +0J400 does not include control panel holder cover.
ATEX-certified function
Q971 ATEX-certified Safe motor disconnection function using the Safe torque off function
Safety functions modules
R704
R705
R706
R707
R708
R709
R711
R712
R713
R714
Q973 FSO-11 safety functions module
Full set of printed manuals in selected language. Note: The delivered manual set may include manuals in English if the translation is not available.
R700
R701
R702
R703
English
German
Italian
Dutch
Danish
Swedish
Finnish
French
Spanish
Portuguese
Russian
Chinese
Polish
Turkish
36 Operation principle and hardware description
Mechanical installation 37
Mechanical installation
4
What this chapter contains
This chapter gives a description of the mechanical installation of the drive.
Safety
WARNING!
For frame sizes R6 to R9: Use the lifting eyes of the drive when you lift the drive. Do not tilt the drive. The drive is heavy and its center of
gravity is high.
An overturning drive can cause physical injury.
38 Mechanical installation
Examining the installation site
The drive must be installed in an upright position with the cooling section against a wall. All IP21 (UL Type 1) and IP55 drives and UL Type 12 drives of frames R1 to R3 can be installed tightly side by side. For UL Type 12 drives of frames R4 to R9, leave
100 mm (4 in) between the hoods.
Make sure that the installation site agrees with these requirements:
• The installation site has sufficient ventilation to prevent overheating of the drive.
See section
Losses, cooling data and noise
.
• The operation conditions of the drive agree with the specifications in section
• The wall is vertical, not flammable and strong enough to hold the weight of the drive. See page
.
• The material below the installation is not flammable.
• There is enough free space above and below the drive for cooling air flow, service and maintenance. See page
. There is enough free space in front of the drive for operation, service and maintenance.
200 mm (7.87 in.)
300 mm (11.81 in.)
Necessary tools
• Drill and drill bits
• Screwdriver and/or wrench with bits. The drive cover has Torx screws.
Mechanical installation 39
Moving the drive
Move the transport package by pallet truck to the installation site.
Unpacking and examining the delivery (frames R1 to R5)
This illustration shows the layout of the transport package. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type.
11
12
13
Item Description
1 Drive with factory installed options.
Control cable grounding shelf.
Romex connectors in IP21 frames
R1 to R3 in a plastic bag inside the cable entry box.
Item Description
13 Vibration damper package (option
+C131)
Frame R4 and IP21 (UL Type 12) frame R5: below the cable entry box
IP21 (Ul Type 1) frame R5: inside the cable entry box
10
11
PET straps
Top cardboard cover
2
3
Manuals CD
Printed quick guides and manuals, multilingual residual voltage warning sticker
4
5
Cardboard tray
Cardboard sleeve
6…9 Cushions
12
-
-
-
-
Hood included with option +B056
40 Mechanical installation
To unpack:
• Cut the straps (10).
• Remove the top cardboard cover (11) and cushions (6…9).
• Lift the cardboard sleeve (5).
• Lift the drive.
Frame R5 cable entry box (IP21, UL Type 1)
This illustration shows the contents of the cable entry box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.
3aua0000118007
Mechanical installation 41
Unpacking and examining the delivery (frames R6 to R9)
This illustration shows the layout of the transport package. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type.
3
5
4
6
7
9
1
2
8
Item Description
1 Cable entry box. Power and control cable grounding shelves in a plastic bag, assembly drawing.
Note: The cable entry box is mounted to the IP55 drive module frame at the factory.
2 Drive with factory installed options
Item Description
6 Straps
7
3
4
5
Top cardboard cover
Cushion
Cardboard sleeve
8
9
-
Printed quick guides and manuals CD and multilingual residual voltage warning sticker
Pallet tray
Vibration damper package (option
+C131). For frame R6: inside the cable entry box.
-
42 Mechanical installation
To unpack:
• Cut the straps (6).
• Remove the top cardboard cover (3) and cushion (4).
• Lift the cardboard sleeve (5).
• Attach lifting hooks to the lifting eyes of the drive. Lift the drive with a hoist.
Frame R6 cable entry box (IP21, UL Type 1)
This illustration shows the contents of the cable entry box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.
3aua0000112044
Mechanical installation 43
Frame R7 cable entry box (IP21, UL Type 1)
This illustration shows the contents of the cable entry box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.
3aua0000111117
44 Mechanical installation
Frame R8 cable entry box (IP21, UL Type 1)
This illustration shows the contents of the cable entry box package. There is also an assembly drawing which shows how to install the cable entry box to the drive module frame.
3aua0000112174
Mechanical installation 45
Frame R9 cable entry box (IP21, UL Type 1)
This illustration shows the contents of the cable entry box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.
3aua0000112356
Installing the drive
This section tells you how to install the drive on wall without vibration dampers.
Marine type approval (option +C132) requires the installation of vibration dampers for frames R4 to R9 in wall installations. See Vibration dampers for ACS880-01 drives
(frames R4 and R5, option +C131) installation guide (3AXD50000010497 [English]) or Vibration dampers for ACS880-01 drives (frames R6 to R9, option +C131)
46 Mechanical installation
installation guide (3AXD50000010497 [English]). The guide is included in the vibration damper package and on the manuals CD.
Frames R1 to R4 (IP21, UL Type 1)
1. See the dimensions in chapter
. Mark the locations for the four mounting holes.
2. Drill the mounting holes.
3. Start the screws or bolts into the mounting holes.
4. Position the drive onto the screws on the wall.
5. Tighten the screws in the wall securely.
1 2 3
M5
× 4
× 4
× 4
5
× 4
4
Mechanical installation 47
Frames R5 to R9 (IP21, UL Type 1)
1. See the dimensions in chapter
four or six mounting holes.
Note: The lowest holes/mounting screws are not necessarily needed. If you use also them, you can replace the drive module without removing the cable entry box from the wall.
2. Drill the mounting holes.
3. Start the screws or bolts into the mounting holes.
4. Position the drive module onto the screws on the wall.
5. Tighten the upper mounting screws in the wall securely.
6. Remove the front cover.
7. Attach the cable entry box to the drive frame. For instructions, see the assembly drawing in the cable entry box. A view of frame R8 is shown below.
8. Tighten the lower mounting screws in the wall securely.
48 Mechanical installation
IP21 (UL Type 1) R5 … R9
200 mm
(7.87”)
1
300 mm
(11.81”)
4
2
3
5
R5
R6
R7
R8
R9
Screw size
M5
M8
M8
M8
M8
6
8
7
< 40 °C
Mechanical installation 49
Frames R1 to R9 (IP55, UL Type 12)
Note: Do not open or remove the cable entry box for easier installation. The gaskets do not fulfill the degree of protection if the box is opened.
1. See the dimensions in chapter
four or six mounting holes. The lowest holes are not necessarily needed.
2. Drill the mounting holes.
3. Start the upper screws or bolts into the mounting holes.
4. Position the drive onto the upper screws on the wall.
5. For UL Type 12 drives of frames R4 to R9: Put the hood onto the upper screws.
6. Tighten the upper screws in the wall securely.
7. Start the lower screws or bolts into the mounting holes.
8. Tighten the lower screws in the wall securely.
50 Mechanical installation
IP55 (UL Type 12) R1…R9
200 mm
(7.87”)
3
1
300 mm
(11.81”)
2
R1…R5
R6…R9
Screw size
M5
M8
UL Type 12 (R4…R9)
5
6
6
4
7
8
Mechanical installation 51
Cabinet installation
This section gives the basic cabinet installation instructions for the drive. For more information, see ACS880-01 drives for cabinet installtion (option +P940) supplement, code 3AUA0000145446 (English).
Cooling
Make sure that there is sufficient cooling:
• Make sure that the temperature of the cooling air that goes into the drive does not exceed +40 °C (+104 °F).
• Prevent cooling air recirculation inside the cabinet. You can use air baffle plates or an extra fan at the inlet or outlet of the cabinet. if you use a fan, we recommend an inlet fan with a filter. Such a fan causes an overpressure inside the cabinet which helps to keep the dust out.
• Prevent cooling air recirculation outside the cabinet. Let the outlet air away from the inlet: to the other side of the cabinet or upwards.
• Make sure that there is sufficient cooling in the room in which the cabinet is placed
.
4
3
6
2
3
4
1
2
5
6
Main air flow in
Main air flow out
Air baffle plate
Drive
Air inlet filter
Air outlet filter
5 1
Note: You can remove the front cover of the drive module for better cooling.
52 Mechanical installation
Grounding inside the cabinet
Leave the contact surfaces of the attaching points of the drive unpainted (bare metalto-metal contact). The drive frame will be grounded to the PE busbar of the cabinet via the attaching surfaces, screws and the cabinet frame. Alternatively, use a separate grounding conductor between the PE terminal of the drive and the PE busbar of the cabinet.
Installing drives above one another
Make sure that the outlet cooling air flows away from the drive above.
3
1 Air flow through the drive
2 Air baffle
3 Mounting plate that allows air through flow
4 Minimum spacing between the drives
max.+40 °C (+104 °F)
4
1 2
Planning the electrical installation 53
Planning the electrical installation
5
What this chapter contains
This chapter contains instructions for planning the electrical installation of the drive.
Some instructions are mandatory to follow in every installation, others provide useful information that only concerns certain applications.
Limitation of liability
The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability 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.
Selecting the supply disconnecting device
Install a hand-operated input disconnecting device between the AC power source and the drive. The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work.
54 Planning the electrical installation
European Union
To meet the European Union Directives, according to standard EN 60204-1, Safety of
Machinery, the disconnecting device must be one of the following types:
• switch-disconnector of utilization category AC-23B (EN 60947-3)
• disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector (EN 60947-3)
• circuit breaker suitable for isolation in accordance with EN 60947-2.
Other regions
The disconnecting device must conform to the applicable safety regulations.
Selecting and dimensioning the main contactor
If a main contactor is used, its utilization category (number of operations under load) must be AC-1 according to IEC 60947-4, Low-voltage switchgear and controlgear.
Dimension the main contactor according to the nominal voltage and current of the drive.
Checking the compatibility of the motor and drive
Use an asynchronous AC induction motor, permanent magnet synchronous motor,
AC induction servomotor or ABB synchronous reluctance motor (SynRM motor) with the drive. Several induction motors can be connected to the drive at a time.
Select the motor size and drive type from to the rating tables in chapter
on basis of the AC line voltage and motor load. Use the DriveSize PC tool if you
need to tune the selection more in detail.
Ensure that the motor withstands the maximum peak voltage in the motor terminals.
. For basics of protecting the motor insulation
and bearings in drive systems, refer to section
Protecting the motor insulation and bearings
below.
Note:
• Consult the motor manufacturer before using a motor whose nominal voltage differs from the AC line voltage connected to the drive input.
• The voltage peaks at the motor terminals are relative to the supply voltage of the drive, not the drive output voltage.
• If the motor and drive are not of the same size, consider the following operation limits of the drive control program:
• motor nominal voltage range 1/6 ... 2 · U
N
• motor nominal current range 1/6 ... 2 · I
N
0 ... 2 · I
N
of the drive in DTC control and
in scalar control. The control mode is selected by a drive parameter.
Planning the electrical installation 55
Protecting the motor insulation and bearings
The drive employs modern IGBT inverter technology. Regardless of frequency, the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time. The pulse voltage can almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals. This can cause additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings. This can gradually erode the bearing races and rolling elements.
Optional du/dt filters protect motor insulation system and reduce bearing currents.
Optional common mode filters mainly reduce bearing currents. Insulated N-end (nondrive end) bearings protect the motor bearings.
Requirements table
The following table shows how to select the motor insulation system and when an optional drive du/dt and common mode filters and insulated N-end (non-drive end) motor bearings are required. Ignoring the requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty.
56 Planning the electrical installation
Motor type
Nominal AC supply voltage
Motor insulation system
Requirement for
ABB du/dt and common mode filters, insulated N-end motor bearings
P
N
< 100 kW and frame size
< IEC 315
100 kW < P
N or
< 350 kW
IEC 315 < frame size <
IEC 400
P
N
< 134 hp and frame size
< NEMA 500
134 hp < P
N
< 469 hp or
NEMA 500 < frame size < NEMA 580
ABB motors
Randomwound
M2_,M3_ and M4_
U
N
< 500 V Standard
500 V < U
N
< 600 V Standard or
Reinforced -
-
+ du/dt
+ N
+ du/dt + N
600 V < U
N
< 690 V
(cable length <
150 m)
600 V < U
N
< 690 V
(cable length >
150 m)
Reinforced
380 V < U
N
< 690 V Standard
+ du/dt
Reinforced n.a.
Formwound
HX_ and
AM_
Old* formwound
HX_ and modular
380 V < U
N
< 690 V Check with the motor manufacturer.
Randomwound
HX_ and
AM_ **
HDP
*
0 V < U
N
< 500 V
500 V < U
N
< 690 V
Enamelled wire with fiber glass taping
Consult the motor manufacturer.
manufactured before 1.1.1998
+ N + CMF
+ du/dt + N + CMF
+ du/dt + N
+ N + CMF
+ du/dt with voltages over 500 V + N +
CMF
** For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
Planning the electrical installation 57
Motor type
Nominal AC supply voltage
Motor insulation system
Requirement for
ABB du/dt and common mode filters, insulated N-end motor bearings
P
N
< 100 kW and frame size
< IEC 315
100 kW < P
N or
< 350 kW
IEC 315 < frame size <
IEC 400
P
N
< 134 hp and frame size
< NEMA 500
134 hp < P
N
< 469 hp or
NEMA 500 < frame size < NEMA 580
Non-ABB motors
Randomwound and formwound
U
N
< 420 V Standard:
Û
LL
= 1300 V
420 V < U
N
< 500 V Standard:
Û
LL
= 1300 V or
Reinforced:
Û
LL
0.2
= 1600 V, microsecond rise time
-
+ du/dt
-
+ N or CMF
+ du/dt + (N or CMF)
+ N or CMF
500 V < U
N
< 600 V Reinforced:
Û
LL
= 1600 V or
+ du/dt + du/dt + (N or CMF)
Reinforced:
Û
LL
= 1800 V
600 V < U
N
< 690 V Reinforced:
Û
LL
= 1800 V
Reinforced:
Û
LL
0.3
= 2000 V, microsecond rise time ***
-
+ du/dt
-
+ N or CMF
+ du/dt + N
N + CMF
*** If the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking, check with the motor manufacturer if additional output filters are needed in the applied drive operation range.
58 Planning the electrical installation
The abbreviations used in the table are defined below.
Abbr.
U
N
Û
LL
P
N du/dt
CMF
N n.a.
Definition
Nominal AC line voltage
Peak line-to-line voltage at motor terminals which the motor insulation must withstand
Motor nominal power du/dt filter at the output of the drive. Available from ABB as an optional add-on kit.
Common mode filter. Depending on the drive type, CMF is available from ABB as an optional add-on kit.
N-end bearing: insulated motor non-drive end bearing
Motors of this power range are not available as standard units. Consult the motor manufacturer.
Additional requirements for explosion-safe (EX) motors
If you will use an explosion-safe (EX) motor, follow the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements.
Additional requirements for ABB motors of types other than M2_, M3_, M4_,
HX_ and AM_
Use the selection criteria given for non-ABB motors.
Additional requirements for the braking applications
When the motor brakes the machinery, the intermediate circuit DC voltage of the drive increases, the effect being similar to increasing the motor supply voltage by up to 20 percent. Consider this voltage increase when specifying the motor insulation requirements if the motor will be braking a large part of its operation time.
Example: Motor insulation requirement for a 400 V AC line voltage application must be selected as if the drive were supplied with 480 V.
Planning the electrical installation 59
Additional requirements for ABB high-output and IP23 motors
The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 (2001). This table shows the requirements for ABB random-wound motor series (for example, M3AA, M3AP and M3BP).
Nominal mains voltage (AC line voltage)
Motor insulation system
U
N
< 500 V Standard
500 V < U
N
< 600 V Standard
-
Requirement for
ABB du/dt and common mode filters, insulated Nend motor bearings
P
N
< 100 kW 100 kW < P
N
200 kW
< P
N
> 200 kW
P
N
< 140 hp
P
N
> 268 hp
+ du/dt
140 hp < P
N
268 hp
<
+ N
+ du/dt + N
+ N + CMF
+ du/dt + N +
CMF or
Reinforced
600 V < U
N
< 690 V Reinforced
-
+ du/dt
+ N
+ du/dt + N
+ N + CMF
+ du/dt + N +
CMF
60 Planning the electrical installation
Additional requirements for non-ABB high-output and IP23 motors
The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 (2001). The table below shows the requirements for random-wound and form-wound non-ABB motors.
Nominal AC line voltage
Motor insulation system
Requirement for
ABB du/dt filter, insulated N-end bearing and ABB common mode filter
P
N
< 100 kW or frame size < IEC 315
100 kW < P
N or
< 350 kW
IEC 315 < frame size <
IEC 400
P
N
< 134 hp or frame size < NEMA 500
134 hp < P
N
NEMA 500 < frame size
< NEMA 580
+ N + CMF
or
< 469 hp
U
N
< 420 V Standard: Û
LL
1300 V
= + N or CMF
420 V < U
N
< 500 V Standard: Û
LL
1300 V
= + du/dt + (N or CMF) + du/dt + N + CMF or
Reinforced:
Û
LL
0.2
= 1600 V, microsecond rise time
+ N or CMF
500 V < U
N
< 600 V Reinforced: Û
LL
= 1600 V
+ du/dt + (N or CMF)
+ N + CMF
+ du/dt + N + CMF or
Reinforced:
Û
LL
= 1800 V
600 V < U
N
< 690 V Reinforced:
Û
LL
= 1800 V
Reinforced:
Û
LL
0.3
= 2000 V, microsecond rise time ***
+ N or CMF
+ du/dt + N
N + CMF
+ N + CMF
+ du/dt + N + CMF
N + CMF
*** If the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking, check with the motor manufacturer if additional output filters are needed in the applied drive operation range.
Planning the electrical installation 61
Additional data for calculating the rise time and the peak line-to-line voltage
If you need to calculate the actual peak voltage and voltage rise time considering the actual cable length, proceed as follows:
• Peak line-to line voltage: Read the relative Û
LL
/U
N
value from the appropriate diagram below and multiply it by the nominal supply voltage (U
N
).
• Voltage rise time: Read the relative values Û
LL
/U
N
and (du/dt)/U
N
from the appropriate diagram below. Multiply the values by the nominal supply voltage (U
N
) and substitute into equation t = 0.8 · Û
LL
/(du/dt).
62 Planning the electrical installation
A
3.0
2.5
2.0
1.5
Û
LL
/U
N
1.0
0.5
du/dt
s)
U
N
0.0
100 200 300
l (m)
B
4.0
3.5
3.0
2.5
5.5
5.0
4.5
2.0
1.5
1.0
du/dt
s)
UN
Û
LL
/U
N
100 200 300
l (m)
A
B
Drive with du/dt filter
Drive without du/dt filter
l
Motor cable length
Û
LL
/U
N
(du/dt)/U
N
Relative peak line-to-line voltage
Relative du/dt value
Note: ÛLL and du/dt values are approximately 20% higher with resistor braking.
Planning the electrical installation 63
Additional note for sine filters
Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with a sine filter. The peak phase-to-phase voltage with the sine filter is approximately
1.5 · U
N
.
Selecting the power cables
General rules
Select the input power and motor cables according to local regulations:
• Select a cable capable of carrying the drive nominal current. See section
(page
) for the rated currents.
• Select a cable rated for at least 70
°
C maximum permissible temperature of conductor in continuous use. For US, see
page
.
• The inductance and impedance of the PE conductor/cable (grounding wire) must be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when a ground fault occurs).
• 600 V AC cable is accepted for up to 500 V AC. 750 V AC cable is accepted for up to 600 V AC. For 690 V AC rated equipment, the rated voltage between the conductors of the cable should be at least 1 kV.
Use symmetrical shielded motor cable (see page
) for drive frame size R5 and larger, or motors larger than 30 kW (40 hp). A four-conductor system can be used up to frame size R4 with up to 30 kW (40 hp) motors, but shielded symmetrical motor cable is always recommended. Ground motor cable shields 360° at both ends. Keep the motor cable and its PE pigtail (twisted shield) as short as possible to reduce highfrequency electromagnetic emissions.
Note: When continuous metal conduit is employed, shielded cable is not required.
The conduit must have bonding at both ends.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable is recommended.
Compared to a four-conductor system, the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation, bearing currents and wear.
The protective conductor must always have an adequate conductivity. The table below shows the minimum cross-sectional area related to the phase conductor size according to IEC 61439-1 when the phase conductor and the protective conductor are made of the same metal.
64 Planning the electrical installation
Cross-sectional area of the phase conductors
S (mm
2
)
S < 16
16 < S < 35
35 < S
Minimum cross-sectional area of the corresponding protective conductor
S p
(mm
2
)
S
16
S/2
Typical power cable sizes
The table below gives copper and aluminum cable types with concentric copper shield for the drives with nominal current.
