ABB ACS880-01 drives Drive Hardware manual

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

5

Table of contents

List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. Safety instructions

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Introduction to the manual


Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Quick installation, start-up and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3. Operation principle and hardware description


Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Layout (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Layout (IP55, option +B056) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Layout (UL Type 12, option +B056) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Layout (IP20 – UL Open Type, option +P940) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

External control connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Control panel mounting platform cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Control panel door mounting kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4. Mechanical installation


Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6

Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Moving the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Unpacking and examining the delivery (frames R1 to R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Frame R5 cable entry box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Unpacking and examining the delivery (frames R6 to R9) . . . . . . . . . . . . . . . . . . . . . . . . . . . 41





Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Frames R1 to R4 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Frames R5 to R9 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Frames R1 to R9 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Grounding inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Installing drives above one another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5. Planning the electrical installation


Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Selecting and dimensioning the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . . . 59

Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . . . 60

Additional data for calculating the rise time and the peak line-to-line voltage . . . . . . 61

Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

7

Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . . . 71

Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 71

Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Protecting the drive and the input power and motor cables against thermal overload . . . 72

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Connecting drives to a common DC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Implementing the Safety functions options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . . . . . 74

Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Switching the motor power supply from drive to direct-on-line . . . . . . . . . . . . . . . . . . 77

Switching the motor power supply from direct-on-line to drive . . . . . . . . . . . . . . . . . . 77

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Connecting a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

6. Electrical installation


Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Connection procedure for frames R1 to R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Connection procedure for frames R4 and R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Connection procedure for frames R6 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . 102

AI1 and AI2 as Pt100 and KTY84 sensor inputs (XAI, XAO) . . . . . . . . . . . . . . . . . . 102

8

Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Safety functions (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Controlling several drives through panel bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Wiring I/O extension, fieldbus adapter and pulse encoder interface modules . . . . . . . . 111

Installation of safety functions modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Installation procedure into Slot 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Installation next to the control unit on frames R7 to R9 . . . . . . . . . . . . . . . . . . . . . . 114

7. Installation checklist

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

8. Start-up


Startup procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

9. Fault tracing


LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

10. Maintenance


Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Preventive maintenance table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Replacing the main cooling fan of frames R1 to R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Replacing the auxiliary cooling fan of IP55 frames R1 to R3 . . . . . . . . . . . . . . . . . . . . . 127

Replacing the main cooling fan of frames R4 and R5 . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Replacing the auxiliary cooling fan of frame R4 and IP55 frame R5 and IP21 frame R5 types ACS880-01-xxxx-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Replacing the main cooling fan of frames R6 to R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Replacing the auxiliary cooling fan of frames R6 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . 131

Replacing the IP55 auxiliary cooling fan of frames R8 and R9 . . . . . . . . . . . . . . . . . . . 132

Replacing the main cooling fans of frame R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Replacing the drive (IP21, UL Type 1, frames R1 to R9) . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

9

Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Replacing safety functions modules (FSO-11, option +Q973) . . . . . . . . . . . . . . . . . . . . . . . 138

11. Technical data


Marine type-approved drives (option +C132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

IP21 (UL Type 1) drive types and other IP55 (UL Type 12) types than listed in the following subheadings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

IP55 (UL Type 12) drive types -274A-2, 293A-3, -260A-5, -302A-5 and -174A-7 . . 148

IP55 (UL Type 12) drive type -240A-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

IP55 (UL Type 12) drive types -363A-3 and -361A-5 . . . . . . . . . . . . . . . . . . . . . . . . 149

IP55 (UL Type 12) drive type -210A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

IP55 (UL Type 12) types -0430A-3, -0414A-5 and -0271A-7 . . . . . . . . . . . . . . . . . . 150

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

aR fuses (frames R1 to R9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

gG fuses (frames R1 to R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Quick guide for selecting between gG and aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Calculating the short-circuit current of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Dimensions. weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

UL listed cable lugs and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Control unit (ZCU-12) connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Compliance with the European RoHS Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Compliance with the EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

10

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

12. Dimension drawings


Frame R1 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Frame R1 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Frame R2 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Frame R2 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Frame R3 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Frame R3 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Frame R4 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Frame R4 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Frame R5 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Frame R5 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Frame R6 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Frame R6 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Frame R7 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Frame R7 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Frame R8 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Frame R8 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Frame R9 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Frame R9 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