Drive type
ACS880-
01-
Frame size
IEC
1)
Cu cable type mm
2
Al cable type mm
2
Cu cable type
US
2)
Al cable type
AWG/kcmil AWG/kcmil
03A3-3
04A0-3
05A6-3
07A2-3
09A4-3
12A6-3
017A-3
025A-3
U
N
= 230 V
04A6-2
06A6-2
07A5-2
10A6-2
16A8-2
24A3-2
031A-2
046A-2
061A-2
075A-2
087A-2
115A-2
145A-2
170A-2
206A-2
274A-2
U
N
= 400 V
02A4-3
R6
R7
R7
R8
R4
R5
R5
R6
R2
R2
R3
R4
R1
R1
R1
R1
R1
R1
R1
R2
R2
R1
R1
R1
R1
3×1.5
3×1.5
3×1.5
3×1.5
3×6
3×6
3×10
3×16
3×25
3×35
3×35
3×50
3×95
3×120
3×150
2 × (3×95)
3)
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×6
3×6
-
-
-
3×35
-
-
-
-
3×35
3×50
3×70
3×70
3×120
3×150
3×240
2 × (3×120)
-
-
-
-
-
-
-
-
-
3
1
4
3
2/0
3/0
250 MCM
2 × 3/0
10
10
8
6
14
14
14
14
14
14
14
10
10
14
14
14
14
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Planning the electrical installation 65
Drive type
ACS880-
01-
R4
R5
R5
R6
R2
R3
R3
R4
R1
R1
R1
R2
R1
R1
R1
R1
R6
R7
R7
R8
R8
R9
R9
027A-5
034A-5
040A-5
052A-5
065A-5
077A-5
096A-5
124A-5
03A0-5
03A4-5
04A8-5
05A2-5
07A6-5
11A0-5
014A-5
021A-5
032A-3
038A-3
045A-3
061A-3
072A-3
087A-3
105A-3
145A-3
169A-3
206A-3
246A-3
293A-3
363A-3
430A-3
U
N
= 500 V
02A1-5
156A-5
180A-5
240A-5
260A-5
302A-5
361A-5
R7
R7
R8
R8
R9
R9
R5
R5
R6
R6
R3
R3
R4
R4
Frame size mm
2
3×10
3×10
3×16
3×25
3×35
3×35
3×50
3×95
3×120
3×150
2 × (3×70)
3)
2 × (3×95)
3)
2 × (3×120)
2 × (3×150)
IEC
1)
Cu cable type Al cable type mm
2
-
-
3×35
3×35
3×50
3×70
3×70
3×120
3×150
3×240
2 × (3×95)
2 × (3×120)
2 × (3×185)
2 × (3×240)
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×6
3×6
3×10
3×10
3×16
3×25
3×35
3×35
3×50
3×95
3×120
3×150
2 × (3×70)
3)
2 × (3×70)
2 × (3×95)
3)
2 × (3×120)
-
-
-
3×25
3×25
3×35
3×50
3×70
-
-
-
-
-
-
-
-
3×95
3×150
3×185
2 × (3×95)
2 × (3×95)
2 × (3×120)
2 × (3×185)
Cu cable type
US
2)
Al cable type
AWG/kcmil
8
8
3
3
6
4
1
2/0
3/0
250 MCM
300 MCM
2 × 3/0
2 × 4/0
2 × 250 MCM
-
-
-
-
-
-
-
-
AWG/kcmil
-
-
-
-
-
-
14
14
14
14
14
14
14
10
10
8
8
6
4
3
3
1
2/0
3/0
250 MCM
300 MCM
2 × 2/0
2 × 3/0
2 × 250 MCM
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
66 Planning the electrical installation
Drive type
ACS880-
01-
414A-5
U
N
= 690 V
07A3-7
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
042A-7
049A-7
061A-7
084A-7
098A-7
119A-7
142A-7
174A-7
210A-7
271A-7
Frame size
R9
R7
R8
R8
R9
R9
R5
R6
R6
R7
R5
R5
R5
R5
R5
R5
R5
R5
IEC
1)
Cu cable type mm
2
2 × (3×150)
Al cable type mm
2
2 × (3×240)
3×16
3×25
3×35
3×50
3×70
3×95
3)
3×120
3)
3×185
3×240
3×1.5
3×1.5
3×2.5
3×4
3×6
3×10
3×10
3×16
-
3×25
3×25
3×25
-
-
-
-
3×25
3×35
3×50
3×70
3×95
3×120
2 × (3×70)
2 × (3×95)
2 × (3×120)
Cu cable type
US
2)
Al cable type
AWG/kcmil
2 × 250 MCM
3
2
6
4
1/0
2/0
4/0
300 MCM
400 MCM
10
8
8
6
14
14
14
12
AWG/kcmil
-
4
3
2
1/0
3/0
4/0
300
2 × 3/0
2 × 4/0
6
4
8
6
12
12
12
10
3AXD00000588487
1)
The cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one on top of the other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (EN 60204-1 and IEC 60364-5-52/2001). For other conditions, size the cables according to local safety regulations, appropriate input voltage and the load current of the drive. See also page
for the accepted cable sizes of the drive.
2)
The cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40 °C (104 °F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or earth (directly buried). For other conditions, size the cables according to local safety regulations, appropriate input voltage and the load current of the drive. See also page
for the accepted cable sizes of the drive.
3)
The biggest cable size accepted by the connection terminals of frame R8 is 2 × (3×150).
Biggest possible cable size is 3x240 or 400 MCM if the terminal type is changed and the cable entry box is not used.
Alternative power cable types
The recommended and not allowed power cable types to be used with the drive are presented below.
Planning the electrical installation 67
Recommended power cable types
PE
Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield. The shield must meet the
requirements of IEC 61439-1, see page
state / country electrical codes for allowance.
PE
Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield. A separate PE conductor is required if the shield does not meet the requirements of
IEC 61439-1, see page
.
PE
Symmetrical shielded cable with three phase conductors and symmetrically constructed PE conductor, and a shield. The PE conductor must meet the requirements of IEC 61439-1.
Power cable types for limited use
PE
A four-conductor system (three phase conductors and a protective conductor on a cable tray) is not allowed for motor
cabling (it is allowed for input cabling).
PVC
EMT
A four-conductor system (three phase conductors and a PE conductor in a PVC conduit) is allowed for input and motor
cabling with phase conductor cross-section less than
10 mm
2
(8 AWG) or motors < 30 kW (40 hp). Not allowed in
USA.
Corrugated or EMT cable with three phase conductors and a protective conductor is allowed for motor cabling with phase conductor cross section less than 10 mm
2
(8 AWG) or motors <
30 kW (40 hp).
Not allowed power cable types
PE
Symmetrical shielded cable with individual shields for each phase conductor is not allowed on any cable size for input and motor cabling.
68 Planning the electrical installation
Motor cable shield
If the motor cable shield is used as the sole protective earth conductor of the motor, ensure that the conductivity of the shield is sufficient. See subsection
above, or IEC 61439-1. To effectively suppress radiated and conducted radiofrequency emissions, the cable shield conductivity must be at least 1/10 of the phase conductor conductivity. The requirements are easily met with a copper or aluminum shield. The minimum requirement of the motor cable shield of the drive is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire. The better and tighter the shield, the lower the emission level and bearing currents.
4
5
1 3 2
1
2
3
4
5
Insulation jacket
Copper wire screen
Helix of copper tape or copper wire
Inner insulation
Cable core
Additional US requirements
Use type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used. For the
North American market, 600 V AC cable is accepted for up to 500 V AC. 1000 V AC cable is required above 500 V AC (below 600 V AC). For drives rated over 100 amperes, the power cables must be rated for 75
°
C (167
°
F).
Conduit
Couple separate parts of a conduit together: bridge the joints with a ground conductor bonded to the conduit on each side of the joint. Also bond the conduits to the drive enclosure and motor frame. Use separate conduits for input power, motor, brake resistor, and control wiring. When conduit is employed, type MC continuous corrugated aluminum armor cable or shielded cable is not required. A dedicated ground cable is always required.
Note: Do not run motor wiring from more than one drive in the same conduit.
Planning the electrical installation 69
Armored cable / shielded power cable
Six conductor (3 phases and 3 ground) type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers (trade names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and Pirelli.
Selecting the control cables
Shielding
All control cables must be shielded.
Use a double-shielded twisted pair cable for analog signals. This type of cable is recommended for the pulse encoder signals also. Employ one individually shielded pair for each signal. Do not use common return for different analog signals.
A double-shielded cable (figure a below) is the best alternative for low-voltage digital signals but single-shielded (b) twisted pair cable is also acceptable.
a b
Signals in separate cables
Run analog and digital signals in separate, shielded cables.
Never mix 24 V DC and 115/230 V AC signals in the same cable.
Signals allowed to be run in the same cable
Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in the same cables as digital input signals. The relay-controlled signals should be run as twisted pairs.
Relay cable type
The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL,
Germany) has been tested and approved by ABB.
70 Planning the electrical installation
Control panel cable length and type
In remote use, the cable connecting the control panel to the drive must not exceed three meters (10 ft). Cable type: shielded CAT 5e or better Ethernet patch cable with
RJ-45 ends.
Routing the cables
Route the motor cable away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. The motor cable, input power cable and control cables should be installed on separate trays. Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage.
Where control cables must cross power cables, ensure they are arranged at an angle as near to 90 degrees as possible. Do not run extra cables through the drive.
The cable trays must have good electrical bonding to each other and to the grounding electrodes. Aluminum tray systems can be used to improve local equalizing of potential.
A diagram of the cable routing is shown below.
Drive
Motor cable
Power cable min 300 mm (12 in.)
Input power cable min 200 mm (8 in.)
90 °
Control cables
Motor cable min 500 mm (20 in.)
Planning the electrical installation 71
Separate control cable ducts
Lead 24 V and 230 V (120 V) control cables in separate ducts unless the 24 V cable is insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V
(120 V).
24 V
230 V
(120 V)
24 V
230 V
(120 V)
Continuous motor cable shield or enclosure for equipment on the motor cable
To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor:
• European Union: Install the equipment in a metal enclosure with 360 degree grounding for the shields of both the incoming and outgoing cable, or connect the shields of the cables otherwise together.
• US: Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding runs consistently without breaks from the drive to the motor.
Implementing thermal overload and short-circuit protection
Protecting the drive and input power cable in short-circuits
Protect the drive and input cable with fuses as follows:
~
~
M
3~
72 Planning the electrical installation
Size the fuses at the distribution board according to instructions given in chapter
. The fuses will protect the input cable in short-circuit situations, restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive.
Circuit breakers
The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers. There are also limitations pertaining to the short-circuit capacity of the supply network. Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known.
WARNING! Due to the inherent operating principle and construction of circuit breakers, independent of the manufacturer, hot ionized gases can escape from the breaker enclosure in case of a short-circuit. To ensure safe use, pay special attention to the installation and placement of the breakers. Obey the manufacturer’s instructions.
Note: Circuit breakers must not be used without fuses. For more information, contact
ABB.
Protecting the motor and motor cable in short-circuits
The drive protects the motor cable and motor in a short-circuit situation when the motor cable is sized according to the nominal current of the drive. No additional protection devices are needed.
Protecting the drive and the input power and motor cables against thermal overload
The drive protects itself and the input and motor cables against thermal overload when the cables are sized according to the nominal current of the drive. No additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, use a separate circuit breaker or fuses for protecting each motor cable and motor against overload.
The drive overload protection is tuned for the total motor load. It may not trip due to an overload in one motor circuit only
Protecting the motor against thermal overload
According to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary. Depending on a drive parameter value, the function either monitors a calculated temperature value (based on a motor thermal model) or an actual
Planning the electrical installation 73
temperature indication given by motor temperature sensors. The user can tune the thermal model further by feeding in additional motor and load data.
The most common temperature sensors are:
• motor sizes IEC180…225: thermal switch, eg, Klixon
• motor sizes IEC200…250 and larger: PTC or Pt100.
See the firmware manual for more information on the motor thermal protection, and the connection and use of the temperature sensors.
Protecting the drive against ground faults
The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable. This is not a personnel safety or a fire protection feature. The ground fault protective function can be disabled with a parameter, refer to the firmware manual.
Residual current device compatibility
The drive is suitable to be used with residual current devices of Type B.
Note: The EMC filter of the drive includes capacitors connected between the main circuit and the frame. These capacitors and long motor cables increase the ground leakage current and may cause fault current circuit breakers to function.
Connecting drives to a common DC system
See ACS880-01 drives common DC systems application guide (3AUA0000127818
[English]).
Implementing the Emergency stop function
For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed. You can use the Safe torque off function of the drive to implement the Emergency stop
Note: Pressing the stop key on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential.
Implementing the Safe torque off function
See chapter
Implementing the Safety functions options
The drive can be equipped with a safety functions module as factory installed (option
+Q973). The module is also available as a retrofilt kit. The safety functions module includes, for example, the following functions: Safe torque off (STO), Safe brake
74 Planning the electrical installation
control (SBC) and Safely-limited speed (SLS). The option uses the internal Safe torque off function of the drive.
For the installation of the safety functions module, see section
Installation of safety functions modules
. For the safety data and more information on the
option, see FSO-11 user’s manual (3AUA0000097054 [English]).
Implementing the ATEX-certified Safe motor disconnection function (option +Q971)
With option +Q971, the drive supplies ATEX-certified safe motor disconnection without contactor that uses the drive Safe torque off function. For more information, see ACS880 ATEX-certified Safe disconnection function application guide
(3AUA0000132231 [English]).
Implementing the Power-loss ride-through function
Implement the power-loss ride-through function as follows:
• Check that the power-loss ride-through function of the drive is enabled with parameter 30.31 Undervoltage control in the ACS880 primary control program.
• If the installation is equipped with a main contactor, prevent its tripping at the input power break. For example, use a time delay relay (hold) in the contactor control circuit.
WARNING! Make sure that the flying restart of the motor will not cause any danger. If you are in doubt, do not implement the Power-loss ride-through function.
Using power factor compensation capacitors with the drive
Power factor compensation is not needed with AC drives. However, if a drive is to be connected in a system with compensation capacitors installed, note the following restrictions.
WARNING! Do not connect power factor compensation capacitors or harmonic filters to the motor cables (between the drive and the motor). They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves.
Planning the electrical installation 75
If there are power factor compensation capacitors in parallel with the three phase input of the drive:
1. Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may trip or even damage the drive.
2. If capacitor load is increased/decreased step by step when the AC drive is connected to the power line, ensure that the connection steps are low enough not to cause voltage transients that would trip the drive.
3. Check that the power factor compensation unit is suitable for use in systems with
AC drives, ie, harmonic generating loads. In such systems, the compensation unit should typically be equipped with a blocking reactor or harmonic filter.
Using a contactor between the drive and the motor
Implementing the control of the output contactor depends on how you select the drive
Implementing a bypass connection
When you have selected to use DTC motor control mode and motor ramp stop, open the contactor as follows:
1. Give a stop command to the drive.
2. Wait until the drive decelerates the motor to zero speed.
3. Open the contactor.
When you have selected to use DTC motor control mode and motor coast stop, or scalar control mode, open the contactor as follows:
1. Give a stop command to the drive.
2. Open the contactor.
WARNING! When the DTC motor control mode is in use, never open the output contactor while the drive controls the motor. The DTC motor control operates extremely fast, much faster than it takes for the contactor to open its contacts. When the contactor starts opening while the drive controls the motor, the
DTC control will try to maintain the load current by immediately increasing the drive output voltage to the maximum. This will damage, or even burn the contactor completely.
Implementing a bypass connection
If bypassing is required, employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line. Ensure with interlocking that the contactors cannot be closed simultaneously.
76 Planning the electrical installation
WARNING! Never connect the drive output to the electrical power network.
The connection may damage the drive.
Example bypass connection
An example bypass connection is shown below.
Q1
Q4
K1
Drive main switch
Bypass circuit breaker
Drive main contactor
S11 Drive main contactor on/off control
S40 Motor power supply selection (drive or direct-on-line)
S41 Start when motor is connected direct-online
Planning the electrical installation 77
K4 Bypass contactor S42 Stop when motor is connected direct-online
K5 Drive output contactor
Switching the motor power supply from drive to direct-on-line
1. Stop the drive and the motor with the drive control panel (drive in local control mode) or with the external stop signal (drive in remote control mode).
2. Open the main contactor of the drive with S11.
3. Switch the motor power supply from the drive to direct-on-line with S40.
4. Wait for 10 seconds to allow the motor magnetization to die away.
5. Start the motor with S41.
Switching the motor power supply from direct-on-line to drive
1. Stop the motor with S42.
2. Switch the motor power supply from direct-on-line to the drive with S40.
3. Close the main contactor of the drive with switch S11 (-> turn to position ST for two seconds and leave at position 1).
4. Start the drive and the motor with the drive control panel (drive in local control mode) or with the external start signal (drive in remote control mode).
Protecting the contacts of relay outputs
Inductive loads (relays, contactors, motors) cause voltage transients when switched off.
The relay contacts on the drive control unit are protected with varistors (250 V) against overvoltage peaks. In spite of this, it is highly recommended that inductive loads are equipped with noise attenuating circuits (varistors, RC filters [AC] or diodes
[DC]) in order to minimize the EMC emission at switch-off. If not suppressed, the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs.
78 Planning the electrical installation
1
230 V AC
2
230 V AC
3
+ 24 V DC
4
1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode
-
Planning the electrical installation 79
Connecting a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non-conductive or conductive but not connected to the protective earth.
To fulfill this requirement, the connection of a thermistor (and other similar components) to the digital inputs of the drive can be implemented in three alternate ways:
1. There is double or reinforced insulation between the thermistor and live parts of the motor.
2. Circuits connected to all digital and analog inputs of the drive are protected against contact and insulated with basic insulation (the same voltage level as the drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for the same voltage level as the main circuit of the drive. For connection, see the firmware manual.
See page
.
The inaccuracy of the drive analog inputs for Pt100 sensors is 10 °C (18 °F). If more accuracy is needed, use the FAIO-01 analog I/O extension module (option +L525).
80 Planning the electrical installation
Electrical installation
Electrical installation 81
6
What this chapter contains
This chapter gives instructions on wiring the drive.
Warnings
WARNING! Only qualified electricians are allowed to carry out the work
described in this chapter. Follow the
this manual. Ignoring the safety instructions can cause physical injury or death.
Checking the insulation of the assembly
Drive
Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive. Every drive has been tested for insulation between the main circuit and the chassis at the factory. Also, there are voltagelimiting circuits inside the drive which cut down the testing voltage automatically.
Input power cable
Check the insulation of the input cable according to local regulations before connecting it to the drive.
82 Electrical installation
Motor and motor cable
Check the insulation of the motor and motor cable as follows:
1. Check that the motor cable is disconnected from the drive output terminals T1/U,
T2/V and T3/W.
2. Measure the insulation resistance between each phase conductor and the
Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at
25 °C or 77 °F). For the insulation resistance of other motors, please consult the manufacturer’s instructions. Note: Moisture inside the motor casing will reduce the insulation resistance. If moisture is suspected, dry the motor and repeat the measurement.
ohm
U1
V1
M
3~
W1 PE
Brake resistor assembly
Check the insulation of the brake resistor assembly (if present) as follows:
1. Check that the resistor cable is connected to the resistor, and disconnected from the drive output terminals R+ and R-.
2. At the drive end, connect the R+ and R- conductors of the resistor cable together.
Measure the insulation resistance between the combined conductors and the PE conductor by using a measuring voltage of 1 kV DC. The insulation resistance must be higher than 1 Mohm.
R+ ohm
R-
PE
Electrical installation 83
Checking the compatibility with IT (ungrounded) systems
EMC filters +E200 and +E202 are not suitable for use in an IT (ungrounded) system.
If the drive is equipped with filter +E200 or +E202, disconnect the filter before connecting the drive to the supply network. Undo the two screws which are marked with EMC AC and EMC DC on the skeleton. See EMC filter disconnecting
instructions for ACS880-01 drives with filters +E200 and +E202 (3AUA0000125152
[English]).
For frame R4, contact ABB
WARNING! If a drive with EMC filter +E200 or +E202 is installed on an IT system (an ungrounded power system or a high resistance-grounded [over 30 ohm] power system), the system will be connected to earth potential through the
EMC filter capacitors of the drive. This can cause danger, or damage the drive.
84 Electrical installation
Connecting the power cables
Connection diagram
ACS880-01
PE
2b
L1 L2 L3
2a
3
R-
UDC+
R+
UDC-
T1/U T2/V T3/W
3 4
7
5
1
(PE) PE (PE) L1 L2 L3
U1
V1
W1
3 ~ M
6
1
Selecting the supply disconnecting device
on page
2 Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity of the shield does not meet the requirements for the PE conductor
(see page
3 360-degree grounding is recommended if shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board.
4 360-degree grounding is required.
5 External brake resistor
6 Use a separate grounding cable if the shield does not meet the requirements of
) and there is no symmetrically constructed grounding
conductor in the cable (see page
7 du/dt filter or sine filter (optional, see page
Note:
If there is a symmetrically constructed grounding conductor on the motor cable in addition to the conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor ends.
Do not use an asymmetrically constructed motor cable for motors above 30 kW (see page
Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.
Electrical installation 85
Connection procedure for frames R1 to R3
1. Undo the mounting screws at the sides of the front cover.
2. Remove the cover by sliding it forward.
3. Attach the residual voltage warning sticker in the local language to the control panel mounting platform.
4. Remove the rubber grommets from the lead-through plate for the cables to be connected.
5. IP21 units: Fasten the cable connectors (included in the delivery in a plastic bag) to the cable lead-through plate holes.
6. Prepare the ends of the input power (a) and motor cables (b) as illustrated in the figure. Note: Bare shield will be grounded 360 degrees.
7. IP21 units: Ground the shields 360 degrees in the connectors by tightening the connector onto the stripped part of the cable. IP55 units: Tighten the clamps onto the stripped part of the cables.
8. Connect the twisted shields of the power cables to the grounding terminals.
9. Connect the additional PE conductor (if used, see page
the grounding terminal.
10. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals and the phase conductors of the motor cable to the T1/U, T2/V and T3/W terminals. Connect the brake resistor conductors (if present) to the R+ and R- terminals. Tighten the screws to the torque given in the figure below.
11. Install the control cable grounding shelf in the cable entry box.
12. Secure the cables outside the unit mechanically.
Note: For US cable conduit installation, see the quick installation guide.
86 Electrical installation
10
IP21
IP55
1
2
1
3
1
5
4
6a
PE
PE
6b
PE
9
8
6b
PE
Electrical installation 87
8
8
8
10
9
10
8
R1
R2
R3
L1, L2, L3, T1/U,
T2/V, T3/W, R-,
R+/UDC+, UDC
(N·m)
0.6
0.6
1.7
(N·m)
1.8
1.8
1.8
7
88 Electrical installation
11
Connection procedure for frames R4 and R5
1. Remove the front cover. IP21 units: Release the retaining clip with a screwdriver
(a) and lift the cover from the bottom outwards (b).
2. For IP21 drives: Remove the cable entry box cover by undoing the mounting screw.
3. For frame R4: Remove the EMC shroud that separates the input and output cabling if needed for earier installation.
4. Remove the shroud on the power cable terminals by releasing the clips and lifting the shroud up from the sides with a screwdriver (a).
Knock out holes in the shroud for the cables to be installed (b).
5. Attach the residual voltage warning sticker in the local language next to the control unit top.
6. Cut adequate holes into the rubber grommets. Slide the grommets onto the cables. Slide the cables through the holes of the bottom plate and attach the grommets to the holes.
7. Prepare the ends of the input power and motor cables as illustrated in the figure.
Note: Bare shield will be grounded 360 degrees under the grounding clamp.
8. Ground the cable shields 360 degrees under the grounding clamps.
9. Connect the twisted cable shields to the grounding terminals.
10. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals and the phase conductors of the motor cable to the T1/U, T2/V and T3/W terminals. Tighten the screws to the torque given in the figure below. Note for
frame R5: For easier installation, the power cable terminals can be removed by undoing their mounting nuts. Fasten the terminals back to their place by tightening the mounting nuts.
Electrical installation 89
11. Install the EMC shroud separating the input and output cabling if not installed yet.
12. Units with option +D150: Slide the brake resistor cable through the brake resistor and control cable clamp assembly. Connect the conductors to the R+ and R- terminals and tighten to the torque given in the figure.
13. Reinstall the shroud on the power terminals.
14. Secure the cables outside the unit mechanically. Install the rubber grommets to the unused lead-through plate holes.
Note: For US cable conduit installation, see the quick installation guide. In case of a cable lug installation, use UL listed cable lugs and tools to agree with UL requirements. See page
.
90 Electrical installation
R4, R5
1b
1a
3
2
IP55
1
IP21
3
4
4b
4a
R4, R5
5
6
PE
Electrical installation 91
PE
7
6
7
6
92 Electrical installation
R4, R5
10
9
9
10
8
R4
R5
L1, L2, L3, T1/U,
T2/V, T3/W
(N·m)
R-, R+/UDC+,
UDC-
(N·m)
3.3
5.6
3.3
5.6
(N·m)
2.9
2.9
12
9
11
13
Electrical installation 93
Connection procedure for frames R6 to R9
1. Remove the front cover: For IP21 drives: Release the retaining clip with a screwdriver (a) and pull the cover by the bottom outwards (b).
2. For IP21 drives: Remove the cable entry box cover by undoing the mounting screws.
3. Attach the residual voltage warning sticker in the local language next to the control unit.
4. Remove the side plates of the cable entry box by undoing the mounting screws.
5. Remove the shroud on the power cable terminals by releasing the clips on the sides with a screwdriver and lifting (a). If parallel cables are installed (frames R8 and R9), knock out holes for the cables (b).
6. Knock out the shrouds on the power cable terminals for the cables to be installed.
7. Prepare the ends of the input power and motor cables as illustrated in the figure.
Note: Bare shield will be grounded 360 degrees under the clamp.
8. Cut adequate holes into the rubber grommets (a). Slide the grommets onto the cables. Slide the cables through the holes of the bottom plate and attach the grommets to the holes (b).
9. Tighten the clamp onto the stripped part of the cable.
10. Fasten the twisted shields of the cables under the grounding clamps.
11. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals and the phase conductors of the motor cable to the T1/U, T2/V and T3/W terminals. Tighten the screws to the torque given in the figure.
Note 1 for frames R8 and R9: if you put only one conductor to the connector, we recommend that you put it under the upper pressure plate.
Note 2 for frames R8 and R9: We do not recommend that you detach the connectors. If you do, detach and reinstall the connector as follows:
• Remove the nut that attaches the connector to its terminal post, and pull the connector off.
• Pur the conductor under the connector pressure plate and pretighten the conductor.
• Put the connector back onto the terminal post. Start the nut, and turn it at least two rotations by hand.
94 Electrical installation
WARNING! Before using tools, make sure that the nut/screw is not crossthreading. Cross-threading will damage the drive and cause danger.
• Tighten the nut to a torque of 24 N·m.
• Tighten the conductor(s) to 40 N·m for frame R8 or to 70 N·m for frame R9.
12. Units with option +D150: Connect the brake resistor cable conductors to the R+ and R- terminals.
13. If parallel cables are installed (frames R8 and R9), install the grounding shelves for them. Repeat steps 8 to 12.
14. Reinstall the shroud on the power terminals.
15. Reinstall the side plates of the cable entry box.
16. Install the control cable grounding shelf in the cable entry box.
17. Secure the cables outside the unit mechanically. Install the rubber grommets to the unused lead-through plate holes.
Note: For US cable conduit installation, see the quick installation guide. In case of a cable lug installation, use UL listed cable lugs and tools to agree with UL requirements. See page
.
Electrical installation 95
R6 … R9
1b
1a
3
3
IP21
4
5a
5b
4
IP55
96 Electrical installation
R6 … R9
R8, R9
PE
7
8a
6
PE
7
R6 … R9
11
12
11
10
10 10
Electrical installation 97
9
Frame L1, L2, L3, T1/U,
T2/V, T3/W
R-, R+/UDC+,
UDC-
T (Wire screw) T (Wire screw)
M… N·m M… N·m
R6
R7
R8
R9
M10 M8
M10 40 (30*) M10
M10
M12
30
40
70
M10
M12
20
30
40
70
* for 525…690 V drives
T
N·m
9.8
9.8
9.8
9.8
98 Electrical installation
R6 … R9
13
R8, R9
16
Electrical installation 99
Grounding the motor cable shield at the motor end
Always ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the lead-through of the motor terminal box.
DC connection
The UDC+ and UDC- terminals are intended for common DC configurations of a number of drives, allowing regenerative energy from one drive to be utilized by the other drives in motoring mode. Contact your local ABB representative for further instructions.
Connecting the control cables
See section
Default I/O connection diagram
below for the default I/O connections of the Factory macro of ACS880 primary control program. For other macros and control
programs, see the firmware manual. Connect the cables as described under
Control cable connection procedure
.
100 Electrical installation
Default I/O connection diagram
Wire sizes:
0.5 … 2.5 mm
2
(24…12 AWG)
Tightening torques: 0.5 N·m
(5 lbf·in) for both stranded and solid wiring.
See the next page for the notes.
Fault
XPOW External power input
1
2
+24VI
GND
24 V DC, 2 A
XAI
Reference voltage and analog inputs
1
2
3
4
5
6
7
J1
+VREF
-VREF
AGND Ground
AI1+
AI1-
AI2+
AI2-
J1
10 V DC, R
-10 V DC, R
Speed reference 0(2)…10 V, R
200 kohm
1)
100 ohm
2)
L
1…10 kohm
L
1…10 kohm in
>
By default not in use. 0(4)…20 mA, R
AI1 current/voltage selection jumper in
=
J2 J2
XAO Analog
AI2 current/voltage selection jumper outputs
1
2
AO1
AGND
Motor speed rpm 0…20 mA, R
L
500 ohm
<
3
4
AO2
AGND
Motor current 0…20 mA, R
XD2D Drive-to-drive link
1
B
2
3
A
BGND
Drive-to-drive link
L
< 500 ohm
J3 J3 Drive-to-drive link termination switch
XRO1, XRO2, XRO3 Relay outputs
1
2
3
1
2
3
1
2
3
NC
COM
NO
NC
COM
NO
NC
COM
NO
Ready
250 V AC / 30 V DC
2 A
Running
250 V AC / 30 V DC
2 A
Faulted(-1)
250 V AC / 30 V DC
2 A
XD24
Digital interlock
1
2
DIIL Run enable
+24VD +24 V DC 200 mA
3)
3
4
5
DICOM Digital input ground
+24VD +24 V DC 200 mA
3)
DIOGND Digital input/output ground
J6 Ground selection switch
XDIO
Digital input/outputs
1
2
DIO1
DIO2
Output: Ready
Output: Running
XDI
Digital inputs
1
DI1 Stop (0) / Start (1)
2
3
4
5
DI2
DI3
DI4
DI5
Forward (0) / Reverse (1)
Reset
Acceleration & deceleration select
Constant speed 1 (1 = On)
6
DI6 By default not in use.
XSTO Safe torque off
4)
1
2
3
4
OUT1
SGND
IN1
IN2
Safe torque off. Both circuits must be closed for the drive to start.
X12
Safety functions module connection
X13
Control panel connection
X205
Memory unit connection
Electrical installation 101
Notes:
1)
Current [0(4)…20 mA, R in
= 100 ohm] or voltage [ 0(2)…10 V, R in with jumper J1. Change of setting requires reboot of control unit.
> 200 kohm] input selected
2)
Current [0(4)…20 mA, R in
= 100 ohm] or voltage [ 0(2)…10 V, R in with jumper J2. Change of setting requires reboot of control unit.
> 200 kohm] input selected
3)
Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus the power taken by DIO1 and DIO2.
4)
0 = open, 1 = closed
DI4 Ramp times according to
0 Parameters 23.12 and 23.13
1 Parameters 23.14 and 23.15
Further information on the usage of the connectors and jumpers is given in the sections below.
See also section
Control unit (ZCU-12) connection data
on page
Jumpers and switches
Jumper/
Switch
J1
(AI1)
Description
Determines whether analog input AI1 is used as a current or voltage input.
Positions
Current (I)
Voltage (U)
J2
(AI2)
Determines whether analog input AI2 is used as a current or voltage input.
Current (I)
Voltage (U)
J3
J6
Drive-to-drive link termination. Must be set to terminated position when the drive is the last unit on the link.
Common digital input ground selection switch.
Determines whether DICOM is separated from
DIOGND (ie, common reference for digital
on page
Bus is terminated.
Bus is not terminated.
DICOM and DIOGND connected (default).
DICOM and DIOGND separated.
102 Electrical installation
External power supply for the control unit (XPOW)
External +24 V (2 A) power supply for the control unit can be connected to terminal block XPOW. Using an external supply is recommended if
• the control board needs to be kept operational during input power breaks, for example, due to continuous fieldbus communication
• immediate restart is needed after power breaks (that is, no control board power up delay is allowed).
AI1 and AI2 as Pt100 and KTY84 sensor inputs (XAI, XAO)
Three Pt100 sensors or one KTY84 sensor for motor temperature measurement can be connected between an analog input and output as shown below. (Alternatively, you can connect the KTY to FEN-11 analog /I/O extension module or FEN-xx encoder interface module.) Do not connect both ends of the cable shields directly to ground. If a capacitor cannot be used at one end, leave that end of the shield unconnected.
1…3 × Pt100 or 1 × KTY
T T
T
XAI
AIn+
AIn-
1)
XAO
AOn
AGND
2)
3.3 nF
> 630 V AC
1) Set the input type to voltage with switch J1 for analog input AI1or with J2 for analog input
AI2. Set the appropriate analog input unit to V (volt) in parameter group 12 Standard AI.
2) Select the excitation mode in parameter group 13 Standard AO.
WARNING! As the inputs pictured above are not insulated according to
IEC 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. If the assembly does not fulfill the requirement, the I/O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I/O terminals.
Electrical installation 103
Drive-to-drive link (XD2D)
The drive-to-drive link is a daisy-chained RS-485 transmission line that allows basic master/follower communication with one master drive and multiple followers.
Set termination activation jumper J3 (see section
above) next to this terminal block to the ON position on the drives at the ends of the drive-to-drive link. On intermediate drives, set the jumper to the OFF position.
Use shielded twisted-pair cable (~100 ohm, for example, PROFIBUS-compatible cable) for the wiring. For best immunity, high quality cable is recommended. Keep the cable as short as possible; the maximum length of the link is 50 meters (164 ft). Avoid unnecessary loops and running the cable near power cables (such as motor cables).
The following diagram shows the wiring of the drive-to-drive link.
. . .
. . .
. . .
. . .
3.3 nF
> 630 V AC
J3 J3 J3
DIIL input (XD24:1)
The DIIL input can be selected as the source of, for example, an emergency stop command or an external event. See the firmware manual for more information.
104 Electrical installation
DI6 (XDI:6) as PTC sensor input
PTC sensors can be connected to this input for motor temperature measurement as follows. The sum of the sensor resistances must not exceed the threshold resistance of the digital input at the motor normal operating temperature. Do not connect both ends of the cable shield directly to ground. If a capacitor cannot be used at one end, leave that end of the shield unconnected. See the firmware manual for parameter settings.
Note: PTC sensors can alternatively be connected to FEN-xx encoder interface module.
T T
PTC
T
3.3 nF
> 630 V AC
+24VD
DI6
“0” > 4 kohm
“1” < 1.5 kohm
I
max
= 5 mA
WARNING! As the inputs pictured above are not insulated according to
IEC 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. If the assembly does not fulfill the requirement, the I/O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I/O terminals.
Safe torque off (XSTO)
For the drive to start, both connections (OUT1 to IN1 and IN2) must be closed. By default, the terminal block has jumpers to close the circuit. Remove the jumpers
before connecting an external Safe torque off circuitry to the drive. See page
Safety functions (X12)
See section
Implementing the Safety functions options
, and FSO-11
user’s manual (3AUA0000097054 [English]).
Electrical installation 105
Control cable connection procedure
WARNING! Follow the safety instructions, page
can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the front cover(s). See section
from page
3. Cut adequate holes into the rubber grommets and slide the grommets onto the cables. Slide the cables through the holes of the bottom plate and attach the grommets to the holes.
4. Route the cables as shown on page
5. Ground the outer shields of all control cables 360 degrees at a grounding clamp in the cable entry box, see page
. Tighten the clamp to 1.5 N·m (13 lbf·in). Keep
the shields continuous as close to the terminals of the control unit as possible.
Secure the cables mechanically at the clamps below the control unit. Frames R1 to R3: Ground also the pair-cable shields and grounding wires at the cable entry box grounding clamp.
6. Frames R4 to R9: Ground the pair-cable shields and all grounding wires to the
clamp below the control unit, see page
7. Connect the conductors to the appropriate terminals (see page
of the control unit and tighten to 0.5 N·m (5 lbf·in).
8. For connecting the fieldbus cables, see appropriate quick installation guide:
ACS880-01 quick installation guide for frames R1 to R3
ACS880-01 quick installation guide for frames R4 and R5
ACS880-01 quick installation guide for frames R6 to R9
3AUA0000085966
3AUA0000099663
3AUA0000099689
Note:
• Leave the other ends of the control cable shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg, 3.3 nF / 630 V.
The shield can also be grounded directly at both ends if they are in the same
ground line with no significant voltage drop between the end points.
• Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling.
106 Electrical installation
0.5 N·m
1.5 N·m
6
7
7
5
1.5 N·m
3
3
Electrical installation 107
Connecting a PC
WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage.
Connect a PC to the drive with an USB data cable (USB Type A <-> USB Type Mini-
B) as follows:
1. Lift the USB connector cover from bottom upwards.
2. Insert the USB cable Mini-B plug in the control panel USB connector.
3. Insert the USB cable A-plug in the USB connector of the PC. -> The panel displays: USB connected.
1
2
3
108 Electrical installation
Controlling several drives through panel bus
One control panel (or PC) can be used to control several drives by constructing a panel bus.
1. Connect the panel to one drive using an Ethernet (eg. CAT5E) cable.
Note for IP55 (UL Type 12) drives: Remove the front cover and put the cables through the control cable lead-throughs.
• Use Menu – Settings – Edit texts – Drive to give a descriptive name to the drive.
• Use parameter 49.01 to assign the drive with a unique node ID number.
• Set other parameters in group 49 if necessary.
• Use parameter 49.06 to validate any changes.
Repeat the above for each drive.
2. With the panel connected to one drive, link the drives together using Ethernet cables. (Each panel platform has two connectors.)
3. In the last drive, switch bus termination on. With a panel platform, move the terminating switch into the outer position.Termination should be off on all other units.
4. On the control panel, switch on the panel bus functionality (Options – Select
drive – Panel bus). The unit to be controlled can now be selected from the list under Options – Select drive.
5. If a PC is connected to the control panel, the drives on the panel bus are automatically displayed in the Drive composer tool.
6. For IP55 (UL Type 12) drives, Install the front cover.
Electrical installation 109
1
IP21 (UL Type 1)
1 2
3
IP55 (UL Type 12)
1
2
3
110 Electrical installation
Installing optional modules
Note: In frames R1 and R2, 90° connector cannot be used in Slot 1. In other frames, there is 50 to 55 mm free space for the connector and its cable available on Slots 1, 2 and 3.
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface modules
See page
for the available slots for each module. Install the optional modules as
follows:
WARNING! Follow the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the front cover (see the section
starting
3. Frames R1 to R3: Pull the control panel mounting platform upwards to gain access to the optional module slots.
4. Insert the module carefully into its position on the control unit.
5. Fasten the mounting screw. Note: The screw tightens the connections and grounds the module. It is essential for fulfilling the EMC requirements and for proper operation of the module.
Electrical installation 111
3
5
4
Wiring I/O extension, fieldbus adapter and pulse encoder interface modules
See the appropriate optional module manual for specific installation and wiring
for the routing of the cables.
112 Electrical installation
Installation of safety functions modules
The safety functions module can be mounted onto Slot 2 on the control unit or, in frames R7 to R9, also next to the control unit.
Installation procedure into Slot 2
WARNING! Follow the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the front cover (see the section
on page
3. Frames R1 to R3: Pull the control panel mounting platform upwards to gain access to the optional module slots.
4. Insert the module carefully into its position on the control unit.
5. Attach the module with four screws. Note: The grounding screw (a) is essential for fulfilling the EMC requirements and for proper operation of the module.
6. Tighten the grounding screw of the electronics.
7. Connect the data communication cable to slot X110 on the module and to connector X12 on the drive control unit.
8. Connect the Safe torque off wires to connector X111 on the module and to
connector XSTO on the drive module control unit as shown in section
on
9. Connect the external +24 V power supply cable to connector X112.
10. Connect the other wires as shown in FSO-11 user’s manual (3AUA0000097054
[English]).
X12
3
Electrical installation 113
5
6
5
5a
5
114 Electrical installation
Installation next to the control unit on frames R7 to R9
WARNING! Follow the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the front cover (see page
).
3. Insert the module carefully into its position.
4. Attach the module with four screws. Note: Correct installation of the grounding screw (a) is essential for fulfilling the EMC requirements and for proper operation of the module.
5. Tighten the grounding screw of the electronics.
6. Connect the data communication cable to slot X110 on the module and to connector X12 on the drive control unit.
7. Connect the Safe torque off wires to connector X111 on the module and to
connector XSTO on the drive module control unit as shown in section
on
8. Connect the external +24 V power supply cable to connector X112.
9. Connect the other wires as shown in FSO-11 user’s manual (3AUA0000097054
[English]).
X12
1
6
5
4
4a
4
4
Electrical installation 115
116 Electrical installation
Installation checklist
Installation checklist 117
7
What this chapter contains
This chapter contains a list for checking the mechanical and electrical installation of the drive.
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person.
WARNING! Only qualified electricians are allowed to carry out the work described below. Follow the complete safety instructions of the drive. Ignoring the safety instructions can cause injury or death. Open the main disconnector of the drive and lock it to open position. Measure to ensure that the drive is not powered.
Check that …
The ambient operating conditions meet the specification in chapter
If the drive will be connected to an IT (ungrounded) supply network: Optional EMC filters of type +E200 and +E202 have been disconnected. Consult ABB for the instructions.
If the drive has been stored over one year: The electrolytic DC capacitors in the DC link of the drive have been reformed. See page
There is an adequately sized protective earth (ground) conductor between the drive and the switchboard.
118 Installation checklist
Check that …
There is an adequately sized protective earth (ground) conductor between the motor and the drive.
All protective earth (ground) conductors have been connected to the appropriate terminals and the terminals have been tightened (pull conductors to check).
The supply voltage matches the nominal input voltage of the drive. Check the type designation label.
The input power cable has been connected to appropriate terminals, the phase order is right, and the terminals have been tightened (pull conductors to check).
Appropriate supply fuses and disconnector have been installed.
The motor cable has been connected to appropriate terminals, the phase order is right, and the terminals have been tightened (pull conductors to check).
The brake resistor cable (if present) has been connected to appropriate terminals, and the terminals have been tightened (pull conductors to check).
The motor cable (and brake resistor cable, if present) has been routed away from other cables.
No power factor compensation capacitors have been connected to the motor cable.
The control cables (if any) have been connected to the control unit.
If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive output contactor are either mechanically or electrically interlocked (cannot be closed simultaneously).
There are no tools, foreign objects or dust from drilling inside the drive.
Drive and motor connection box covers are in place.
The motor and the driven equipment are ready for start-up.
8
Start-up 119
Start-up
What this chapter contains
This chapter describes the start-up procedure of the drive.
Startup procedure
1. Run setup of the drive control program according to the start-up instructions given in Quick start-up guide for ACS880 primary control program or in the firmware manual. For option +N7502, see also ACS880 drives with SynRM motors (option
+N7502) supplement (3AUA0000145506 [English]).
2. Validate the Safe torque off function according to the instructions given in chapter
3. Validate the Safety functions (option +Q973) as described in FSO-11 user’s
manual (3AUA0000097054 [English]).
120 Start-up
Fault tracing 121
9
Fault tracing
What this chapter contains
This chapter describes the fault tracing possibilities of the drive.
LEDs
Where
Control panel mounting platform
LED
POWER
FAULT
Color
Green
Red
When the LED is lit
Control unit is powered and +15 V is supplied to the control panel.
Drive in fault state.
Warning and fault messages
See the firmware manual for the descriptions, causes and remedies of the drive control program warning and fault messages.
122 Fault tracing
Maintenance 123
10
Maintenance
What this chapter contains
This chapter contains preventive maintenance instructions.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
The table below lists the routine maintenance intervals recommended by ABB.
The recommended maintenance intervals and component replacements are based on specified operational and environmental conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. For more information on maintenance counters, see the firmware manual. Consult your local
ABB Service representative for more details on the maintenance. On the Internet, go to www.abb.com/searchchannels .