13. Safe Torque off function


Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Multiple drives (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Multiple drives (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Authorized person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

11

Safety data (SIL, PL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Safety data (SIL, PL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

14. Resistor braking


Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Selecting the brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Selecting and routing the brake resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Frames R1 to R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Frames R5 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Degree of protection of JBR, SACE and SAFUR resistors . . . . . . . . . . . . . . . . . . . . . . . 225

Terminals and cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

15. Common mode, du/dt and sine filters


Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

When is a common mode filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

When is a du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

du/dt filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . . . . 228

Description, installation and technical data of the NOCH filters . . . . . . . . . . . . . . . . . . . 228

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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.


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)

power system. See page

83

.

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.


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.


General safety

These instructions are intended for all who install and service the drive.


• 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.




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.


• 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

Start-up

for reference of the

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.


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.


Introduction to the manual 21

2

Introduction to the manual


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.

Safety instructions

gives safety instructions for the installation, start up, operation and

maintenance of the drive.

Introduction to the manual

introduces the manual.

Operation principle and hardware description

describes the drive.

Mechanical installation

describes how to install the basic drive mechanically.

Planning the electrical installation

contains instructions for the motor and cable selection, protections and cable routing.

22 Introduction to the manual

Electrical installation

gives instructions on wiring the drive.

Installation checklist

contains a list for checking the mechanical and electrical installation of the drive.

Start-up

describes the start-up procedure of the drive.

Fault tracing

describes the fault tracing of the drive.

Maintenance

contains preventive maintenance instructions.

Technical data

contains the technical specifications of the drive, eg, the ratings, sizes

and technical requirements, provisions for fulfilling the requirements for CE and other markings.

Dimension drawings

contains dimension drawings of the drives and auxiliary

components.

Safe Torque off function

describes the Safe torque off function of the drive and gives instructions on its implementing.

Resistor braking

describes selection, protection and wiring of brake choppers and

resistors. The chapter also contains technical data.

Common mode, du/dt and sine filters

describes selection external filters for the drive.

Related manuals

See

List of related manuals

on the inside of the front cover.

Categorization by frame size and option code

The instructions, technical data and dimension drawings which concern only certain drive frame sizes are marked with the symbol of the frame size (R1, R2, etc.). The frame size is marked on the type designation label.

The instructions and technical data which concern only certain optional selections are marked with option codes (such as +E200). The options included in the drive can be identified from the option codes visible on the type designation label. The option

selections are listed in section

Type designation key

on page

33

.

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

53

)

Technical data

(page

139

)

Check the installation site.

Ambient conditions

(page

173

)

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.

Mechanical installation

(page

39

or

41

)

If the drive has been non-operational for more than one year, the converter

DC link capacitors need to be

reformed (page

136

)

Route the cables.

Check the insulation of the supply cable, the motor and the motor cable.

Connect the power cables.

Connect the control cables.

Routing the cables

(page

99

)

(page

70

)

Checking the insulation of the assembly

(page

81

)

Connecting the power cables

(page

84

),

Connecting the control cables

Check the installation.

Start the drive up.

Installation checklist

Start-up

(page

119

)

(page

117

)

Operate the drive: start, stop, speed control etc.

ACS880 quick start-up guide,

firmware manual

24 Introduction to the manual

Terms and abbreviations

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


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.




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




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




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]).




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

designation key

, page

33

..

4 Memory unit, see page

137.

5 Connector for safety functions modules, see page

112

.

Type

6 See page

31

,

Default I/O connection diagram

(page

100

) and

Control unit (ZCU-12) connection data

(page

170

).

7 See section

Control panel

, page

32

.

8 du/dt, common mode or sine filter (optional), see page

227

.


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)




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].


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

Type designation, see section

Type designation key

on page

33

.

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

140

Voltage range

208…240 V

380…415 V


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


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


Mechanical installation 37

Mechanical installation

4


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

on page

163

.

• The operation conditions of the drive agree with the specifications in section

Ambient conditions

(page

173

).

• The wall is vertical, not flammable and strong enough to hold the weight of the drive. See page

162

.

• 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

162

. 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.


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.


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


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


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


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


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.

-


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.





3aua0000112044






3aua0000111117





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






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)


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







. Mark the locations for the

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.