124 Maintenance
Preventive maintenance table
Component Years from start-up
1 2 3 4 5 6 7 8 9 10 11 12 …
Cooling
Main cooling fan of drive module
Auxiliary cooling fan of drive module
(frames R6 to R9)
Auxiliary IP55 cooling fan of IP55 drive module (frames R8 and R9)
Aging
(R)
R
R
R
(R)
R
R
(R)
R
R
R
(R)
…
R …
R …
Battery for control panel and ZCU control unit
R …
To maintain optimal performance and reliability of the drive, contact ABB at least once in three years for possible replacements of aging components such as circuit boards and electrolytic capacitors.
Connections and environment
Dustiness, corrosion and temperature (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) …
Spare parts
Capacitor reforming.
P P P P P P P P P P P P …
Recommended annual cleanings by user
• Clean the heatsinks of the drive module,
Recommended annual inspections by user
• Make sure that the operation conditions (dustines, moisture, temperature) agree with the drive spesifications.
(I)
P
Visual inspection and maintenance action if needed
Performance of on/off-site work (commissioning, tests, measurements or other work)
R Replacement of component if ambient temperature is below 40 °C (104 °F) and there is no cyclic heavy load and no continuous nominal load.
(R) Replacement of component in demanding operation conditions: ambient temperature is constantly higher than 40 °C (104 °F) or ambient conditions are especially dusty or humid or if the load is cyclic or if normal load is constantly high.
Heatsink
The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. When necessary, clean the heatsink as follows.
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Maintenance 125
WARNING! Use a vacuum cleaner with antistatic hose and nozzle. Using a normal vacuum cleaner creates static discharges which can damage circuit boards.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the cooling fan(s). See section
3. Blow clean compressed air (not humid) from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust. Note: If there is a risk of dust entering adjoining equipment, perform the cleaning in another room.
4. Refit the cooling fan.
Fans
The lifespan of the cooling fans of the drive depend on the running time of the fan, ambient temperature and dust concentration. See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after a fan replacement.
Replacement fans are available from ABB. Do not use other than ABB specified spare parts.
126 Maintenance
Replacing the main cooling fan of frames R1 to R3
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Release the retaining clip by pushing with a flat screwdriver and turning to the right.
3. Lift the fan assembly up.
4. Install the new fan assembly in reverse order. Make sure that the fan blows upwards.
3
2
Maintenance 127
Replacing the auxiliary cooling fan of IP55 frames R1 to R3
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the front cover by undoing the mounting screws at the sides.
3. Unplug the fan power supply wires.
4. Lift the fan off.
5. Install the new fan in reverse order. Make sure that the arrow (a) on the fan points down. Note: Bundle the wires under the clip (b) otherwise the cover will not fit properly.
3
5b
5a
128 Maintenance
Replacing the main cooling fan of frames R4 and R5
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Lift the fan mounting plate up from the front edge.
3. Unplug the power supply wires.
4. Lift the fan assembly off.
5. Install the new fan assembly in reverse order. Make sure that the fan blows upwards.
2
3
4
Maintenance 129
Replacing the auxiliary cooling fan of frame R4 and IP55 frame R5 and IP21 frame R5 types ACS880-01-xxxx-7
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the front cover.
3. Unplug the fan power supply wires.
4. Lift the fan up.
5. Install the new fan in reverse order. Make sure that the arrow in the fan points to the direction marked on the drive frame.
4
5
3
130 Maintenance
Replacing the main cooling fan of frames R6 to R8
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Undo the mounting screws of the fan mounting plate (view from bottom below).
3. Pull the fan mounting plate down from the side edge.
4. Unplug the power supply wires.
5. Lift the fan mounting plate off.
6. Remove the fan from the mounting plate.
7. Install the new fan in reverse order. Make sure that the fan blows upwards.
2
3
2
6
Maintenance 131
Replacing the auxiliary cooling fan of frames R6 to R9
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the lower front cover (see page
3. Unplug the control panel power supply wires from the control unit terminal X13 and the auxiliary cooling fan power supply wires from the terminal X208:FAN2.
4. Remove the upper front cover.
5. Release the retaining clips.
6. Lift the fan up.
7. Install the new fan in reverse order. Make sure that the arrow on the fan points up.
4
3
5
6
132 Maintenance
Replacing the IP55 auxiliary cooling fan of frames R8 and R9
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the IP55 front cover.
3. Remove the lower front cover from the IP55 cover.
4. Unplug the fan power supply wires.
5. Remove the fan.
6. Install the new fan in reverse order. Make sure that the arrow on the fan points up.
3
3
5
4
Maintenance 133
134 Maintenance
Replacing the main cooling fans of frame R9
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Undo the two mounting screws of the fan mounting plate (view from drive bottom below).
3. Turn the mounting plate downwards.
4. Disconnect the fan power supply wires.
5. Remove the fan mounting plate.
6. Remove the fan by undoing the two mounting screws.
7. Install the new fan in reverse order. Make sure that the fan blows upwards.
2 2
3
6
4
Maintenance 135
Replacing the drive (IP21, UL Type 1, frames R1 to R9)
This section gives instructions for replacing the drive module without the cable entry box. This allows you to leave the cables installed (except from disconnecting the conductors).
Note for IP55 (UL Type 12) drives: It is not allowed to remove the cable entry box.
WARNING! Obey the safety instructions, page
. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
2. Remove the front covers. See section
Connection procedure for frames R1 to R3
on page
Connection procedure for frames R4 and R5
3. For frames R6 to R9: Remove the side plates of the cable entry box by loosening the mounting screws.
4. Disconnect the power and control cables.
5. Undo the screw(s) that fasten drive module to the cable entry box.
6. Undo the two screws that fasten drive module to the wall from top.
7. Undo the two screws which attach the drive module and cable entry box to the wall. Leave the lower wall mounting screws of the cable box in place.
8. Lift the drive off.
9. Install the new drive module in reverse order.
136 Maintenance
R1…R3 R4, R5
6
6
4
6
4
5
3
4
5
Capacitors
The drive intermediate DC circuit employs several electrolytic capacitors. Their lifespan depends on the operating time of the drive, loading and ambient temperature. Capacitor life can be prolonged by lowering the ambient temperature.
In frames R1 to R3, the capacitors are integrated to the ZINT board and in frames R4 to R5 to the ZMAC board. In frames R6 to R8, the capacitors are separate.
Maintenance 137
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts.
Reforming the capacitors
The capacitors must be reformed if the drive has been stored for a year or more. See page
for information on finding out the manufacturing date. For information on
reforming the capacitors, see Converter module capacitor reforming instructions
(3BFE64059629 [English]).
Memory unit
When a drive is replaced, the parameter settings can be retained by transferring the memory unit from the defective drive to the new drive. The memory unit is located on
.
WARNING! Do not remove or insert a memory unit when the drive is powered or the control unit is powered from an external power source.
After power-up, the drive will scan the memory unit. If different parameter settings are detected, they are copied to the drive. This may take several minutes.
Replacing the memory unit
Undo the memory unit mounting screw and take the memory unit up. Replace the unit in reverse order. Note: There is a spare screw next to the memory unit slot.
138 Maintenance
Replacing the control panel battery
The battery is housed on the rear of the control panel. Replace with a new CR 2032 battery. Dispose the old battery according to local disposal rules or applicable laws.
Replacing safety functions modules (FSO-11, option
+Q973)
Do not repair safety functions modules. Replace a faulty module with a new one as described under
Installation of safety functions modules
Technical data 139
11
Technical data
What this chapter contains
This chapter contains the technical specifications of the drive, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for
CE and other markings.
Marine type-approved drives (option +C132)
See ACS880-01 marine type-approved drives (option +C132) supplement
(3AXD50000010521 [English]) for the ratings, marine-specific data and reference to valid marine type approvals.
140 Technical data
Ratings
The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table.
Drive type
ACS880-
01-
Frame size
Input rating
I
1N
A
IEC RATINGS
I
max
A
Nominal use
I
N
A
P
N kW
Output ratings
Light-overload use
I
Ld
A
P
Ld kW
Heavy-duty use
I
Hd
A
P
Hd kW
03A3-3
04A0-3
05A6-3
07A2-3
09A4-3
12A6-3
017A-3
025A-3
032A-3
038A-3
045A-3
061A-3
072A-3
U
N
= 230 V
04A6-2
06A6-2
07A5-2
10A6-2
16A8-2
24A3-2
031A-2
046A-2
061A-2
075A-2
087A-2
115A-2
145A-2
170A-2
206A-2
274A-2
U
N
= 400 V
02A4-3
17
25
32
38
45
61
5.6
8.0
10.0
12.6
1.8
2.4
3.3
4.0
11
15
18.5
22
30
37
0.75
1.1
1.5
2.2
3.0
4.0
5.5
7.5
24
30
36
43
58
68
7.6
9.5
12.0
16
2.3
3.1
3.8
5.3
11
15
18.5
22
30
37
0.75
1.1
1.5
2.2
3.0
4.0
5.5
7.5
25
32
38
45
61
72
8.0
10.0
12.9
17
2.4
3.3
4.0
5.6
29
42
54
64
76
104
9.5
12.2
16.0
21
3.1
4.1
5.6
6.8
25
32
38
45
61
72
8.0
10.0
12.9
17
2.4
3.3
4.0
5.6
R2
R3
R3
R4
R4
R5
R1
R1
R1
R2
R1
R1
R1
R1
11.0
15
18.5
22.0
30.0
37
45
55
2.2
4.0
5.5
7.5
0.55
0.75
1.1
1.5
105
145
169
213
45
61
72
87
10.6
16.8
24.3
38
3.7
4.6
6.6
7.5
37
45
55
75
15
18.5
22
30
0.75
1.1
1.5
2.2
4.0
5.5
7.5
11
138
162
196
260
58
71
83
109
4.4
6.3
7.1
10.1
16.0
23.1
29.3
44
37
45
55
75
15
18.5
22
30
0.75
1.1
1.5
2.2
4.0
5.5
7.5
11
145
170
206
274
61
75
87
115
4.6
6.6
7.5
10.6
16.8
24.3
31
46
178
247
287
362
76
104
122
148
6.3
7.8
11.2
12.8
18.0
28.6
41
64
145
170
206
274
61
75
87
115
4.6
6.6
7.5
10.6
16.8
24.3
31.0
46
R6
R7
R7
R8
R4
R5
R5
R6
R2
R2
R3
R4
R1
R1
R1
R1
7.5
11
15.0
19
22
30
2.2
3.0
4.0
5.5
0.55
0.75
1.1
1.5
Technical data 141
096A-5
124A-5
156A-5
180A-5
240A-5
260A-5
361A-5
414A-5
014A-5
021A-5
027A-5
034A-5
040A-5
052A-5
065A-5
077A-5
U
N
= 400 V
02A1-5
03A0-5
03A4-5
04A8-5
05A2-5
07A6-5
11A0-5
IEC RATINGS
Drive type
ACS880-
01-
Frame size
Input rating
Nominal use
Output ratings
Light-overload use
Heavy-duty use
087A-3
105A-3
145A-3
169A-3
206A-3
246A-3
293A-3
363A-3
R5
R6
R6
R7
R7
R8
R8
R9
I
1N
A
87
105
145
169
206
246
293
363
I
max
A
122
148
178
247
287
350
418
498
I
N
A
87
105
145
169
206
246
293
363
P
N kW
45
55
75
90
110
132
160
200
I
Ld
A
83
100
138
161
196
234
278
345
P
Ld kW
45
55
75
90
110
132
160
200
I
Hd
A
72
87
105
145
169
206
246*
293
P
Hd kW
37
45
55
75
90
110
132
160
430A-3 R9 451 * 545 451 * 250 400 200 363** 200
* Available at 25 °C (77 °F) ambient temperature. At 40 °C (104 °F) ambient temperature the current is 430A.
R4
R5
R5
R6
R2
R3
R3
R4
R1
R1
R1
R2
R1
R1
R1
R1
R6
R7
R7
R8
R8
R9
R9
2.1
3.0
3.4
4.8
5.2
7.6
11.0
14
21
27
34
40
52
65
77
96
124
156
180
240
260
361
414
3.1
4.1
5.6
6.8
9.5
12.2
16.0
21
29
42
54
64
76
104
122
148
178
247
287
350
418
542
542
2.1
3.0
3.4
4.8
5.2
7.6
11.0
14
21
27
34
40
52
65
77
96
124
156
180
240
260
361
414
0.75
1.1
1.1
1.5
2.2
3.0
4.0
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
200
200
2.0
2.8
3.2
4.6
5.0
7.2
10.4
13
19
26
32
38
49
62
73
91
118
148
171
228
247
343
393
0.55
1.1
1.1
1.5
2.2
3.0
4.0
5.5
7.5
11
15.0
18.5
22
30
37
45
55
75
90
110
132
160
200
40
52
65
77
14
21
27
34
4.8
5.2
7.6
11
1.7
2.1
3.0
3.4
96
124
156
180
240*
302
361 **
18.5
22
30
37
5.5
7.5
11
15
0.55
0.75
1.1
1.1
1.5
2.2
3.0
4.0
45
55
75
90
110
160
200
142 Technical data
Drive type
ACS880-
01-
Frame size
Input rating
I
1N
A
096A-5
124A-5
156A-5
180A-5
240A-5
260A-5
361A-5
414A-5
014A-5
021A-5
027A-5
034A-5
040A-5
052A-5
065A-5
077A-5
U
N
= 500 V
02A1-5
03A0-5
03A4-5
04A8-5
05A2-5
07A6-5
11A0-5
R4
R5
R5
R6
R2
R3
R3
R4
R1
R1
R1
R2
R1
R1
R1
R1
R6
R7
R7
R8
R8
R9
R9
52
65
77
96
21
27
34
40
5.2
7.6
11.0
14
2.1
3.0
3.4
4.8
124
156
180
240
260
361
414
76
104
122
148
29
42
54
64
9.5
12.2
16.0
21
3.1
4.1
5.6
6.8
178
247
287
350
418
542
542
IEC RATINGS
I
max
A
Nominal use
I
N
A
P
N kW
Output ratings
Light-overload use
I
Ld
A
P
Ld kW
Heavy-duty use
I
Hd
A
P
Hd kW
2.1
3.0
3.4
4.8
5.2
7.6
11.0
14
21
27
34
40
52
65
77
96
124
156
180
240
260
361
414
0.75
1.1
1.5
2.2
3.0
4.0
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
160
200
250
2.0
2.8
3.2
4.6
4.9
7.2
10.4
13
19
26
32
38
49
62
73
91
118
148
171
228
247
343
393
0.75
1.1
1.5
2.2
3.0
4.0
5.5
7.5
11.0
15
18.5
22
30
37
45
55
75
90
110
132
160
200
250
40
52
65
77
14
21
27
34
4.8
5.2
7.6
11
1.7
2.1
3.0
3.4
96
124
156
180
240*
302
361**
22
30
37
45
7.5
11
15.0
19
2.2
3.0
4.0
5.5
0.55
0.75
1.1
1.5
55
75
90
110
132
200
200
Technical data 143
Drive type
ACS880-
01-
Frame size
Input rating
I
1N
A
042A-7
049A-7
061A-7
084A-7
098A-7
119A-7
142A-7
174A-7
210A-7
271A-7
U
N
= 690 V
07A3-7
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
R7
R8
R8
R9
R9
R5
R6
R6
R7
R5
R5
R5
R5
R5
R5
R5
R5
119
142
174
210
271
49
61
84
98
22
26
35
42
7.3
9.8
14.2
18
198
250
274
384
411
76
104
124
168
44
54
64
74
12.2
18
22
30
IEC RATINGS
I
max
A
Nominal use
I
N
A
P
N kW
Output ratings
Light-overload use
I
Ld
A
P
Ld kW
Heavy-duty use
I
Hd
A
P
Hd kW
7.3
9.8
14.2
18
22
26
35
42
49
61
84
98
119
142
174
210
271
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
160
200
250
6.9
9.3
13.5
17
21
25
33
40
47
58
80
93
113
135
165
200
257
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
160
200
250
98
119
142
174
210
42
49
61
84
18
22
26
35
5.6
7.3
9.8
14.2
3AXD00000588487
90
110
132
160
200
37
45
55
75
15
18.5
22
30
4
5.5
7.5
11
144 Technical data
Drive type
ACS880-
01-
Frame size
Input rating
I
1N
A
Max. current
I
max
A
NEMA RATINGS
Output ratings
Light-overload use
I
Ld
A kW
P
Ld hp
Heavy-duty use
I
Hd
A kW
P
Hd hp
046A-2
061A-2
075A-2
087A-2
115A-2
145A-2
170A-2
206A-2
274A-2
U
N
= 230 V
04A6-2
06A6-2
07A5-2
10A6-2
16A8-2
24A3-2
031A-2
R1
R1
R1
R1
R2
R2
R3
R4
R4
R5
R5
R6
R6
R7
R7
R8
4.4
6.3
7.1
10.1
16.0
23.1
29.3
44
58
71
83
109
138
162
196
260
6.3
7.8
11.2
12.8
18.0
28.6
41
64
76
104
122
148
178
247
287
362
4.4
6.3
7.1
10.1
16.0
23.1
29.3
44
58
71
83
109
138
162
196
260
0.75
1.1
1.5
2.2
4.0
5.5
7.5
11
15
18.5
22
30
37
45
55
75
1.0
1.5
2.0
3.0
5.0
7.5
10
15
20
25
30
40
50
60
75
100
3.7
4.6
6.6
7.5
10.6
16.8
24.3
38
45
61
72
87
105
145
169
213
11.0
15
18.5
22.0
30.0
37
45
55
2.2
4.0
5.5
7.5
0.55
0.75
1.1
1.5
40
50
60
75
15
20
25
30
3.0
5.0
7.5
10
0.75
1.0
1.5
2.0
Technical data 145
Drive type
ACS880-
01-
Frame size
Input rating
I
1N
A
Max. current
I
max
A
NEMA RATINGS
Output ratings
Light-overload use
I
Ld
A kW
P
Ld hp
Heavy-duty use
I
Hd
A kW
P
Hd hp
R4
R5
R5
R6
R2
R3
R3
R4
R1
R1
R1
R2
R1
R1
R1
R1
R8
R9
R9
R9
R6
R7
R7
R8
096A-5
124A-5
156A-5
180A-5
240A-5
260A-5
302A-5
361A-5
414A-5
014A-5
021A-5
027A-5
034A-5
040A-5
052A-5
065A-5
077A-5
U
N
= 460 V
02A1-5
03A0-5
03A4-5
04A8-5
05A2-5
07A6-5
11A0-5
2.1
3.0
3.4
4.8
5.2
7.6
11
14
21
27
34
40
52
65
77
96
124
156
180
240
260
302
361
414
3.1
4.1
5.6
6.8
9.5
12.2
16.0
21
29
42
54
64
76
104
122
148
178
247
287
350
418
498
542
542
2.1
3.0
3.4
4.8
5.2
7.6
11
14
21
27
34
40
52
65
77
96
124
156
180
240
260
302
361
414***
0.75
1.1
1.5
2.2
3.0
4.0
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
132
200
200
250
1.0
1.5
2.0
3.0
3.0
5.0
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
200
250
300
350
40
52
65
77
14
21
27
34
4.8
5.2
7.6
11
1.7
2.1
3.0
3.4
96
124
156
180
240*
260
302
361**
22
30
37
45
7.5
11
15
18.5
0.55
0.75
1.1
1.5
1.5
2.2
4.0
5.5
110
132
200
200
55
75
90
110
30
40
50
60
10
15
20.0
25
2.0
3.0
5.0
7.5
0.75
1.0
1.5
2.0
150
200
250
300
75
100
125
150
146 Technical data
Drive type
ACS880-
01-
Frame size
Input rating
I
1N
A
Max. current
I
max
A
NEMA RATINGS
Output ratings
Light-overload use
I
Ld
A kW
P
Ld hp
Heavy-duty use
I
Hd
A kW
P
Hd hp
042A-7
049A-7
061A-7
084A-7
098A-7
119A-7
142A-7
174A-7
210A-7
271A-7
U
N
= 575 V
07A3-7
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
R5
R5
R5
R5
R5
R5
R5
R5
R5
R6
R6
R7
R7
R8
R8
R9
R9
9
11
17
22
27
32
41
52
52
62
77
99
125
144
180
242
271
12.2
18
22
30
44
54
64
74
76
104
124
168
198
250
274
384
411
9
11
17
22
27
32
41
52
52
62
77
99
125
144
180
242
271
5.5
7.5
11
15
18.5
22
30
37
37
45
55
75
90
110
132
160
200
7.5
10
15
20
25
30
40
50
50
60
75
100
125
150
200
250
250
6.1
9
11
17
22
27
32
41
41
52
62
77
99
125
144
192
242*
75
90
110
132
160
30
37
45
55
15
18.5
22
30
4.0
5.5
7.5
11
3AXD00000588487
100
125
150
200
250
40
50
60
75
20
25
30
40
5.0
7.5
10
15
Technical data 147
Definitions
U
N
I
1N
I
N
P
N
I
Ld
P
Ld
I
max
Supply voltage range
Nominal rms input current
Nominal output current (available continuously with no over-loading)
Typical motor power in no-overload use
Continuous rms output current allowing 10% overload for 1 minute every 5 minutes
Typical motor power in light-overload use
Maximum output current. Available for 10 seconds at start. then as long as allowed by drive temperature.
I
Hd
Continuous rms output current allowing 50% overload for 1 minute every 5 minutes.
* Continuous rms output current allowing 30% overload for 1 minute every 5 minutes.
** Continuous rms output current allowing 25% overload for 1 minute every 5 minutes.
*** at an ambient temperature of 30 °C (86 °F). 393 A at 40 °C (104 °F).
P
Hd
Typical motor power in heavy-duty use
Note 1: The ratings apply at an ambient temperature of 40 °C (104 °F).
Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current.
The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.
Derating
Ambient temperature derating
IP21 (UL Type 1) drive types and other IP55 (UL Type 12) types than listed in the following subheadings
In the temperature range +40…55 °C (+104…131 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k):
k
1.00
0.95
0.90
0.85
0.80
-15 °C
-59 °F
…
+40 °C
+104 °F
+50 °C
+122 °F
+55 °C
+131 °F
T
148 Technical data
IP55 (UL Type 12) drive types -274A-2, 293A-3, -260A-5, -302A-5 and -174A-7
In the temperature range +40…45 °C (+104…113 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). In the temperature range +45…55 °C
(+113…131 °F), the rated output current is derated by 2.5% for every added 1 °C
(1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k):
k
1.00
0.95
0.90
0.85
0.80
0.75
0.70
-15 °C
-59 °F
…
+40 °C
+104 °F
+45 °C
+113 °F
+50 °C
+122 °F
+55 °C
+131 °F
T
IP55 (UL Type 12) drive type -240A-5
In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). In the temperature range +50…55 °C
(+122…131 °F), the rated output current is derated by 2.5% for every added 1 °C
(1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k):
k
1.00
0.95
0.90
0.85
0.80
0.75
-15 °C
-59 °F
…
+40 °C
+104 °F
+45 °C
+113 °F
+50 °C
+122 °F
+55 °C
+131 °F
T
Technical data 149
IP55 (UL Type 12) drive types -363A-3 and -361A-5
In the temperature range +40…45 °C (+104…113 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). In the temperature range +45…50 °C
(+113…122 °F), the rated output current is derated by 2.5% for every added 1 °C
(1.8 °F). In the temperature range +50…55 °C (+122…131 °F), the rated output current is derated by 5% for every added 1 °C (1.8 °F).The output current can be calculated by multiplying the current given in the rating table by the derating factor (k):
k
1.00
0.95
0.90
0.85
0.80
0.75
0.70
0.65
0.60
0.55
-15 °C
-59 °F
…
+40 °C
+104 °F
+45 °C
+113 °F
+50 °C
+122 °F
+55 °C
+131 °F
T
150 Technical data
IP55 (UL Type 12) drive type -210A-7
In the temperature range +40…45 °C (+104…113 °F), the rated output current is derated by 3.5% for every added 1 °C (1.8 °F). The maximum temperature is 45 °C
(113 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k):
k
1.00
0.95
0.90
0.85
0.80
-15 °C
-59 °F
…
+40 °C
+104 °F
+45 °C
+113 °F
T
IP55 (UL Type 12) types -0430A-3, -0414A-5 and -0271A-7
The maximum ambient temperature is 35 °C (95 °F).
Altitude derating
At altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the continuous output currents given above must be derated 1% for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool.
Switching frequency derating
Switching frequencies other than default can require output current derating. Please, contact ABB for more information.
Fuses (IEC)
gG and aR fuses for protection against short-circuit in the input power cable or drive are listed below. Either fuse type can be used for frames R1 to R6 if it operates rapidly enough. The operating time depends on the supply network impedance and the cross-sectional area and length of the supply cable. For frames R7 to R9 ultrarapid (aR) fuses must be used.
Implementing thermal overload and short-circuit protection
on page
Note 2: Fuses with higher current rating than the recommended ones must not be used. Fuses with lower current rating can be used.
Technical data 151
Note 3: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.
aR fuses (frames R1 to R9)
Drive type
ACS880-
01-
U
N
= 230 V
04A6-2
06A6-2
07A5-2
10A6-2
16A8-2
24A3-2
031A-2
046A-2
061A-2
075A-2
087A-2
115A-2
145A-2
170A-2
206A-2
Min. shortcircuit current
1)
(A)
30
30
30
53
65
120
160
280
300
380
380
500
700
1000
1280
274A-2
U
N
= 400 V
02A4-3
03A3-3
04A0-3
05A6-3
07A2-3
65
65
65
65
09A4-3
12A6-3
017A-3
025A-3
65
65
65
120
032A-3
038A-3
045A-3
061A-3
072A-3
120
170
170
280
380
480
Ultrarapid (aR) fuses (one fuse per phase)
Input current
(A)
A A
2 s V
Fuse
Manufacturer
4.6
6.6
7.5
10.6
16.8
24.3
31.0
46
61
75
87
115
145
170
206
274
2.4
3.3
4.0
5.6
8.0
10.0
12.9
17
25
32
38
45
61
72
16
16
16
20
25
40
50
80
100
125
125
160
200
250
315
48
48
48
78
130
460
770
2550
2450
3700
3700
7500
15000
28500
46500
690
690
690
690
690
690
690
690
690
690
690
690
690
690
690
400 105000 690
25
25
25
25
25
25
25
40
40
63
63
80
130
130
130
130
130
130
130
460
460
1450
1450
2550
690
690
690
690
690
690
690
690
690
690
690
690
100 4650 690
125 8500 690
Bussmann 170M1559
Bussmann 170M1559
Bussmann 170M1559
Bussmann 170M1560
Bussmann 170M1561
Bussmann 170M1563
Bussmann 170M1564
Bussmann 170M1566
Bussmann 170M3812
Bussmann 170M3813
Bussmann 170M3813
Bussmann 170M3814
Bussmann 170M3815
Bussmann 170M3816
Bussmann 170M3817
Bussmann 170M3819
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Type
170M1561
170M1561
170M1561
170M1561
170M1561
170M1561
170M1561
170M1563
170M1563
170M1565
170M1565
170M1566
170M1567
170M1568
Type
IEC 60263
1
1
1
1
1
1
1
1
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
152 Technical data
Drive type
ACS880-
01-
087A-3
105A-3
145A-3
169A-3
206A-3
246A-3
293A-3
363A-3
430A-3
U
N
= 500 V
02A1-5
Min. shortcircuit current
1)
(A)
480
700
700
1280
1280
1520
1810
2620
3010
03A0-5
03A4-5
04A8-5
05A2-5
65
65
65
65
07A6-5
11A0-5
014A-5
021A-5
65
65
65
120
027A-5
034A-5
040A-5
052A-5
120
170
170
280
065A-5
077A-5
096A-5
124A-5
300
480
480
700
156A-5
180A-5
240A-5
260A-5
700
1280
1280
1520
361A-5
414A-5
1810
2620
3010
Ultrarapid (aR) fuses (one fuse per phase)
Input current
(A)
A A
2 s V
Fuse
Manufacturer
87
105
145
169
206
246
293
363
430
2.1
3.0
3.4
4.8
5.2
7.6
11.0
14
21
27
34
40
52
65
77
96
124
156
180
240
260
361
414
125
160
200
315
315
350
200
8500
16000
28000
46500
46500
68500
28000
690
690
690
690
690
690
400 105000 690
550 190000 690
630 275000 690
25
25
25
25
25
25
25
40
40
63
63
80
100 4650 690
125 8500 690
125 8500 690
160 16000 690
315
315
350
130
130
130
130
130
130
130
460
460
1450 690
1450 690
2550 690
46500
46500
68500
690
690
690
690
690
690
690
690
690
690
690
690
690
400 105000 690
550 190000 690
630 275000 690
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Type
170M1568
170M1569
170M1570
170M3817
170M3817
170M3818
170M3819
170M5811
170M5812
Bussmann 170M1561
Bussmann 170M1561
Bussmann 170M1561
Bussmann 170M1561
Bussmann 170M1561
Bussmann 170M1561
Bussmann 170M1561
Bussmann 170M1563
Bussmann 170M1563
Bussmann 170M1565
Bussmann 170M1565
Bussmann 170M1566
Bussmann 170M1567
Bussmann 170M1568
Bussmann 170M1568
Bussmann 170M1569
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
170M1570
170M3817
170M3817
170M3818
170M3819
170M5811
170M5812
Type
IEC 60263
1
2
1
1
2
000
000
000
1
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
1
2
2
000
1
1
1
Technical data 153
Drive type
ACS880-
01-
U
N
= 690s V
07A3-7
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
042A-7
049A-7
061A-7
084A-7
098A-7
119A-7
142A-7
174A-7
210A-7
271A-7
Min. shortcircuit current
1)
(A)
40
53
94
120
160
160
170
280
280
480
700
700
700
1000
1280
1610
1610
Ultrarapid (aR) fuses (one fuse per phase)
Input current
(A)
A A
2 s V
Fuse
Manufacturer
7.3
9.8
14.2
18
22
26
35
42
49
61
84
98
119
142
174
210
271
16
20
32
40
50
50
63
80
80
125
160
160
200
250
315
400
400
48
78
270
460
770
770
1450
2550
2550
8500
16000
16000
15000
28500
46500
74000
74000
690
690
690
690
690
690
690
690
690
690
690
690
690
690
690
690
690
Type
Bussmann 170M1559
Bussmann 170M1560
Bussmann 170M1562
Bussmann 170M1563
Bussmann 170M1564
Bussmann 170M1564
Bussmann 170M1565
Bussmann 170M1566
Bussmann 170M1566
Bussmann 170M1568
Bussmann 170M1569
Bussmann 170M1569
Bussmann 170M3815
Bussmann 170M3816
Bussmann 170M3817
Bussmann 170M5808
Bussmann 170M5808
Type
IEC 60263
1
2
1
1
2
000
000
000
0
000
000
000
000
000
000
000
000
1)
minimum short-circuit current of the installation
154 Technical data
gG fuses (frames R1 to R6)
Check on the fuse time-current curve to ensure the operating time of the fuse is below 0.5 seconds. Obey the local regulations.
Drive type
ACS880-
01…
Min. shortcircuit current
1)
A
Input current gG fuses (one fuse per phase)
Fuse
A A A
2 s V Manufacturer Type IEC size
032A-3
038A-3
045A-3
061A-3
072A-3
087A-3
105A-3
145A-3
03A3-3
04A0-3
05A6-3
07A2-3
09A4-3
12A6-3
017A-3
025A-3
U
N
= 230 V
04A6-2
06A6-2
07A5-2
10A6-2
16A8-2
24A3-2
031A-2
046A-2
061A-2
075A-2
087A-2
115A-2
145A-2
U
N
= 400 V
02A4-3
200
350
400
500
40
80
120
120
800
1000
1300
1700
2300
61
72
87
105
145
25
32
38
45
8.0
10.0
12.9
17
2.4
3.3
4.0
5.6
250
350
400
500
800
1000
1000
1300
1700
80
120
120
200
17
40
40
80
4.6
6.6
7.5
10.6
16.8
24.3
31.0
46
61
75
87
115
145
6
10
16
16
110
360
740
740
25
40
2500
7700
500
500
50 16000 500
63 20100 500
500
500
500
500
80 37500 500
100 65000 500
125 100000 500
160 170000 500
200 300000 500
10
16
16
25
6
10
4
6
53
110
110
355
355
700
700
2500
32
40
4500
7700
500
500
50 15400 500
63 21300 500
80 37000 500
100 63600 500
100 63600 500
125 103000 500
160 185000 500
500
500
500
500
500
500
500
500
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
OFAF000H6
OFAF000H10
OFAF000H16
OFAF000H16
OFAF000H25
OFAF000H40
OFAF000H50
OFAF000H63
OFAF000H80 000
OFAF000H100 000
OFAF00H125
OFAF00H160
OFAF0H200
00
00
0
000
000
000
000
000
000
000
000
OFAF000H4
OFAF000H6
OFAF000H6
OFAF000H10
OFAF000H10
OFAF000H16
OFAF000H16
OFAF000H25
OFAF000H32
OFAF000H40
OFAF000H50
OFAF000H63
OFAF000H80 000
OFAF000H100 000
OFAF000H100 000
OFAF00H125 00
OFAF00H160 00
000
000
000
000
000
000
000
000
000
000
000
000
Technical data 155
Drive type
ACS880-
01…
Min. shortcircuit current
1)
A
Input current gG fuses (one fuse per phase)
Fuse
A A A
2 s V Manufacturer
096A-5
124A-5
U
N
= 690 V
07A3-7
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
042A-7
049A-7
061A-7
084A-7
014A-5
021A-5
027A-5
034A-5
040A-5
052A-5
065A-5
077A-5
U
N
= 500 V
02A1-5
03A0-5
03A4-5
04A8-5
05A2-5
07A6-5
11A0-5
250
350
400
500
800
1000
1000
1300
1700
80
120
120
200
17
40
40
80
115
145
190
280
450
450
520
800
800
1050
1700
2.1
3.0
3.4
4.8
5.2
7.6
11.0
14
21
27
34
40
52
65
77
96
124
22
26
35
42
7.3
9.8
14.2
18
49
61
84
4
6
6
10
10
16
16
25
32
40
53
110
110
355
355
700
700
2500
4500
7700
500
500
500
500
500
500
500
500
500
500
50 15400 500
63 21300 500
80 37000 500
100 63600 500
100 63600 500
125 103000 500
160 185000 500
16
20
1200
2400
690
690
25 4000 690
35 12000 690
50 24000 690
50 24000 690
63 30000 690
80 51000 690
80 51000 690
100 95000 690
160 240000 690
1)
minimum short-circuit current of the installation
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
ABB
Type
OFAF000H4
OFAF000H6
OFAF000H6
OFAF000H10
OFAF000H10
OFAF000H16
OFAF000H16
OFAF000H25
OFAF000H32
OFAF000H40
OFAF000H50
OFAF000H63
IEC size
000
000
000
000
000
000
000
000
000
000
000
000
OFAF000H80 000
OFAF000H100 000
OFAF000H100 000
OFAF00H125 00
OFAF00H160 00
OFAA000GG16 000
OFAA000GG20 000
OFAA000GG25 000
OFAA000GG35 000
OFAA000GG50 000
OFAA000GG50 000
OFAA000GG63 000
OFAA0GG80 0
OFAA0GG80
OFAA0GG100
OFAA1GG160
0
0
1
156 Technical data
Quick guide for selecting between gG and aR fuses
The combinations (cable size, cable length, transformer size and fuse type) in this table fulfil the minimum requirements for the proper operation of the fuse. Use this table to select between gG and aR fuses or calculate the short-circuit current of the
installation as described under
Calculating the short-circuit current of the installation
on page
).
Drive type
ACS880-
01…
Cable type
Copper Aluminium
mm
2 mm
2
Supply transformer minimum apparent power S
N
(kVA)
Maximum cable legth with gG fuses
10 m
Maximum cable legth
50 m 100 m 10 m
with aR fuses
100 m 200 m
03A3-3
04A0-3
05A6-3
07A2-3
09A4-3
12A6-3
017A-3
025A-3
032A-3
038A-3
045A-3
061A-3
072A-3
087A-3
105A-3
U
N
= 230 V
04A6-2
06A6-2
07A5-2
10A6-2
16A8-2
24A3-2
031A-2
046A-2
061A-2
075A-2
087A-2
115A-2
145A-2
U
N
= 400 V
02A4-3
3×6
3×10
3×10
3×16
3×25
3×35
3×35
3×50
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×6
3×1.5
3×1.5
3×1.5
3×1.5
3×6
3×6
3×10
3×16
3×25
3×35
3×35
3×50
3×95
-
-
-
3×25
3×25
3×35
3×50
3×70
-
-
-
-
-
-
-
-
-
-
-
3×35
-
-
-
-
3×35
3×50
3×70
3×70
3×120
18
23
23
34
5.8
8.2
8.2
13
3.1
3.1
3.1
5.8
3.1
3.1
3.1
3.1
42
52
52
68
13
18
21
26
4.4
8.4
8.4
10
0.82
2.0
2.0
4.4
39
49
49
65
12
17
20
24
4.0
6.2
6.2
9.8
0.82
1.9
1.9
4.0
39
48
48
63
12
17
19
24
3.8
5.8
5.8
9.6
0.82
1.9
1.9
3.8
5.8
11
12
15
1.1
2.4
4.3
4.3
24
29
39
52
70
5.5
9.7
11
14
1.1
2.2
3.3
3.3
22
28
36
48
64
1.8
3.3
4.4
7.7
1.1
1.1
1.1
1.5
8.3
11
11
14
19
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1.8
3.5
4.6
8.2
1.2
1.2
1.2
1.8
8.6
11
11
14
20
19
24
24
35
5.9
8.3
8.3
14
3.4
3.4
3.4
5.9
3.4
3.4
3.4
3.4
20
25
25
37
6.2
8.7
8.7
15
5.0
5.0
5.0
6.2
5.0
5.0
5.0
5.0
Technical data 157
Drive type
ACS880-
01…
Cable type
Copper Aluminium
mm
2
3×95 mm
2
3×95
065A-5
077A-5
096A-5
124A-5
U
N
= 690 V
07A3-7
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
042A-7
049A-7
061A-7
084A-7
145A-3
U
N
= 500 V
02A1-5
03A0-5
03A4-5
04A8-5
05A2-5
07A6-5
11A0-5
014A-5
021A-5
027A-5
034A-5
040A-5
052A-5
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×1.5
3×6
3×6
3×10
3×10
3×16
3×25
3×35
3×35
3×50
3×95
3×1.5
3×1.5
3×2.5
3×4
3×6
3×10
3×10
3×16
3×16
3×25
3×35
-
-
-
3×35
3×35
3×50
3×70
3×70
3×120
-
-
-
-
-
-
-
-
-
3×25
3×25
3×25
-
-
-
-
3×25
3×35
3×50
Supply transformer minimum apparent power S
N
(kVA)
Maximum cable legth with gG fuses
Maximum cable legth with aR fuses
10 m
82
50 m 100 m
85 88
10 m
46
100 m 200 m
47 50
1.0
2.4
2.4
4.8
4.8
7.2
7.2
12
15
21
24
30
48
60
60
78
103
9.5
12
16
23
37
37
43
66
66
87
141
1.0
2.4
2.4
4.9
4.9
7.5
7.5
12
15
21
24
30
49
61
61
80
105
9.7
12
16
24
38
38
44
67
67
89
145
1.0
2.4
2.4
5.2
5.2
8.9
8.9
12
16
22
25
31
51
63
63
83
108
10.4
14
17
25
41
39
45
70
70
91
152
3.9
3.9
3.9
3.9
3.9
3.9
3.9
7.2
7.2
10
10
17
18
29
29
42
57
3.3
4.4
7.8
9.9
13
13
14
23
23
40
58
18
29
29
43
59
7.3
10
10
17
4.1
4.1
4.1
7.3
4.1
4.1
4.1
4.1
3.3
4.5
8.0
10
13
13
14
23
23
40
59
19
30
30
45
61
7.6
11
11
18
5.0
5.0
5.0
7.6
5.0
5.0
5.0
5.0
14
14
14
24
3.5
4.7
8.6
11
24
42
61
158 Technical data
Calculating the short-circuit current of the installation
Check that the short-circuit current of the installation is at least the value given in the fuse table.
The short-circuit current ot the installation can be calculated as follows:
U
I
k2-ph
=
2 ·
R
c
2
+ (Z k
+ X c
)
2 where
I
k2-ph
= short-circuit current in symmetrical two-phase short-circuit
U = network line-to-line voltage (V)
R
c
= cable resistance (ohm)
Z
k
= z k
· U
N
2
/S
N
= transformer impedance (ohm) z k
= transformer impedance (%)
U
N
= transformer rated voltage (V)
S
N
= nominal apparent power of the transformer (kVA)
X
c
= cable reactance (ohm).
Calculation example
Drive:
• ACS880-01-145A-3
• supply voltage = 410 V
Transformer:
• rated power S
N
= 600 kVA
• rated voltage (drive supply voltage) U
N
= 430 V
• transformer impedance z k
= 7.2%.
Supply cable:
• length = 170 m
• resistance/length = 0.398 ohm/km
• reactance/length = 0.082 ohm/km.
Technical data 159
Z
k
= z
k
·
U
N
2
S
N
= 0.072
·
R
c
= 170 m · 0.398
ohm km
(430 V)
2
600 kVA
= 22.19 mohm
= 67.66 mohm
X
c
= 170
I
k2-ph
= m · 0.082
ohm km
= 13.94 mohm
410 V
2 ·
(67.66 mohm)
2
+ (22.19 mohm + 13.94 mohm)
2
= 2.7 kA
The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF00H160 (1700 A). -> The 500 V gG fuse (ABB
Control OFAF00H160) can be used.
Fuses (UL)
UL class T fuses for branch circuit protection per NEC are listed below. Fast acting class T or faster fuses are recommended in the USA. Check on the fuse time-
current curve to ensure the operating time of the fuse is below 0.5 seconds for units of frame sizes R1 to R6 and below 0.1 seconds for units of frame sizes R7 to R9. Obey local regulations.
Note 1: See also
Implementing thermal overload and short-circuit protection
on page
.
Note 2: Fuses with higher current rating than the recommended ones must not be used. Fuses with lower current rating can be used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.
160 Technical data
Input current
A
138
162
196
260
58
71
83
109
4.4
6.3
7.1
10.1
16.0
23.1
29.3
44
52
65
77
96
21
27
34
40
124
156
180
240
260
5.2
7.6
11
14
2.1
3.0
3.4
4.8
Drive type
ACS880-01…
027A-5
034A-5
040A-5
052A-5
065A-5
077A-5
096A-5
124A-5
03A0-5
03A4-5
04A8-5
05A2-5
07A6-5
11A0-5
014A-5
021A-5
156A-5
180A-5
240A-5
260A-5
U
N
= 230 V
04A6-2
06A6-2
07A5-2
10A6-2
16A8-2
24A3-2
031A-2
046A-2
061A-2
075A-2
087A-2
115A-2
145A-2
170A-2
206A-2
274A-2
U
N
= 460 V
02A1-5
A
200
250
300
400
100
125
125
150
25
40
50
80
15
15
15
20
80
90
110
150
35
40
50
60
200
225
300
350
400
10
15
20
25
3
6
6
10
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
V
Fuse (one fuse per phase)
Manufacturer Type
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
JJS-100
JJS-125
JJS-125
JJS-150
JJS-200
JJS-250
JJS-300
JJS-400
JJS-15
JJS-15
JJS-15
JJS-20
JJS-25
JJS-40
JJS-50
JJS-80
UL class
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
JJS-35
JJS-40
JJS-50
JJS-60
JJS-80
JJS-90
JJS-110
JJS-150
JJS-3
JJS-6
JJS-6
JJS-10
JJS-10
JJS-15
JJS-20
JJS-25
JJS-200
JJS-225
JJS-300
JJS-350
JJS-400
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
Drive type
ACS880-01…
061A-7
084A-7
098A-7
119A-7
142A-7
174A-7
210A-7
271A-7
302A-5
361A-5
414A-5
U
N
= 575 V
07A3-7
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
042A-7
049A-7
125
144
180
242
271
52
62
77
99
27
32
41
52
9.0
11
17
22
Input current
A
302
361
414
200
250
300
400
400
80
110
150
150
50
50
60
80
15
20
30
40
A
400
500
600
Technical data 161
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
Fuse (one fuse per phase)
V
600
600
600
Manufacturer
Bussmann
Bussmann
Bussmann
Type
JJS-400
JJS-500
JJS-600
UL class
T
T
T
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
Bussmann
JJS-80
JJS-110
JJS-150
JJS-150
JJS-200
JJS-250
JJS-300
JJS-400
JJS-400
JJS-15
JJS-20
JJS-30
JJS-40
JJS-50
JJS-50
JJS-60
JJS-80
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
162 Technical data
Dimensions. weights and free space requirements
Frame
R5
R6
R7
R8
R1
R2
R3
R4
R9
Frame
R5
R6
R7
R8
R9
R1
R2
R3
R4
525
576
730
726
H1
mm
450
450
880
963
955
475
576
730
726
H1
mm
409
409
880
963
955
-
-
-
-
H2
mm
-
-
-
-
-
420
490
596
569
H2
mm
370
370
600
681
680
251
284
300
380
IP55
W
mm
162
155
172
203
203
IP21
W
mm
155
252
284
300
380
161
180
203
203
261
274
274
357
D
mm
226
249
365
386
413
327
344
344
421
D
mm
292
315
423
452
477
10
18.5
23
45
55
72
100
Weight
kg
6
8
10
18.5
23
45
H1
in.