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.


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





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.



. Mark the locations for the

four or six mounting holes. The lowest holes are not necessarily needed.


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.


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


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.


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


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

Technical data

on basis of the AC line voltage and motor load. Use the DriveSize PC tool if you

need to tune the selection more in detail.

Ensure that the motor withstands the maximum peak voltage in the motor terminals.

See the

Requirements table

on page

55

. For basics of protecting the motor insulation

and bearings in drive systems, refer to section

Protecting the motor insulation and bearings

below.

Note:

• Consult the motor manufacturer before using a motor whose nominal voltage differs from the AC line voltage connected to the drive input.

• The voltage peaks at the motor terminals are relative to the supply voltage of the drive, not the drive output voltage.

• 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.




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.


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.


Motor type

Nominal AC supply voltage


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 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.


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.


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)


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


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


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 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.


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).


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.


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

Ratings

(page

140

) for the rated currents.

• Select a cable rated for at least 70

°

C maximum permissible temperature of conductor in continuous use. For US, see

Additional US requirements,

page

68

.

• The inductance and impedance of the PE conductor/cable (grounding wire) must be rated according to permissible touch voltage appearing under fault conditions

(so that the fault point voltage will not rise excessively when a ground fault occurs).

• 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

66

) for drive frame size R5 and larger, or motors larger than 30 kW (40 hp). A four-conductor system can be used up to frame size R4 with up to 30 kW (40 hp) motors, but shielded symmetrical motor cable is always recommended. Ground motor cable shields 360° at both ends. Keep the motor cable and its PE pigtail (twisted shield) as short as possible to reduce 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.


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

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-


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

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-


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

166

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

167

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.


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

63

. Check with local /

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

63

.

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.




Motor cable shield

If the motor cable shield is used as the sole protective earth conductor of the motor, ensure that the conductivity of the shield is sufficient. See subsection

General rules

above, or IEC 61439-1. To effectively suppress radiated and conducted 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.


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.




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.)




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~


Size the fuses at the distribution board according to instructions given in chapter

Technical data

. The fuses will protect the input cable in short-circuit situations, restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive.

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


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

function. See chapter


on page

203

.

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


on page

203

.

Implementing the Safety functions options

The drive can be equipped with a safety functions module as factory installed (option

+Q973). The module is also available as a retrofilt kit. The safety functions module includes, for example, the following functions: Safe torque off (STO), Safe brake


control (SBC) and Safely-limited speed (SLS). The option uses the internal Safe torque off function of the drive.

For the installation of the safety functions module, see section

Installation of safety functions modules

on page

112

. 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.


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

to operate. See also section

Implementing a bypass connection

on page

75

.

When you have selected to use DTC motor control mode and motor ramp stop, open the contactor as follows:

1. Give a stop command to the drive.

2. Wait until the drive decelerates the motor to zero speed.

3. Open the contactor.

When you have selected to use DTC motor control 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.


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


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.


1

230 V AC

2

230 V AC

3

+ 24 V DC

4

1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode

-


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

102

.

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).


Electrical installation

Electrical installation 81

6


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


in the first chapter of

this manual. Ignoring the safety instructions can cause physical injury or death.

Checking the insulation of the assembly



Drive

Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive. Every drive has been tested for insulation between the main circuit and the chassis at the factory. Also, there are 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


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.


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

For alternatives, see section

Selecting the supply disconnecting device

on page

53.

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

63

).

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

IEC 61439-1 (see page

63

) and there is no symmetrically constructed grounding

conductor in the cable (see page

68

).

7 du/dt filter or sine filter (optional, see page

227

).

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

63

).

Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.




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

15

) of the input cable to

the grounding terminal.

10. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals and the phase conductors of the motor cable to the T1/U, T2/V and T3/W terminals. Connect the brake resistor conductors (if present) to the R+ and R- terminals. Tighten the screws to the torque given in the figure below.

11. Install the control cable grounding shelf in the cable entry box.

12. Secure the cables outside the unit mechanically.

Note: For US cable conduit installation, see the quick installation guide.


10

IP21

IP55

1

2

1

3

1

5

4

6a

PE

PE

6b

PE

9

8

6b

PE


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


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.


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

168

.