H2
in.
UL type 1
W
in.
D
in.
16.11
14.57
6.10
8.89
16.11
14.57
6.10
9.80
18.71
16.54
6.77
10.28
22.70
19.30
7.99
10.80
28.74
23.46
7.99
10.79
28.60
22.40
9.92
14.09
55
70
98
34.70
23.60
11.22
14.37
37.90
26.82
11.81
15.21
37.59
26.77
14.96
16.27
UL type 12
Weight H1 *
kg in.
6
8
17.72
17.72
H3
in.
-
-
W **
in.
6.38
6.38
D
in.
11.50
12.40
20.70
22.70
28.73
28.60
34.66
37.90
37.59
-
-
-
-
-
-
-
7.09
12.87
7.99
13.54
7.99
13.54
9.92
16.46
11.18
16.65
11.81
17.78
14.96
18.78
Weight
lb
13
18
22
41
51
99
121
154
216
Weight
lb
20
18
22
41
51
99
121
159
220
H1 Height with cable entry box.
H2 Height without cable entry box
H3 Height with hood
W Width with cable entry box
D Depth with cable entry box
* Hood increases height with 155 mm (6.10 in) in frames R4 to R8 and with 230 mm
(9.06 in) in frame R9.
** Hood increases width with 23 mm (0.91 in) in frames R4 and R5, 40 mm (1.57 in) in frames R6 and R7 and 50 mm (1.97 in) in frames R8 and R9.
Note: For more information on dimensions, see chapter
.
200 mm (7.87 in.) free space is required at top of the drive.
300 mm (11.81 in.) free space (when measured from the drive base without the cable entry box) is required at bottom of the drive.
Technical data 163
Losses, cooling data and noise
Drive type
ACS880-01-
Frame Air flow
m
3
/h ft
3
/min
032A-3
038A-3
045A-3
061A-3
072A-3
087A-3
105A-3
145A-3
03A3-3
04A0-3
05A6-3
07A2-3
09A4-3
12A6-3
017A-3
025A-3
169A-3
206A-3
246A-3
U
N
= 230 V
04A6-2
06A6-2
07A5-2
10A6-2
16A8-2
24A3-2
031A-2
046A-2
061A-2
075A-2
087A-2
115A-2
145A-2
170A-2
206A-2
274A-2
U
N
= 400 V
02A4-3
R4
R5
R5
R6
R2
R3
R3
R4
R6
R7
R7
R8
R1
R1
R1
R2
R1
R1
R1
R1
435
450
450
550
280
280
280
435
88
88
134
134
44
44
44
44
R6
R7
R7
R8
R4
R5
R5
R6
R2
R2
R3
R4
R1
R1
R1
R1
256
265
265
324
165
165
165
256
52
52
79
79
26
26
26
26
280
280
280
435
88
134
134
134
435
450
450
550
44
44
44
88
44
44
44
44
165
165
165
256
52
79
79
79
256
265
265
324
26
26
26
52
26
26
26
26
Heat dissipation
W
630
680
730
840
940
1260
1500
2100
232
337
457
500
73
94
122
172
337
457
562
667
907
1117
1120
1295
94
122
172
232
30
40
52
73
1440
1940
2310
3300
Noise
dB(A)
62
62
62
67
51
57
57
62
67
67
67
65
46
46
46
51
46
46
46
46
67
67
67
65
62
62
62
67
51
51
57
62
46
46
46
46
164 Technical data
Drive type
ACS880-01-
027A-5
034A-5
040A-5
052A-5
065A-5
077A-5
096A-5
124A-5
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
042A-7
049A-7
061A-7
156A-5
180A-5
240A-5
260A-5
302A-5
361A-5
414A-5
U
N
= 690 V
07A3-7
293A-3
363A-3
430A-3
U
N
= 500 V
02A1-5
03A0-5
03A4-5
04A8-5
05A2-5
07A6-5
11A0-5
014A-5
021A-5
Frame
280
280
280
435
88
134
134
134
44
44
44
88
44
44
44
44
435
450
450
550
550
1150
1150
1150
280
280
280
280
280
280
280
280
280
435 m
3
/h
550
1150
1150
Air flow
ft
3
/min
324
677
677
165
165
165
256
52
79
79
79
26
26
26
52
26
26
26
26
324
677
677
677
256
265
265
324
165
165
165
165
165
165
165
165
165
256
R8
R9
R9
R4
R5
R5
R6
R2
R3
R3
R4
R1
R1
R1
R2
R1
R1
R1
R1
R8
R9
R9
R9
R6
R7
R7
R8
R5
R5
R5
R5
R5
R5
R5
R5
R5
R6
Heat dissipation
W
3900
4800
6000
337
457
562
667
907
1117
1120
1295
94
122
172
232
30
40
52
73
1440
1940
2310
3300
3900
4200
4800
6000
578
660
864
998
217
284
399
490
1120
1295
62
62
62
67
51
57
57
62
46
46
46
51
46
46
46
46
65
68
68
68
67
67
67
65
62
62
62
62
62
62
62
62
62
67
Noise
dB(A)
65
68
68
Drive type
ACS880-01-
084A-7
098A-7
119A-7
142A-7
174A-7
210A-7
271A-7
R6
R7
R7
R8
R8
R9
R9
Frame
m
3
/h
435
450
450
550
550
1150
1150
Air flow
ft
3
/min
256
265
265
324
324
677
677
Heat dissipation
W
1440
1940
2310
3300
3900
4200
4800
Technical data 165
Noise
dB(A)
67
67
67
65
65
68
68
166 Technical data
Terminal and lead-through data for the power cables
IEC
Input, motor, resistor and DC cable terminal screw sizes, accepted wire sizes (per phase) and tightening torques (T) are given below. l denotes stripping length inside the terminal.
Frame Cable leadthroughs
Ø *
R1
R2
R3
R4
R5
R6
R7
R8
R9
2
2
2
2 pcs mm
2 17
2
2
17
21
24
32
45
54
4
4
45
54 mm
2
0.75…6
0.75…6
0.5…16
0.5…35
6…70
25…150
L1, L2, L3, T1/U, T2/V, T3/W
Wire size
95…240
(25…150**)
T (Wire srew)
M…
l
T (Terminal nut)
Max. wire size
N·m mm M...
N·m mm
2
-
-
-
-
M8
M10
M10
0.6
0.6
1.7
3.3
5.6
30
40
(30**)
8
8
10
18
18
30
30
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Grounding terminals
T
25
25
25
25
35
185
185
N·m
1.8
1.8
1.8
2.9
2.9
9.8
9.8
2 × (50…150) M10
2 × (95…240) M12
40
70
30 M10 24 2×185 9.8
30 M10 24 2×185 9.8
Frame Cable leadthroughs
R1
R2
R3
R4
R5
R6
R7
R8
R9 pcs
1
1
1
1
1
1
1
2
2
Ø *
mm
17
17
21
24
32
35
43
45
54
Wire size
mm
2
0.75…6
0.75…6
0.5…16
0.5…35
6…70
25…95
25…150
2 × (50…150)
2 × (95…240)
R-, R+/UDC+ and UDC- terminals
-
-
M8
M8
T (Wire screw)
M… N·m
-
-
0.6
0.6
1.7
3.3
5.6
20
M10
M10
M12
30
40
70
10
18
18
30
l
mm
8
8
30
30
30
-
-
-
-
T (Terminal nut)
M… N·m
-
-
-
-
6
6
-
6
-
M8
M8
6
24
24
* maximum cable diameter accepted. For the lead-through plate hole diameters, see chapter
.
** 525…690 V drives
Note: When you use a cable size smaller than what is accepted by the terminal, remove the terminal and use suitable cable lugs for connecting the cable directly under the head of the bolt.
Technical data 167
US
Input, motor, resistor and DC cable terminal screw sizes, accepted wire sizes (per phase) and tightening torques (T) in US units are given below. l denotes stripping length inside the terminal.
Frame Cable leadthroughs
Ø *
R1
R2
R3
R4
R5
R6
R7
R8
R9
L1, L2, L3, T1/U, T2/V, T3/W
Wire size T (Wire screw)
l T
(Terminal nut)
Grounding terminals
Max. wire size
pcs in.
2
2
2
2
2
2
2
4
0.67
0.67
0.83
0.94
1.26
1.77
2.13
kcmil/AWG
18…10
18…10
20…6
20…2
10…2/0
4…300 MCM
3/0…400 MCM
M…
-
-
-
-
M8 lbf·ft
0.4
0.4
1.3
2.4
4.1
in.
0.31
0.31
0.39
0.70
0.70
M…
-
-
-
-
-
-
-
-
-
-
AWG lbf·ft
4
4
4
4
2
1.3
1.3
1.3
2.1
2.1
350 MCM 7.2
(4…300 MCM)
M10 22.1
1.18
-
M10 29.5
(22.1**)
1.18
-
1.77 2 × (1/0…300 MCM) M10 29.5
1.18 M10 17.7
350 MCM 7.2
2×
350 MCM
7.2
4 2.13 2 × (3/0…400 MCM) M12 51.6
1.18 M10 17.7
2×
350 MCM
7.2
Frame Cable leadthroughs
R1
R2
R3
R4
R5
R6
R7
R8
R9
1
1
1
2
2
Ø *
pcs in.
1
1
1
1
0.67
0..67
0.83
0.94
1.26
1.38
Wire size
kcmil/AWG
18…10
18…10
20…6
20…2
10…2/0
4…3/0
R-, R+/UDC+ and UDC- terminals
T (Wire screw)
M…
-
-
-
-
M8
M8
1.69
4…300 MCM M10
1.77 2 × (1/0…300 MCM) M10
2.13 2 × (3/0…400 MCM) M12 lbf·ft
0.4
0.4
1.3
2.4
4.1
14.8
22,1
29.5
51.6
l
mm
0.31
0.31
0.39
0.70
1.18
1.18
1.18
1.18
1.18
T (Terminal nut)
M… lbf·ft
-
-
-
-
-
-
-
-
-
M8
M8
-
-
-
-
-
17.7
17.7
* maximum cable diameter accepted. Cable connector inside diameter: 3/4” (frames R1 and R2), 1” (R3). For
the lead-through plate hole diameters, see chapter
** 525…690 V drives
168 Technical data
UL listed cable lugs and tools
Wire size
kcmil/AWG
6
4
2
1
1/0
2/0
Compression lug
Manufacturer Type
Thomas &
Betts
E10731
54136
Burndy
Ilsco
Thomas &
Betts
YAV6C-L2
CCL-6-38
54140
Burndy
Ilsco
Thomas &
Betts
Burndy
Ilsco
Ilsco
Thomas &
Betts
Burndy
Ilsco
Ilsco
Thomas &
Betts
Burndy
Ilsco
Ilsco
Thomas &
Betts
Burndy
Ilsco
Ilsco
YA4C-L4BOX
CCL-4-38
54143TB
54142TB
YA2C-L4BOX
CRC-2
CCL-2-38
54148
YA1C-L4BOX
CRA-1-38
CCL-1-38
54109
YA25-L4BOX
CRB-0
CCL-1/0-38
54110
YAL26T38
CRA-2/0
CCL-2/0-38
Manufacturer
Crimping tool
Type No. of crimps
Thomas &
Betts
TBM4S
TBM45S
1
Burndy
Ilsco
Thomas &
Betts
MY29-3
ILC-10
TBM4S
1
2
1
Burndy
Ilsco
Thomas &
Betts
Burndy
Ilsco
Ilsco
Thomas &
Betts
Burndy
Ilsco
Ilsco
Thomas &
Betts
Burndy
Ilsco
Ilsco
Thomas &
Betts
Burndy
Ilsco
Ilsco
MY29-3
MT-25
TBM4S
TBM4S
MY29-3 2
IDT-12 1
MT-25
TBM-8
1
3
1
1
1
MY29-3
IDT-12 1
MT-25
TBM-8
MY29-3
1
3
2
IDT-12 1
MT-25
TBM-8
MY29-3
MT-25
2
1
3
2
IDT-12 1
1
Terminal data for the control cables
Control unit (ZCU-12) connection data
Technical data 169
Electrical power network specification
Voltage (U
1
)
Network type
Rated conditional short-circuit current (IEC 61439-1)
Short-circuit current protection
(UL 508C,
CSA C22.2 No. 14-05)
Frequency
Imbalance
Fundamental power factor
(cos phi
1
)
ACS880-01-xxxx-2 units: 208 … 240 V AC 3-phase
+10%…-15%
ACS880-01-xxxx-3 units: 380 … 415 V AC 3-phase
+10%…-15%
ACS880-01-xxxx-5 units: 380 … 500 V AC 3-phase
+10%…-15%
ACS880-01-xxxx-7 units: 525 … 690 V AC 3-phase
+10%…-15%
TN (grounded) and IT (ungrounded) systems.
65 kA when protected by fuses given in the fuse tables
US and Canada: The drive is suitable for use on a circuit capable of delivering not more than 100 kA symmetrical amperes (rms) at 600 V maximum when protected by fuses given in the fuse table
47 to 63 Hz, maximum rate of change 17%/s
Max. ± 3% of nominal phase to phase input voltage
0.98 (at nominal load)
Motor connection data
Motor types
Voltage (U
2
)
Frequency
Current
Switching frequency
Maximum recommended motor cable length
Asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors)
0 to U
1 point
, 3-phase symmetrical, U max
at the field weakening
0…500 Hz
See section
2.7 kHz (typically)
For ACS880-01-xxxx-2, ACS880-01-xxxx-3 and ACS880-
01-xxxx-5 frames R1 to R3 and for types ACS880-01-
07A3-7, ACS880-01-09A8-7, ACS880-01-14A2-7 and
ACS880-01-018A-7: 150 m (492 ft)
For ACS880-01-xxxx-2, ACS880-01-xxxx-3 and ACS880-
01-xxxx-5 frames R4 to R9 and for types from ACS880-01-
022A-7 to ACS880-01-271A-7: 300 m (984 ft).
Note: With motor cables longer than 150 m (492 ft) or switching frequencies higher than default, the EMC
Directive requirements may not be fulfilled.
170 Technical data
Control unit (ZCU-12) connection data
Power supply
(XPOW)
Relay outputs RO1…RO3
(XRO1 … XRO3)
+24 V output
(XD24:2 and XD24:4)
Digital inputs DI1…DI6
(XDI:1 … XDI:6)
Start interlock input DIIL
(XD24:1)
Digital inputs/outputs DIO1 and
DIO2 (XDIO:1 and XDIO:2)
Input/output mode selection by parameters.
DIO1 can be configured as a frequency input (0…16 kHz with hardware filtering of 4 microseconds) for 24 V level square wave signal (sinusoidal or other wave form cannot be used).
DIO2 can be configured as a 24 V level square wave frequency output. See the firmware manual, parameter group 11.
24 V (±10%) DC, 2 A
Supplied from the power unit of the drive, or from an external power supply through connector XPOW (pitch
5 mm, wire size 2.5 mm
2
).
Connector pitch 5 mm, wire size 2.5 mm
2
250 V AC / 30 V DC, 2 A
Protected by varistors
Connector pitch 5 mm, wire size 2.5 mm
2
Total load capacity of these outputs is 4.8 W (200 mA /
24 V) minus the power taken by DIO1 and DIO2.
Connector pitch 5 mm, wire size 2.5 mm
2
24 V logic levels: “0” < 5 V, “1” > 15 V
R
in
: 2.0 kohm
Input type: NPN/PNP (DI1…DI5), NPN (DI6)
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
DI6 (XDI:6) can alternatively be used as an input for PTC sensors.
“0” > 4 kohm, “1” < 1.5 kohm
I
max
: 15 mA (for DI6 5 mA)
Connector pitch 5 mm, wire size 2.5 mm
2
24 V logic levels: “0” < 5 V, “1” > 15 V
R
in
: 2.0 kohm
Input type: NPN/PNP
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
Connector pitch 5 mm, wire size 2.5 mm
2
As inputs:
24 V logic levels: “0” < 5 V, “1” > 15 V
R
in
: 2.0 kohm
Filtering: 0.25 ms
As outputs:
Total output current from +24VD is limited to 200 mA.
+24VD
DIOx
R
L
DIOGND
Technical data 171
Reference voltage for analog inputs +VREF and -VREF
(XAI:1 and XAI:2)
Analog inputs AI1 and AI2
(XAI:4 … XAI:7).
Current/voltage input mode selection by jumpers. See page
Analog outputs AO1 and AO2
(XAO)
Drive to drive link
(XD2D)
Safe torque off connection
(XSTO)
Connector pitch 5 mm, wire size 2.5 mm
10 V ±1% and –10 V ±1%, R load
2
1…10 kohm
Connector pitch 5 mm, wire size 2.5 mm
2
Current input: –20…20 mA, R in
Voltage input: –10…10 V, R in
: 100 ohm
: > 200 kohm
Differential inputs, common mode range ±30 V
Sampling interval per channel: 0.25 ms
Hardware filtering: 0.25 ms, adjustable digital filtering up to
8 ms
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
Inaccuracy for Pt100 sensors: 10 °C (18 °F)
Connector pitch 5 mm, wire size 2.5 mm
2
0…20 mA, R load
< 500 ohm
Frequency range: 0…300 Hz
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
Connector pitch 5 mm, wire size 2.5 mm
2
Physical layer: RS-485
Termination by switch
Connector pitch 5 mm, wire size 2.5 mm
2
Current consumption per channel: 55 mA (continuous)
For the drive to start, both connections must be closed
(OUT1 to IN1 and IN2).
Control panel / PC connection
Connector: RJ-45
Cable length < 3 m
The terminals on the board fulfil the Protective Extra Low Voltage (PELV) requirements. The
PELV requirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output.
172 Technical data
Ground isolation diagram
+24VI
GND
XPOW
1
2
XAI
1 +VREF
-VREF
AGND
AI1+
AI1-
AI2+
AI2-
2
3
4
5
6
AO1
AGND
AO2
AGND
7
XAO
1
2
3
B
A
4
XD2D
1
2
BGND 3
XRO1, XRO2, XRO3
NC 1
COM
NO
NC
COM
NO
NC
COM
NO
2
3
1
2
2
3
1
DIIL
+24VD
DICOM
+24VD
DIOGND
3
XD24
3
4
1
2
DIO1
DIO2
DI1
DI2
DI3
DI4
DI5
DI6
4
5
6
2
3
5
XDIO
1
2
XDI
1
OUT1
SGND
IN1
IN2
XSTO
1
2
3
4
Common mode voltage between channels +30 V
J6
Switch J6 settings:
All digital inputs and outputs share a common ground.
Ground of digital inputs DI1…DI5 and
DIIL (DICOM) is separated from the DIO signal ground (DIOGND)
(insulation voltage 50 V).
Ground
Technical data 173
Efficiency
Approximately 98% at nominal power level
Protection classes
Degree of protection
(IEC/EN 60529)
Enclosure types (UL508C)
IP21, IP55. Option +P940: IP20
Overvoltage category
(IEC 60664-1)
Protective class (IEC/EN 61800-
5-1)
I
UL Type 1, UL Type 12. Option +P940: UL Open Type. For indoor use only.
III
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment.
Operation
installed for stationary use
Storage
in the protective package
Transportation
in the protective package
Installation site altitude
• 0 to 4000 m
(13123 ft) above sea level
1)
-
Air temperature
Relative humidity
Contamination levels
(IEC 60721-3-3, IEC 60721-3-2,
IEC 60721-3-1)
Atmospheric pressure
• 0 to 2000 m
(6561 ft) above sea level
2)
Above 1000 m
[3281 ft]), see page
-15 to +55 °C (5 to
131 °F).
3)
-40 to +70 °C (-40 to +158 °F)
-40 to +70 °C (-40 to +158 °F)
No frost allowed.
See section
.
5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of corrosive gases.
No conductive dust allowed.
Chemical gases:
Class 3C2
Solid particles:
Class 3S2
70 to 106 kPa
0.7 to 1.05 atmospheres
Chemical gases:
Class 1C2
Solid particles:
Class 1S3
70 to 106 kPa
0.7 to 1.05 atmospheres
Chemical gases:
Class 2C2
Solid particles:
Class 2S2
60 to 106 kPa
0.6 to 1.05 atmospheres
174 Technical data
Vibration (IEC 60068-2)
Shock (IEC 60068-2-27)
Free fall
Max. 1 mm
(0.04 in.)
(5 to 13.2 Hz), max. 7 m/s
2
(23 ft/s
2
)
(13.2 to 100 Hz) sinusoidal
Not allowed
Not allowed
Max. 1 mm
(0.04 in.)
(5 to 13.2 Hz), max. 7 m/s
2
(23 ft/s
2
)
(13.2 to 100 Hz) sinusoidal
Max. 100 m/s
2
(330 ft./s
2
), 11 ms
100 mm (4 in.) for weight over 100 kg (220 lb)
Max. 3.5 mm
(0.14 in.)
(2 to 9 Hz), max. 15 m/s
2
(49 ft/s
2
)
(9 to 200 Hz) sinusoidal
Max. 100 m/s
2
(330 ft./s
2
), 11 ms
100 mm (4 in.) for weight over 100 kg (220 lb)
1. For neutral-grounded TN and TT systems and non-corner grounded IT systems
2. For corner-grounded TN, TT and IT systems
3. For IP55 (UL Type 12) type -210A-7: -15 to +45 °C (5 to 113 °F). For IP55 (UL Type 12) types -0430A-3, -0414A-5 and -0271A-7: -15 to +35 °C (5 to 95 °F).
Materials
Drive enclosure
Package
Disposal
• PC/ABS 3 mm, color NCS 1502-Y (RAL 9002 / PMS 1C
Cool Grey) and RAL 9017
• PC+10%GF 3.0mm, Color RAL 9017 (in frames R1 to
R3 only)
• hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness of coating 100 micrometers, color NCS 1502-Y
Plywood and cardboard. Foam cushions PP-E, bands PP.
The main parts of the drive can be recycled to preserve natural resources and energy. Produt parts and materials should be dismantled and separated.
Generally all metals, such as steel, aluminum, copper and its alloys, and precious metals can be recycled as material. Plastics, rubber, cardboard and other packaging material can be used in energy recovery. Printed circuit boards and DC capacitors (C1-1 to C1-x) need selective treatment according to IEC 62635 guidelines. To aid recycling, plastic parts are marked with an approppriate identification code.
Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.
Technical data 175
Applicable standards
The drive complies with the following standards. The compliance with the European Low
Voltage Directive is verified according to standard EN 61800-5-1.
EN 60204-1:2006 + A1 2009
Safety of machinery. Electrical equipment of machines.
Part 1: General requirements. Provisions for compliance:
The final assembler of the machine is responsible for installing
- emergency-stop device
- supply disconnecting device.
IEC/EN 60529:1991 + A1 2000
IEC 60664-1:2007
Degrees of protection provided by enclosures (IP code)
Insulation coordination for equipment within low-voltage systems. Part 1: Principles, requirements and tests.
EN 61800-3:2004
EN 61800-5-1:2007
EN 61800-5-2:2007
UL 508C:2002
Adjustable speed electrical power drive systems. Part 3:
EMC requirements and specific test methods
Adjustable speed electrical power drive systems. Part 5-1:
Safety requirements – electrical, thermal and energy
Adjustable speed electrical power drive systems. Part 5-2:
Safety requirements – Functional
UL Standard for Safety, Power Conversion Equipment, third edition
NEMA 250:2008
CSA C22.2 No. 14-10
GOST R 51321-1:2007
Enclosures for Electrical Equipment (1000 Volts
Maximum)
Industrial control equipment
Low-voltage switchgear and control gear assemblies. Part
1 - Requirements for type-tested and partially type-tested assemblies - General technical requirements and methods of tests
CE marking
A CE mark is attached to the drive to verify that the drive follows the provisions of the
European Low Voltage, EMC and RoHS Directives. The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the
Machinery Directive as a safety component.
Compliance with the European Low Voltage Directive
The compliance with the European Low Voltage Directive has been verified according to standards EN 60204-1 and EN 61800-5-1.
Compliance with the European EMC Directive
The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union. The EMC product standard (EN 61800-
3:2004) covers requirements stated for drives. See section
176 Technical data
Compliance with the European RoHS Directive
The RoHS Directive defines the restriction of the use of certain hazardous substances in electrical and electronic equipment.
Compliance with the European Machinery Directive
The drive is an electronic product which is covered by the European Low Voltage
Directive. However, the drive includes the Safe torque off function and can be equipped with other safety functions for machinery which, as safety components, are in the scope of the Machinery Directive. These functions of the drive comply with
European harmonized standards such as EN 61800-5-2. The declaration of conformity is shown below.
Declaration of Conformity
Technical data 177
178 Technical data
Technical data 179
Compliance with the EN 61800-3:2004
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.
Second environment includes establishments connected to a network not supplying domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment.
Note: A professional is a person or organization having necessary skills in installing and/or starting up power drive systems, including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above 400 A, or intended for use in complex systems in the second environment.
Category C2
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter +E202.
2. The motor and control cables are selected as specified in the hardware manual.
3. The drive is installed according to the instructions given in the hardware manual.
4. Maximum motor cable length is 150 meters.
WARNING! The drive may cause radio interference if used in residential or domestic environment. The user is required to take measures to prevent interference, in association to the requirements for the CE compliance listed above, if necessary.
Note: Do not install a drive equipped with EMC filter +E202 on IT (ungrounded) systems. The supply network becomes connected to ground potential through the
EMC filter capacitors which may cause danger or damage to the unit.
180 Technical data
Category C3
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter +E200 or +E201.
2. The motor and control cables are selected as specified in the hardware manual.
3. The drive is installed according to the instructions given in the hardware manual.
4. Maximum motor cable length is 150 meters.
WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.
Category C4
If the provisions under
cannot be met, the requirements of the standard can be met as follows:
1. It is ensured that no excessive emission is propagated to neighboring low-voltage networks. In some cases, the inherent suppression in transformers and cables is sufficient. If in doubt, the supply transformer with static screening between the primary and secondary windings can be used.
Medium voltage network
Supply transformer
Neighboring network
Static screen
Low voltage
Point of measurement
Equipment
(victim)
Equipment
Low voltage
Equipment
Drive
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative.
3. The motor and control cables are selected as specified in the hardware manual.
4. The drive is installed according to the instructions given in the hardware manual.
Technical data 181
WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.
UL marking
UL Type 1 (IP21) drives are cULus Listed
UL Type 12 (IP55) drives of frames R1 to R7 are cULus Listed. The listing is pending for frames R8 and R9.
UL checklist
• The drive is to be used in a heated, indoor controlled environment. The drive must be installed in clean air according to enclosure classification. Cooling air must be clean, free from corrosive materials and electrically conductive dust. See page
.
• The maximum ambient air temperature is 40 °C (104 °F) at rated current. The current is derated for 40 to 55 °C (104 to 131 °F).
• The drive is suitable for use in a circuit capable of delivering not more than
100,000 rms symmetrical amperes, 600 V maximum. The ampere rating is based on tests done according to UL 508C.
• The cables located within the motor circuit must be rated for at least 75 °C
(167 °F) in UL-compliant installations.
• The input cable must be protected with fuses. Circuit breakers must not be used
without fuses in the USA. Suitable IEC (class aR) fuses are listed on page
and UL (class T) fuses on page
. For suitable circuit breakers, contact your
local ABB representative.
• For installation in the United States, branch circuit protection must be provided in accordance with the National Electrical Code (NEC) and any applicable local codes. To fulfill this requirement, use the UL classified fuses.
• For installation in Canada, branch circuit protection must be provided in accordance with the Canadian Electrical Code and any applicable provincial codes. To fulfill this requirement, use the UL classified fuses.
• The drive provides overload protection in accordance with the National Electrical
Code (NEC).
CSA marking
CSA-marked Type 1 (IP21) drives:
• frames R1 to R3
• frames R4 to R9 of voltage ranges 380...415 V, 380...500 V and 525...600 V.
The marking is pending for frames R4 to R8 of voltage range 208…240 V.
182 Technical data
CSA-marked Type 12 (IP55) drives:
• frame R4 of voltage ranges 380...415 V, 380...500 V and 525...600 V
• frame R5 of voltage ranges 380...415 V, 380...500 V and 525...600 V
Listing is pending for other types.
“C-tick” marking
The drive is “C-tick”-marked.
“C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to the 380…500 V drives to verify compliance with the relevant standard (IEC 61800-
3:2004), mandated by the Trans-Tasman Electromagnetic Compatibility Scheme.
For fulfilling the requirements of the standard, see section
EAC marking
EAC marking is required in Russia, Belarus and Kazakhstan. The EAC certificate of conformity is pending for the drive.
Disclaimer
The manufacturer shall have no obligation hereunder with respect to any product which (i) has been improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident; (iii) has been used in a manner contrary to the Manufacturer's instructions; or (iv) has failed as a result of ordinary wear and tear.
Dimension drawings 183
Dimension drawings
12
What this chapter contains
This chapter contains dimension drawings of the standard drive (IP21, UL Type 1) and drive with option +B056 (IP55, UL Type 12). For dimension drawings of option
+P940 (IP20, UL Open Type), see ACS880-01 drives for cabinet installation (option
+P940) supplement (3AUA0000145446 [English].
184 Dimension drawings
Frame R1 (IP21, UL Type 1)
Frame R1 (IP55, UL Type 12)
Dimension drawings 185
186 Dimension drawings
Frame R2 (IP21, UL Type 1)
Frame R2 (IP55, UL Type 12)
Dimension drawings 187
188 Dimension drawings
Frame R3 (IP21, UL Type 1)
Frame R3 (IP55, UL Type 12)
Dimension drawings 189
190 Dimension drawings
Frame R4 (IP21, UL Type 1)
7[.28]
WITHOUT GLAND BOX
490[19.291]
18[.72]
8[.32]
505[19.88]
475[18.70]
SUGGESTED MOUNTING HOLES
48[1.89]
124[4.86]
576[22.69]
Frame R4 (IP55, UL Type 12)
7[.28]
490[19.291]
Dimension drawings 191
18[.72]
8[.32]
505[19.88]
475[18.70]
SUGGESTED MOUNTING HOLES
29[1.13]
165[6.51]
576[22.69]
192 Dimension drawings
Frame R5 (IP21, UL Type 1)
7[.28]
WITHOUT GLAND BOX
596[23.46]
8[.32]
612[24.07]
581[22.87]
SUGGESTED MOUNTING HOLES
48[1.88]
124[4.86]
730[28.73]
Frame R5 (IP55, UL Type 12)
7[.28]
WITHOUT GLAND BOX
596[23.46]
Dimension drawings 193
8[.32]
612[24.07]
581[22.87]
SUGGESTED MOUNTING HOLES
29[1.13]
165[6.51]
730[28.73]
194 Dimension drawings
Frame R6 (IP21, UL Type 1)
Frame R6 (IP55, UL Type 12)
Dimension drawings 195
196 Dimension drawings
Frame R7 (IP21, UL Type 1)
Frame R7 (IP55, UL Type 12)
Dimension drawings 197
198 Dimension drawings
Frame R8 (IP21, UL Type 1)
Frame R8 (IP55, UL Type 12)
Dimension drawings 199
200 Dimension drawings
Frame R9 (IP21, UL Type 1)
Frame R9 (IP55, UL Type 12)
Dimension drawings 201
202 Dimension drawings
Safe Torque off function 203
13
Safe Torque off function
What this chapter contains
This chapter describes the Safe torque off function of the drive and gives instructions for its use.
Description
The Safe torque off function can be used, for example, to construct safety or supervision circuits that stop the drive in case of danger (such as an emergency stop circuit). Another possible application is a prevention of unexpected start-up switch that enables short-time maintenance operations like cleaning or work on nonelectrical parts of the machinery without switching off the power supply to the drive.
When activated, the Safe torque off function disables the control voltage of the power semiconductors of the drive output stage (A, see diagram below), thus preventing the drive from generating the torque required to rotate the motor. If the motor is running when Safe torque off is activated, it coasts to a stop.
The Safe torque off function has a redundant architecture, that is, both channels must be used in the safety function implementation. The safety data given in this manual is calculated for redundant use, and does not apply if both channels are not used.
The Safe torque off function of the drive complies with these standards:
Standard
EN 60204-1:2006 +
AC:2010
Name
Safety of machinery – Electrical equipment of machines – Part 1:
General requirements
204 Safe Torque off function
Standard
IEC 61326-3-1:2008
IEC 61508-1:2010
IEC 61508-2:2010
IEC 61511:2003
IEC/EN 61800-5-2:2007
IEC/EN 62061:2005 +
AC:2010
EN ISO 13849-1:2008 +
AC:2009
EN ISO 13849-2:2012
Name
Electrical equipment for measurement, control and laboratory use
– EMC requirements – Part 3-1: Immunity requirements for safetyrelated systems and for equipment intended to perform safetyrelated functions (functional safety) – General industrial applications
Functional safety of electrical/electronic/programmable electronic safety-related systems – Part 1: General requirements
Functional safety of electrical/electronic/programmable electronic safety-related systems – Part 2: Requirements for electrical/electronic/programmable electronic safety-related systems
Functional safety – Safety instrumented systems for the process industry sector
Adjustable speed electrical power drive systems –
Part 5-2: Safety requirements – Functional
Safety of machinery – Functional safety of safety-related electrical, electronic and programmable electronic control systems
Safety of machinery – Safety-related parts of control systems –
Part 1: General principles for design
Safety of machinery – Safety-related parts of control systems –
Part 2: Validation
The function also corresponds to prevention of unexpected start-up as specified by
EN 1037:1995 + A1:2008 and uncontrolled stop (stop category 0) as specified in
EN 60204-1:2006 + AC:2010.
Compliance with the European Machinery Directive
See section
Compliance with the European Machinery Directive
Wiring
The following diagrams show examples of Safe torque off wiring for
)
• multiple drives (page
)
• multiple drives when an external 24 V DC power supply is used (page
For information on the specifications of the STO input, see section
.
Safe Torque off function 205
Activation switch
In the wiring diagrams below, 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.
• If a manually operated activation switch is used, the switch must be of a type that can be locked out to the open position.
• The contacts of the switch or relay must open/close within 200 ms of each other.
• An FSO-xx safety functions module can also be used. For more information, see the FSO-xx module documentation.
Cable types and lengths
Double-shielded twisted-pair cable is recommended.
Maximum cable lengths:
• 30 m (100 ft) between activation switch (K) and drive control unit
• 60 m (200 ft) between multiple drives
• 60 m (200 ft) between external power supply and first drive.
Note that the voltage at the INx terminals of each drive must be at least 17 V DC to be interpreted as “1”.
Grounding of protective shields
• Ground the shield in the cabling between the activation switch and the control unit at the control unit.
• Ground the shield in the cabling between two control units at one control unit only.
206 Safe Torque off function
Single drive (internal power supply)
ACS880-01
ZCU
+24 V
OUT1
SGND
Control logic
IN1
IN2
UDC+
A T1/U, T2/V, T3/W
UDC-
K
Multiple drives (internal power supply)
ACS880-01
ZCU
+24 V
OUT1
SGND
IN1
IN2
Safe Torque off function 207
K
ACS880-01
ZCU
OUT1
SGND
IN1
IN2
ACS880-01
ZCU
OUT1
SGND
IN1
IN2
208 Safe Torque off function
Multiple drives (external power supply)
ACS880-01
ZCU
+24 V
OUT1
SGND
IN1
IN2
ACS880-01
ZCU
OUT1
SGND
IN1
IN2
ACS880-01
ZCU
OUT1
SGND
IN1
IN2
-
+24 V DC
+
K
Safe Torque off function 209
Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open).
2. STO inputs on the drive control unit de-energize.
3. The control unit cuts off the control voltage from the drive IGBTs.
4. The control program generates an indication as defined by parameter 31.22 (refer to the firmware manual of the drive).
5. Motor coasts to stop (if running). The drive cannot restart while the activation switch or safety relay contacts are open. After the contacts close, a new start command is required to start the drive.
Start-up including acceptance test
To ensure safe operation of the Safe torque off function, validation is required. The final assembler of the machine must validate the function by performing an acceptance test.
The acceptance test must be performed:
• at initial start-up of the safety function
• after any changes related to the safety function (circuit boards, wiring, components, settings, etc.)
• after any maintenance work related to the safety function.
Authorized person
The acceptance test of the safety function must be carried out by an authorized person with expertise and knowledge of the safety function. The test must be documented and signed by the authorized person.
Acceptance test reports
Signed acceptance test reports must be stored in the logbook of the machine. The report shall include documentation of start-up activities and test results, references to failure reports and resolution of failures. Any new acceptance tests performed due to changes or maintenance shall be logged into the logbook.
210 Safe Torque off function
Acceptance test procedure
After wiring the Safe torque off function, validate its operation as follows. Setting of the control program parameters is not needed. If an FSO-xx safety functions module is installed, refer to its documentation.
Action
WARNING! Obey the
can cause physical injury or death, or damage to the equipment.
Ensure that the drive can be run and stopped freely during start-up.
Stop the drive (if running), switch the input power off and isolate the drive from the power line by a disconnector.
Check the Safe torque off (STO) circuit connections against the circuit diagram.
Close the disconnector and switch the power on.
Test the operation of the STO function when the motor is stopped.
• Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill.
Make sure that the drive operates as follows:
• Open the STO circuit. The drive generates an indication if one is defined for
‘stopped’ state in parameter 31.22 (see the firmware manual).
• Give a start command to verify that the STO function blocks the drive operations.
The motor should not start.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.
Test the operation of the STO function when the motor is running:
• Start the drive and make sure the motor is running.
• Open the STO circuit. The motor should stop. The drive generates an indication if one is defined for ‘running’ state in parameter 31.22 (see the firmware manual).
• Reset any active faults and try to start the drive.
• Make sure that the motor stays at standstill and the drive operates as described above in testing the operation when the motor is stopped.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.
Document and sign the acceptance test report which verifies that the safety function is safe and accepted for operation.
Safe Torque off function 211
Use
1. Open the activation switch, or activate the safety functionality that is wired to the
STO connection.
2. STO inputs on the drive control unit de-energize, and the drive control unit cuts off the control voltage from the inverter IGBTs.
3. The control program generates an indication as defined by parameter 31.22 (refer to the firmware manual of the drive).
4. Motor coasts to stop (if running). The drive will not restart while the activation switch or safety relay contacts are open.
5. Deactivate the STO by closing the activation switch, or reseting the safety functionality that is wired to the STO connection.
6. Reset any faults before restarting.
WARNING! The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive. Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply.
WARNING! (With permanent magnet or synchronous reluctance [SynRM] motors only) In case of a multiple IGBT power semiconductor failure, the drive system can produce an alignment torque which maximally rotates the motor shaft by
180/p (with permanent magnet motors) or 180/2p (with synchronous reluctance
[SynRM] motors) degrees regardless of the activation of the Safe torque off function.
p denotes the number of pole pairs.
Notes:
• If a running drive is stopped by using the Safe torque off function, the drive will cut off the motor supply voltage and the motor will coast to a stop. If this causes danger or is not otherwise acceptable, stop the drive and machinery using the appropriate stop mode before activating the Safe torque off function.
• The Safe torque off function overrides all other functions of the drive.
• The Safe torque off function is ineffective against deliberate sabotage or misuse.
• The Safe torque off function has been designed to reduce the recognized hazardous conditions. In spite of this, it is not always possible to eliminate all potential hazards. The assembler of the machine must inform the final user about the residual risks.
212 Safe Torque off function
Maintenance
After the operation of the circuit is verified at start-up, it does not need any maintenance. However, it is a good practice to check the operation of the function when the other maintenance procedures are carried out on the machinery.
Include the Safe torque off operation test described above in the routine maintenance program of the machinery that the drive runs.
If any wiring or component change is needed after start up, or the parameters are
restored, follow the test given in section
Start-up including acceptance test
Fault tracing
The indications given during the normal operation of the Safe torque off function are selected by drive parameter 31.22.
The diagnostics of the Safe torque off function cross-compare the status of the two
STO channels. In case the channels are not in the same state, a fault reaction function is performed and the drive trips on an “STO hardware failure” fault. An attempt to use the STO in a non-redundant manner, for example activating only one channel, will trigger the same reaction.
See the drive firmware manual for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics.
Any failures of the Safe torque off function must be reported to ABB.
Safety data (SIL, PL)
The safety data for the Safe torque off function is given below.
Note: The safety data is calculated for redundant use, and does not apply if both channels are not used.
Frame
SIL SC
IEC 61508 and EN/IEC 61800-5-2
PFH
(1/h) d
HFT SFF
(%)
Lifetime
(Years)
PFD
(T1 = 2a)
R4
R5
R6
R7
R8
U
N
= 230 V
R1 3
R2
R3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2.33E-09 (2.33 FIT)
2.33E-09 (2.33 FIT)
2.33E-09 (2.33 FIT)
2.43E-09 (2.43 FIT)
2.43E-09 (2.43 FIT)
2.44E-09 (2.44 FIT)
2.44E-09 (2.44 FIT)
2.44E-09 (2.44 FIT)
1
1
1
1
1
1
1
1
99.67
99.67
99.68
99.66
99.66
99.65
99.65
99.65
20
20
20
20
20
20
20
20
4.58E-7
4.58E-7
3.69E-7
5.85E-7
5.85E-7
8.70E-7
8.70E-7
8.70E-7
Safe Torque off function 213
Frame
U
N
= 500 V
R1
R2
R3
3
3
R4
R5
3
3
R6
R7
3
3
R8
R9
3
3
3
U
N
= 690 V
R5
R6…R9
3
3
Frame
SIL
PL
R4
R5
R6
R7
U
N
= 230 V
R1
R2
R3
R8
U
N
= 500 V
R1
R6
R7
R8
R9
R2
R3
R4
R5
U
N
= 690 V
R5
R6…R9 e e e e e e e e e e e e e e e e e e e
80
80
80
80
80
80
80
80
80
80
80
SC
3
3
3
3
3
3
3
3
3
IEC 61508 and EN/IEC 61800-5-2
PFH
(1/h) d
HFT SFF
(%)
Lifetime
(Years)
PFD
(T1 = 2a)
2.33E-09 (2.33 FIT)
2.33E-09 (2.33 FIT)
2.33E-09 (2.33 FIT)
2.43E-09 (2.43 FIT)
2.43E-09 (2.43 FIT)
2.44E-09 (2.44 FIT)
2.44E-09 (2.44 FIT)
2.44E-09 (2.44 FIT)
3.84E-09 (3.84 FIT)
1
1
1
1
1
1
1
1
1
99.67
99.67
99.68
99.66
99.66
99.65
99.65
95.04
95.04
20
20
20
20
20
20
20
20
20
4.58E-7
4.58E-7
3.69E-7
5.85E-7
5.85E-7
8.70E-7
8.70E-7
1.56E-4
1.56E-4
3
3
2.89E-09 (2.89 FIT)
3.84E-09 (3.84 FIT)
CCF
(%)
EN ISO 13849-1
MTTF d
(Years)
DC*
(%)
80
80
80
80
80
80
80
80
7321
7321
9093
5731
5731
3847
3847
3847
> 90
> 90
> 90
> 90
> 90
> 90
> 90
> 90
1
1
91.78
95.04
Cat.