R4, R5

1b

1a

3

2

IP55

1

IP21

3

4

4b

4a

R4, R5

5

6

PE


PE

7

6

7

6


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




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.


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

168

.


R6 … R9

1b

1a

3

3

IP21

4

5a

5b

4

IP55


R6 … R9

R8, R9

PE

7

8a

6

PE

7

R6 … R9

11

12

11

10

10 10


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


R6 … R9

13

R8, R9

16




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

on page

105

.




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


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


on page

170

.

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

inputs floats). See

Ground isolation diagram

on page

172

.

Bus is terminated.

Bus is not terminated.

DICOM and DIOGND connected (default).

DICOM and DIOGND separated.


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.


Drive-to-drive link (XD2D)

The drive-to-drive link is a daisy-chained RS-485 transmission line that allows basic master/follower communication with one master drive and multiple followers.

Set termination activation jumper J3 (see section

Jumpers and switches

above) next to this terminal block to the ON position on the drives at the ends of the drive-to-drive link. On intermediate drives, set the jumper to the OFF position.

Use shielded twisted-pair cable (~100 ohm, for example, PROFIBUS-compatible cable) for the wiring. For best immunity, high quality cable is recommended. Keep the cable as short as possible; the maximum length of the link is 50 meters (164 ft). Avoid unnecessary loops and running the cable near power cables (such as motor cables).

The following diagram shows the wiring of the drive-to-drive link.

. . .

. . .

. . .

. . .

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.


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

203

.

Safety functions (X12)

See section

Implementing the Safety functions options

on page

73

, and FSO-11

user’s manual (3AUA0000097054 [English]).




Control cable connection procedure

WARNING! Follow the safety instructions, page

14

. 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(s). See section


starting

from page

84

.

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

106

.

5. Ground the outer shields of all control cables 360 degrees at a grounding clamp in the cable entry box, see page

106

. Tighten the clamp to 1.5 N·m (13 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

106

.

7. Connect the conductors to the appropriate terminals (see page

100)

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.


0.5 N·m

1.5 N·m

6

7

7

5

1.5 N·m

3

3


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


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.


1

IP21 (UL Type 1)

1 2

3

IP55 (UL Type 12)

1

2

3


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

30

for the available slots for each module. Install the optional modules as

follows:


14

. Ignoring the instructions can cause physical injury or death, or damage to the equipment.


2. Remove the front cover (see the section


starting

from page

84

.

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.


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

instructions. See page

106

for the routing of the cables.




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


14



2. Remove the front cover (see the section


on page

84

).

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

Wiring

on

page

204

.

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


5

6

5

5a

5


Installation next to the control unit on frames R7 to R9


14



2. Remove the front cover (see page

95

).

3. Insert the module carefully into its position.

4. Attach the module with four screws. Note: Correct installation of the grounding screw (a) is essential for fulfilling the EMC requirements and for proper operation of the module.

5. Tighten the grounding screw of the electronics.

6. Connect the data communication cable to slot X110 on the module and to connector X12 on the drive control unit.

7. Connect the Safe torque off wires to connector X111 on the module and to

connector XSTO on the drive module control unit as shown in section

Wiring

on

page

204

.

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



Installation checklist

Installation checklist 117

7


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

Technical data

.

If the drive will be connected to an IT (ungrounded) supply network: Optional EMC filters of type +E200 and +E202 have been disconnected. Consult ABB for the instructions.

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

136

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


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


on page

203

.

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


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


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

14


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.


2. Remove the cooling fan(s). See section

Fans

below.

3. Blow clean compressed air (not humid) from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust. Note: If there is a risk of dust entering adjoining equipment, perform the cleaning in another room.

4. Refit the cooling fan.

Fans

The lifespan of the cooling fans of the drive depend on the running time of the fan, ambient temperature and dust concentration. See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after a fan replacement.

Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

126 Maintenance



Replacing the main cooling fan of frames R1 to R3


14



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


14



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


14



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


14



2. Remove the front cover.


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


14



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


14



2. Remove the lower front cover (see page

93

).

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


14



2. Remove the IP55 front cover.

3. Remove the lower front cover from the IP55 cover.


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


14



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.


14



2. Remove the front covers. See section

Connection procedure for frames R1 to R3

on page

85

or

Connection procedure for frames R4 and R5

on page

88

.

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

33

for information on finding out the manufacturing date. For information on

reforming the capacitors, see Converter module capacitor reforming instructions

(3BFE64059629 [English]).

Memory unit

When a drive is replaced, the parameter settings can be retained by transferring the memory unit from the defective drive to the new drive. The memory unit is located on

the control unit, see page

31

.

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

on page

112

.

Technical data 139

11

Technical data


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


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


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


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


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


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


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


Drive type

ACS880-

01-

Frame size

Input rating

I

1N

A

Max. current

I

max

A

NEMA RATINGS

Output ratings


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


Drive type

ACS880-

01-

Frame size

Input rating

I

1N

A

Max. current

I

max

A

NEMA RATINGS

Output ratings


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


Drive type

ACS880-

01-

Frame size

Input rating

I

1N

A

Max. current

I

max

A

NEMA RATINGS

Output ratings


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




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


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



(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


IP55 (UL Type 12) drive types -363A-3 and -361A-5



(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


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.

Note 1: See also

Implementing thermal overload and short-circuit protection

on page

71

.

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.



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


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


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


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


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


1)

(A)

40

53

94

120

160

160

170

280

280

480

700

700

700

1000

1280

1610

1610


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




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…


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


Drive type

ACS880-

01…


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




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

158

).

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


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




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.


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

71

.

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.


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


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


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.


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


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


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


W

1440

1940

2310

3300

3900

4200

4800


Noise

dB(A)

67

67

67

65

65

68

68


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


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

-

-

-

-


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.




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.


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


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


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


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

See


below.


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%


+10%…-15%


+10%…-15%


+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

Ratings.

2.7 kHz (typically)

For ACS880-01-xxxx-2, ACS880-01-xxxx-3 and ACS880-

01-xxxx-5 frames R1 to R3 and for types ACS880-01-

07A3-7, ACS880-01-09A8-7, ACS880-01-14A2-7 and

ACS880-01-018A-7: 150 m (492 ft)

For ACS880-01-xxxx-2, ACS880-01-xxxx-3 and ACS880-

01-xxxx-5 frames R4 to R9 and for types from ACS880-01-

022A-7 to ACS880-01-271A-7: 300 m (984 ft).

Note: With motor cables longer than 150 m (492 ft) or switching frequencies higher than default, the EMC

Directive requirements may not be fulfilled.


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


2

Total load capacity of these outputs is 4.8 W (200 mA /

24 V) minus the power taken by DIO1 and DIO2.


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)


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


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


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

101

.

Analog outputs AO1 and AO2

(XAO)

Drive to drive link

(XD2D)

Safe torque off connection

(XSTO)


10 V ±1% and –10 V ±1%, R load

2

1…10 kohm


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)


2

0…20 mA, R load

< 500 ohm

Frequency range: 0…300 Hz

Resolution: 11 bit + sign bit

Inaccuracy: 2% of full scale range


2

Physical layer: RS-485

Termination by switch


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.


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


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

150

.

-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

Ratings

.

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


Chemical gases:

Class 2C2

Solid particles:

Class 2S2

60 to 106 kPa



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.


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

Compliance with the

EN 61800-3:2004

below.




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




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.




Category C3

The drive complies with the standard with the following provisions:

1. The drive is equipped with EMC filter +E200 or +E201.



4. Maximum motor cable length is 150 meters.

WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.



Category C4

If the provisions under

Category C3

cannot be met, the requirements of the standard can be met as follows:

1. 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.




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

173

.

• 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

150

and UL (class T) fuses on page

159

. 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.


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

Compliance with the

EN 61800-3:2004

on page

179

.

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


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)













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]


7[.28]

490[19.291]


18[.72]

8[.32]

505[19.88]

475[18.70]


29[1.13]

165[6.51]

576[22.69]



7[.28]

WITHOUT GLAND BOX

596[23.46]

8[.32]

612[24.07]

581[22.87]


48[1.88]

124[4.86]

730[28.73]


7[.28]

WITHOUT GLAND BOX

596[23.46]


8[.32]

612[24.07]

581[22.87]


29[1.13]

165[6.51]

730[28.73]


















Safe Torque off function 203

13

Safe Torque off function


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

on page

176

.