20
20
7.70E-5
1.56E-4
EN/IEC 62061 IEC 61511
SILCL SIL
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
7321
7321
9093
5731
5731
3847
3847
1374
1374
1374
1374
> 90
> 90
> 90
> 90
> 90
> 90
> 90
> 90
> 90
> 90
> 90
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
214 Safe Torque off function
* according to Table E.1 in EN/ISO 13849-1
• This temperature profile is used in the safety value calculations:
• 670 on/off cycles per year with T = 71.66 °C
• 1340 on/off cycles per year with T = 61.66 °C
• 30 on/off cycles per year with T = 10.0 °C
• 32 °C board temperature at 2.0% of time
• 60 °C board temperature at 1.5% of time
• 85 °C board temperature at 2.3% of time.
• The STO is a type A safety component as defined in IEC 61508-2.
• Relevant failure modes:
• The STO trips spuriously (safe failure)
• The STO does not activate when requested
A fault exclusion on the failure mode “short circuit on printed circuit board” has been made (EN 13849-2, table D.5). The analysis is based on an assumption that one failure occurs at one time. No accumulated failures have been analyzed.
• STO reaction time (shortest detectable break): 1 ms
• STO response time: 2 ms (typical), 5 ms (maximum)
• Fault detection time: Channels in different states for longer than 200 ms
• Fault reaction time: Fault detection time + 10 ms
• STO fault indication (parameter 31.22) delay: < 500 ms
• STO warning indication (parameter 31.22) delay: < 1000 ms
Safety data (SIL, PL)
Abbr.
CCF
DC
FIT
HFT
MTTF d
Reference
EN ISO 13849-1
EN ISO 13849-1
IEC 61508
IEC 61508
EN ISO 13849-1
PFD
PFH
D
PL
IEC 61508
IEC 61508
EN ISO 13849-1
SC
SFF
IEC 61508
IEC 61508
SIL IEC 61508
SILCL EN/IEC 62061
Description
Common cause failure (%)
Diagnostic coverage
Failure in time: 1E-9 hours
Hardware fault tolerance
Mean time to dangerous failure: (The total number of life units)
/ (the number of dangerous, undetected failures) during a particular measurement interval under stated conditions
Probability of failure on demand
Probability of dangerous failures per hour
Performance level. Levels a…e correspond to SIL
Systematic capability
Safe failure fraction (%)
Safety integrity level (1…3)
Maximum SIL (level 1…3) that can be claimed for a safety function or subsystem
Abbr.
SS1
STO
T1
Reference Description
EN/IEC 61800-5-2 Safe stop 1
EN/IEC 61800-5-2 Safe torque off
IEC 61508 Proof test interval
Safe Torque off function 215
216 Safe Torque off function
Resistor braking 217
14
Resistor braking
What this chapter contains
This chapter describes how to select, protect and wire brake choppers and resistors.
The chapter also contains technical data.
Operation principle and hardware description
Frames R1 to R4 have a built-in brake chopper as standard. Frames R5 and up can be equipped with optional built-in brake chopper (+D150). Brake resistors are available as add-on kits.
The brake chopper handles the energy generated by a decelerating motor. The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program. Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected.
Planning the braking system
Selecting the brake circuit components
1. Calculate the maximum power generated by the motor during braking (P max
).
2. Select a suitable drive, brake chopper and brake resistor combination for the
application from the rating table on page
. The braking power of the chopper
must be greater or equal than the maximum power generated by the motor during the braking.
218 Resistor braking
Note: A custom resistor can be selected within the limits imposed by the internal brake chopper of the drive:
• The resistance value of the custom resistor is at least R min
. The braking power capacity of the resistor can be calculated from the following equation:
P
max
<
U
DC
2
R
where
P
max
U
DC
R
Maximum power generated by the motor during braking
Voltage over the resistor during braking. U
DC
equals to
1.35 · 1.25 · 240 V DC (when supply voltage is 208 to 240 V AC)
1.35 · 1.25 · 415 V DC (when supply voltage is 380 to 415 V AC)
1.35 · 1.25 · 500 V DC (when supply voltage is 440 to 500 V AC) or
1.35 · 1.25 · 690 V DC (when supply voltage is 525 to 690 AC)
Resistor resistance (ohm)
WARNING! Never use a brake resistor with a resistance below the value specified for the particular drive / brake chopper / resistor combination. The drive and the chopper are not able to handle the overcurrent caused by the low resistance.
3. Check the resistor selection. The energy generated by the motor during a 400second period must not exceed the resistor heat dissipation capacity E
R
.
Note: If the E
R
value is not sufficient, it is possible to use a four-resistor assembly in which two standard resistors are connected in parallel, two in series. The E
R
value of the four-resistor assembly is four times the value specified for the standard resistor.
Selecting and routing the brake resistor cables
Use the same cable type for the resistor cabling as for the drive input cabling to ensure that the input fuses also protect the resistor cable. Alternatively, a two conductor shielded cable with the same cross-sectional area can be used.
Resistor braking 219
Minimizing electromagnetic interference
Follow these rules in order to minimize electromagnetic interference caused by the rapid current changes in the resistor cables:
• Shield the braking power line completely, either by using shielded cable or a metallic enclosure. Unshielded single-core cable can only be used if it is routed inside a cabinet that efficiently suppresses the radiated emissions.
• Install the cables away from other cable routes.
• Avoid long parallel runs with other cables. The minimum parallel cabling separation distance should be 0.3 meters.
• Cross the other cables at right angles.
• Keep the cable as short as possible in order to minimize the radiated emissions and stress on chopper IGBTs. The longer the cable the higher the radiated emissions, inductive load and voltage peaks over the IGBT semiconductors of the brake chopper.
Maximum cable length
The maximum length of the resistor cable(s) is 10 m (33 ft).
EMC compliance of the complete installation
Note: ABB has not verified that the EMC requirements are fulfilled with external userdefined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.
Placing the brake resistors
Install the resistors outside the drive in a place where they will cool.
Arrange the cooling of the resistor in a way that:
• no danger of overheating is caused to the resistor or nearby materials
• the temperature of the room the resistor is located in does not exceed the allowed maximum.
Supply the resistor with cooling air/water according to the resistor manufacturer’s instructions.
WARNING! The materials near the brake resistor must be non-flammable. The surface temperature of the resistor is high. Air flowing from the resistor is of hundreds of degrees Celsius. If the exhaust vents are connected to a ventilation system, ensure that the material withstands high temperatures. Protect the resistor against contact.
220 Resistor braking
Protecting the system against thermal overload
The brake chopper protects itself and the resistor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. The drive control program includes a resistor and resistor cable thermal protection function which can be tuned by the user. See the firmware manual.
Frames R1 to R4
Equipping the drive with a main contactor is highly recommended for safety reasons.
Wire the contactor so that it opens in case the resistor overheats. This is essential for safety since the drive will not otherwise be able to interrupt the main supply if the chopper remains conductive in a fault situation. An example wiring diagram is shown below. ABB resistors are equipped with a thermal switch (1) inside the resistor assembly as standard. The switch indicates overtemperature and overload.
We recommend that you also wire the thermal switch to a digital input ot the drive.
L1 L2 L3
OFF
1
2
1 3 5
2 4 6
ACS880
L1 L2 L3
1
13
14
ON
3
4
ACS880
+24VD x
DIx x
K1
Frames R5 to R9
A main contactor is not required for protecting against resistor overheating when the resistor is dimensioned according to the instructions and the internal brake chopper is in use. The drive will disable power flow through the input bridge if the chopper remains conductive in a fault situation but the charging resistor may fail.
Note: If an external brake chopper (outside the drive module) is used, a main contactor is always required.
Resistor braking 221
A thermal switch (standard in ABB resistors) is required for safety reasons. The thermal switch cable must be shielded and may not be longer than the resistor cable.
Wire the switch to a digital input on the drive control unit as shown in the figure below.
+24VD
DIx x x
Protecting the resistor cable against short-circuits
The input fuses will also protect the resistor cable when it is identical with the input cable.
Mechanical installation
All brake resistors must be installed outside the drive. Follow the resistor manufacturer’s instructions.
Electrical installation
Checking the insulation of the assembly
Follow the instructions given under
.
Connection diagram
See section
.
Connection procedure
• Connect the resistor cables to the R+ and R- terminals in the same way as the other power cables. If a shielded three-conductor cable is used, cut the third conductor, insulate it, and ground the twisted shield of the cable (protective earth conductor of the resistor assembly) at both ends.
• Connect the thermal switch of the brake resistor as described above in section
or
.
Start-up
Note: Protective oil on the brake resistors will burn off when the brake resistor is used for the first time. Make sure that the airflow is sufficient.
222 Resistor braking
Set the following parameters (ACS880 primary control program):
• Disable the overvoltage control of the drive by parameter 30.30 Overvoltage
control.
• Set parameter 31.01 External event 1 source to point to the digital input where the thermal switch of the brake resistor is wired.
• Set parameter 31.02 External event 1 type to Fault.
• Enable the brake chopper by parameter 43.06 Brake chopper enable. If
Enabled with thermal model is selected, set also the brake resistor overload protection parameters 43.08 and 43.09 according to the application.
• For frames R5 to R9: Set parameter 43.07 Brake chopper runtime enable to
Other [bit] and select from parameter 10.01 DI status the digital input where the thermal switch of the brake resistor is wired.
• Check the resistance value of parameter 43.10 Brake resistance.
With these parameter settings, the drive stops by coasting on brake resistor overtemperature.
WARNING! If the drive is equipped with a brake chopper but the chopper is not enabled by the parameter setting, the internal thermal protection of the drive against resistor overheating is not in use. In this case, the brake resistor must be disconnected.
For settings of other control programs, see the appropriate firmware manual.
Resistor braking 223
Technical data
Ratings
Drive type Internal brake chopper
P
brcont kW
R
min ohm
U
N
= 230 V
ACS880-01-04A6-2
ACS880-01-06A6-2
ACS880-01-07A5-2
ACS880-01-10A6-2
ACS880-01-16A8-2
ACS880-01-24A3-2
ACS880-01-031A-2
ACS880-01-046A-2
ACS880-01-061A-2
ACS880-01-075A-2
ACS880-01-087A-2
ACS880-01-115A-2
ACS880-01-145A-2
ACS880-01-170A-2
ACS880-01-206A-2
ACS880-01-274A-2
U
N
= 400 V
ACS880-01-02A4-3
ACS880-01-03A3-3
ACS880-01-04A0-3
ACS880-01-05A6-3
ACS880-01-07A2-3
ACS880-01-09A4-3
ACS880-01-12A6-3
ACS880-01-017A-3
ACS880-01-025A-3
ACS880-01-032A-3
ACS880-01-038A-3
ACS880-01-045A-3
ACS880-01-061A-3
ACS880-01-072A-3
ACS880-01-087A-3
ACS880-01-105A-3
ACS880-01-145A-3
37
45
55
75
11
18.5
22
30
0.75
1.1
1.5
2.2
4.0
5.5
7.5
11
3.5
2.4
2.4
1.8
12
6
6
3.5
18
18
13
12
65
65
65
65
22
37
45
55
75
11
15
18.5
22
0.75
1.1
1.5
2.2
3.0
4.0
5.5
7.5
13
8
8
5.4
5.4
39
19
19
13
78
78
78
39
78
78
78
78
JBR-03
JBR-03
JBR-03
JBR-03
JBR-03
JBR-03
JBR-03
SACE08RE44
SACE08RE44
SACE15RE22
SACE15RE22
SACE15RE13
SACE15RE13
SAFUR90F575
SAFUR90F575
SAFUR80F500
SAFUR80F500
Example brake resistor(s)
Type
JBR-03
JBR-03
JBR-03
JBR-03
SACE15RE22
SACE15RE22
SACE15RE13
SACE15RE13
SACE15RE13
SAFUR90F575
SAFUR90F575
SAFUR125F500
SAFUR125F500
SAFUR200F500
SAFUR200F500
SAFUR200F500
R ohm
80
80
80
80
22
22
13
13
13
8
8
4
4
2.7
2.7
2.7
E
R kJ
P
Rcont kW
9
13.5
13.5
13.5
2
4.5
4.5
9
2
2
2
2
0.14
0.14
0.14
0.14
435
1800
1800
3600
3600
5400
5400
5400
420
420
435
435
40
40
40
40
13
8
8
6
6
44
22
22
13
80
80
80
44
80
80
80
80
2
4.5
4.5
6
6
2
2
1
2
0.14
0.14
0.14
0.14
0.14
0.14
0.14
1
210
420
420
435
435
1800
1800
2400
2400
40
40
40
210
40
40
40
40
224 Resistor braking
Drive type
ACS880-01-169A-3
ACS880-01-206A-3
ACS880-01-246A-3
ACS880-01-293A-3
ACS880-01-363A-3
ACS880-01-430A-3
U
N
= 500 V
ACS880-01-02A1-5
ACS880-01-03A0-5
ACS880-01-03A4-5
ACS880-01-04A8-5
ACS880-01-05A2-5
ACS880-01-07A6-5
ACS880-01-11A0-5
ACS880-01-014A-5
ACS880-01-021A-5
ACS880-01-027A-5
ACS880-01-034A-5
ACS880-01-040A-5
ACS880-01-052A-5
ACS880-01-065A-5
ACS880-01-077A-5
ACS880-01-096A-5
ACS880-01-124A-5
ACS880-01-156A-5
ACS880-01-180A-5
ACS880-01-240A-5
ACS880-01-260A-5
ACS880-01-302A-5
ACS880-01-361A-5
ACS880-01-414A-5
U
N
= 690 V
ACS880-01-07A3-7
ACS880-01-09A8-7
ACS880-01-14A2-7
ACS880-01-018A-7
ACS880-01-022A-7
ACS880-01-026A-7
Internal brake chopper
P
brcont kW
R
min ohm
90
110
132
132
160
160
3.3
3.3
2.3
2.3
2.0
2.0
6
8
11
17
23
28
22
37
45
55
11
15
18.5
22
3.0
4.0
5.5
7.5
0.75
1.1
1.5
2.2
132
160
160
160
75
90
110
132
18
18
18
18
18
18
13
8
8
5.4
39
19
19
13
78
78
78
39
78
78
78
78
2.3
2.3
2.3
2.3
5.4
3.3
3.3
2.3
Example brake resistor(s)
Type
SAFUR125F500
SAFUR125F500
SAFUR200F500
SAFUR200F500
SAFUR200F500
SAFUR200F500
R ohm
4
4
2.7
2.7
2.7
2.7
E
R kJ
3600
3600
5400
5400
5400
5400
P
Rcont kW
9
9
13.5
13.5
13.5
13.5
JBR-03
JBR-03
JBR-03
JBR-03
JBR-03
JBR-03
JBR-03
SACE08RE44
SACE08RE44
SACE15RE22
SACE15RE22
SACE15RE13
SACE15RE13
SAFUR90F575
SAFUR90F575
SAFUR80F500
SAFUR80F500
SAFUR125F500
SAFUR125F500
SAFUR200F500
SAFUR200F500
SAFUR200F500
SAFUR200F500
SAFUR200F500
SACE08RE44
SACE08RE44
SACE08RE44
SACE15RE22
SACE15RE22
SACE15RE22
13
8
8
6
44
22
22
13
80
80
80
44
80
80
80
80
2.7
2.7
2.7
2.7
6
4
4
2.7
44
44
44
22
22
22
210
420
420
435
435
1800
1800
2400
40
40
40
210
40
40
40
40
2400
3600
3600
5400
5400
5400
5400
5400
210
210
210
420
420
420
2
4.5
4.5
6
2
2
1
2
0.14
0.14
0.14
0.14
0.14
0.14
0.14
1
6
9
9
13.5
13.5
13.5
13.5
13.5
1
2
1
1
2
2
Resistor braking 225
Drive type
ACS880-01-035A-7
ACS880-01-042A-7
ACS880-01-049A-7
ACS880-01-061A-7
Internal brake chopper
P
brcont kW
R
min ohm
ACS880-01-084A-7
ACS880-01-098A-7
65
90
ACS880-01-119A-7 110
ACS880-01-142A-7 132
33
45
45
55
ACS880-01-174A-7 160
ACS880-01-210A-7 200
ACS880-01-271A-7 200
18
18
18
13
13
8
8
6
6
4
4
Example brake resistor(s)
Type
SACE15RE22
SACE15RE22
SACE15RE22
SACE15RE13
SACE15RE13
SAFUR90F575
SAFUR90F575
SAFUR80F500
SAFUR80F500
SAFUR125F500
SAFUR125F500
R ohm
22
22
22
13
13
8
8
6
6
4
4
P
brcont
R
min
R
The internal brake chopper will withstand this continuous braking power.
The minimum allowed resistance value of the brake resistor
Resistance value for the listed resistor assembly
E
R
P
Rcont
Short energy pulse that the resistor assembly withstands every 400 seconds
Continuous power (heat) dissipation of the resistor when placed correctly
The rating apply at an ambient temperature of 40 °C (104 °F)
E
R kJ
420
420
420
435
435
1800
1800
2400
2400
3600
3600
3AXD00000588487
P
Rcont kW
2
2
2
2
2
4.5
4.5
6
6
9
9
Degree of protection of JBR, SACE and SAFUR resistors
JBR
SACE
SAFUR
IP20
IP21
IP00
Terminals and cable lead-through data
See section
Terminal and lead-through data for the power cables
226 Resistor braking
Common mode, du/dt and sine filters 227
15
Common mode, du/dt and sine filters
What this chapter contains
This chapter describes how to select external filters for the drive.
Common mode filters
When is a common mode filter needed?
See section
Checking the compatibility of the motor and drive
mode filter kit is available from ABB with order number is 64315811 for the drive. The kit includes three wound cores. For installation instructions of the cores, see the instruction included in the core package.
du/dt filters
When is a du/dt filter needed?
See section
Checking the compatibility of the motor and drive
228 Common mode, du/dt and sine filters
du/dt filter types
072A-3
087A-3
105A-3
145A-3
169A-3
206A-3
246A-3
293A-3
363A-3
430A-3
-
Drive type
ACS880-01-
U
N
= 400 V
02A4-3
03A3-3
04A0-3
05A6-3
07A2-3
09A4-3
12A6-3
017A-3
025A-3
032A-3
038A-3
045A-3
061A-3
du/dt filter type Drive type
ACS880-01-
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0030-6X
NOCH0030-6X
NOCH0070-6X
NOCH0070-6X
NOCH0070-6X
NOCH0070-6X
NOCH0070-6X
NOCH0120-6X
NOCH0120-6X
FOCH0260-70
FOCH0260-70
FOCH0260-70
FOCH0260-70
FOCH0260-70
FOCH0320-50
FOCH0320-50
-
U
N
= 500 V
02A1-5
03A0-5
03A4-5
04A8-5
05A2-5
07A6-5
11A0-5
014A-5
021A-5
027A-5
034A-5
040A-5
052A-5
065A-5
077A-5
096A-5
124A-5
156A-5
180A-5
240A-5
260A-5
302A-5
361A-5
414A-5
du/dt filter type Drive type
ACS880-01-
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0030-6X
NOCH0030-6X
NOCH0070-6X
NOCH0070-6X
NOCH0070-6X
NOCH0070-6X
NOCH0070-6X
NOCH0120-6X
NOCH0120-6X
FOCH0260-70
FOCH0260-70
FOCH0260-70
FOCH0260-70
FOCH0260-70
FOCH0320-50
FOCH0320-50
FOCH0320-51
U
N
= 690 V
07A3-7
09A8-7
14A2-7
018A-7
022A-7
026A-7
035A-7
042A-7
049A-7
061A-7
084A-7
098A-7
119A-7
142A-7
174A-7
210A-7
271A-7
-
-
-
-
-
-
-
du/dt filter type
NOCH0016-6X
NOCH0016-6X
NOCH0016-6X
NOCH0030-6X
NOCH0030-6X
NOCH0030-6X
NOCH0070-6X
NOCH0070-6X
NOCH0070-6X
NOCH0120-6X
NOCH0120-6X
NOCH0120-6X
FOCH0260-70
FOCH0260-70
FOCH0260-70
FOCH0260-70
FOCH0260-70
-
-
-
-
-
-
-
3AXD00000588487
Description, installation and technical data of the FOCH filters
See FOCH du/dt filters hardware manual (3AFE68577519 [English]).
Description, installation and technical data of the NOCH filters
See AOCH and NOCH du/dt filters hardware manual (3AFE58933368 [English]).
Sine filters
Contact your local ABB representative for more information.
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels .
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Training courses.
Providing feedback on ABB Drives manuals
Your comments on our manuals are welcome. Go to www.abb.com/drives and select
Document Library – Manuals feedback form (LV AC drives).
Document library on the Internet
You can find manuals and other product documents in PDF format on the Internet.
Go to www.abb.com/drives and select Document Library. You can browse the library or enter selection criteria, for example a document code, in the search field.
Contact us
www.abb.com/drives www.abb.com/drivespartners
3AUA0000078093 Rev H (EN) EFFECTIVE. 2014-02-14
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Key Features
- Built-in safety functions
- Easy to use and configure
- Reliable
- Efficient
- High-performance
- Wide range of applications
- Compact design
- IP21 protection class