Wiring

The following diagrams show examples of Safe torque off wiring for

• a single drive (page

206

)

• multiple drives (page

207

)

• multiple drives when an external 24 V DC power supply is used (page

208

).

For information on the specifications of the STO input, see section

Control unit (ZCU-

12) connection data

on page

170

.




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.




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


K

ACS880-01

ZCU

OUT1

SGND

IN1

IN2

ACS880-01

ZCU

OUT1

SGND

IN1

IN2




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


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.




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


, page

13

. Ignoring the instructions

can cause physical injury or death, or damage to the equipment.

Ensure that the drive can be run and stopped freely during start-up.

Stop the drive (if running), switch the input power off and isolate the drive from the power line by a disconnector.

Check the Safe torque off (STO) circuit connections against the circuit diagram.

Close the disconnector and switch the power on.

Test the operation of the STO function when the motor is stopped.

• 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.


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.


Maintenance

After the operation of the circuit is verified at start-up, it does not need any maintenance. However, it is a good practice to check the operation of the function when the other maintenance procedures are carried out on the machinery.

Include the Safe torque off operation test described above in the routine maintenance program of the machinery that the drive runs.

If any wiring or component change is needed after start up, or the parameters are

restored, follow the test given in section

Start-up including acceptance test

, page

209

.

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


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


* 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



• 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



Resistor braking 217

14

Resistor braking


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

223

. 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.


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.




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.


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

Brake resistor assembly

on page

82

.



Connection diagram

See section

Connection diagram

on page

84

.



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

Frames R1 to R4

or

Frames R5 to R9

.

Start-up

Note: Protective oil on the brake resistors will burn off when the brake resistor is used for the first time. Make sure that the airflow is sufficient.


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.


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


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


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


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


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

on page

166

.


Common mode, du/dt and sine filters 227

15

Common mode, du/dt and sine filters


This chapter describes how to select external filters for the drive.

Common mode filters



When is a common mode filter needed?

See section

Checking the compatibility of the motor and drive

, page

54

. A common

mode filter kit is available from ABB with order number is 64315811 for the drive. The kit includes three wound cores. For installation instructions of the cores, see the instruction included in the core package.

du/dt filters



When is a du/dt filter needed?

See section

Checking the compatibility of the motor and drive

, page

54

.

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

ABB ACS880-01 drives Drive Hardware manual

Assistant Bot

Hardware manual

List of related manuals

Hardware manual

Table of contents

Safety instructions

What this chapter contains

Use of warnings

Safety in installation and maintenance

Electrical safety

General safety

Printed circuit boards

Safe start-up and operation

General safety

Introduction to the manual

What this chapter contains

Target audience

Contents of the manual

Related manuals

Categorization by frame size and option code

Quick installation, start-up and operating flowchart

Terms and abbreviations

Operation principle and hardware description

What this chapter contains

Product overview

Main circuit

Layout (IP21, UL Type 1)

Layout (IP55, option +B056)

Layout (UL Type 12, option +B056)

Layout (IP20 – UL Open Type, option +P940)

Overview of power and control connections

Control panel

Type designation label

Type designation key

Mechanical installation

What this chapter contains

Safety

Examining the installation site

Necessary tools

Moving the drive

Unpacking and examining the delivery (frames R1 to R5)

Frame R5 cable entry box (IP21, UL Type 1)

Unpacking and examining the delivery (frames R6 to R9)

Frame R6 cable entry box (IP21, UL Type 1)

Frame R7 cable entry box (IP21, UL Type 1)

Frame R8 cable entry box (IP21, UL Type 1)

Frame R9 cable entry box (IP21, UL Type 1)

Installing the drive

Frames R1 to R4 (IP21, UL Type 1)

× 4

Frames R5 to R9 (IP21, UL Type 1)

Frames R1 to R9 (IP55, UL Type 12)

Cabinet installation

Cooling

Grounding inside the cabinet

Installing drives above one another

Planning the electrical installation

What this chapter contains

Limitation of liability

Selecting the supply disconnecting device

European Union

Other regions

Selecting and dimensioning the main contactor

Checking the compatibility of the motor and drive

Protecting the motor insulation and bearings

Requirements table

A

B

Selecting the power cables

General rules

°

Typical power cable sizes

Alternative power cable types

Motor cable shield

Additional US requirements

°

°

Selecting the control cables

Shielding