Page 1 ABB industrial drives Hardware manual ACS880-07 drives (45 to 710 kW, 50 to 700 hp)
Page 2 List of related manuals Drive hardware manuals and guides Code (English) Drive/converter/inverter safety instructions Multilingual code: 3AXD50000037978 ACS880-07 drives (45 to 710, 50 to 700 hp) hardware 3AUA0000105718 manual EMC filter and ground-to-phase varistor disconnecting 3AUA0000125152 instructions for ACS880 frames R1 to R11 ACX-AP-x assistant control panels user’s manual...
Page 3 Hardware manual ACS880-07 drives (45 to 710 kW, 50 to 700 hp) Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 10. Start-up  2017 ABB Oy. All Rights Reserved. 3AUA0000105718 Rev F EFFECTIVE: 2017-12-11...
Page 5: Table Of Contents
Table of contents 1. Safety instructions Contents of this chapter ..........15 Use of warnings .
Page 6 Cooling air intake through bottom of cabinet (option +C128) ....48 Channeled air outlet (option +C130) ........48 Marine construction (option +C121) .
Page 7 Additional requirements for the braking applications ..... . . 81 Additional requirements for ABB high-output and IP23 motors ....81 Additional requirements for non-ABB high-output and IP23 motors .
Page 8 Relay cable type ........... . 88 Control panel cable length and type .
Page 9 EMC filter +E200 ..........105 EMC filter +E202 and (ARFI-10) .
Page 10 Layout ............. 138 Default I/O connection diagram of frames R6 to R9 .
Page 11 Inlet (door) filters (IP54 / UL Type 12) ....... . . 164 Outlet (roof) filters (IP54 / UL Type 12) .
Page 12 Ambient conditions ........... 219 Auxiliary circuit power consumption .
Page 13 Providing feedback on ABB Drives manuals ....... . . 259...
Page 15: Safety Instructions
Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 16: General Safety In Installation, Start-Up And Maintenance
16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the drive and do maintenance work on WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 17 Safety instructions 17 • Do not use the module installation ramp with plinth heights which exceed the maximum height (50 mm [1.97 in]) marked on the ramp. • Secure the module installation ramp carefully. • To prevent the drive module from falling, attach its top lifting lugs with chains to the cabinet lifting lug before you push the module into the cabinet and pull it from the cabinet.
Page 18: Electrical Safety In Installation, Start-Up And Maintenance
18 Safety instructions Note: • If you select an external source for start command and it is on, the drive will start immediately after fault reset unless you configure the drive for pulse start. See the firmware manual. • When the control location is not set to Local, the stop key on the control panel will not stop the drive.
Page 19: Additional Instructions And Notes
Safety instructions 19 L1, L2, L3 • Make sure that the voltage between the drive module UDC+ and UDC- terminals and the grounding (PE) busbar is close to 0 V. 6. Install temporary grounding as required by the local regulations. 7.
Page 20: Grounding
20 Safety instructions WARNING! Use a grounding wrist band when you handle the printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge. WARNING! Obey these instructions. If you ignore them, equipment malfunction and damage to the fiber optic cables can occur.
Page 21: Additional Instructions For Permanent Magnet Motor Drives
Safety instructions 21 Additional instructions for permanent magnet motor drives Safety in installation, start-up and maintenance  These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death and equipment malfunction can occur.
Page 22 22 Safety instructions...
Page 23: Introduction To The Manual
Introduction to the manual 23 Introduction to the manual Contents of this chapter This chapter describes the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals.
Page 24: Related Manuals
24 Introduction to the manual Electrical installation gives instructions on wiring the drive. Control unit of frames R6 to R9 contains the default I/O connection diagrams, descriptions of the terminals and technical data for the control unit. Control unit of frames R10 and R11 contains the default I/O connection diagrams and references for the descriptions of the terminals and technical data of the control unit.
Page 25 Introduction to the manual 25 Task Unpack and check the units (only intact units may be started up). Mechanical installation (page 61) Make sure that all necessary option modules and equipment are present and correct. Install the drive mechanically. Route the cables. Routing the cables (page 89) Check the insulation of the supply cable, the motor and the motor...
Page 26: Terms And Abbreviations
26 Introduction to the manual Terms and abbreviations Term/ Explanation Abbreviation Common mode filtering DDCS Distributed drives communication system; a protocol used in optical fiber communication Drive Frequency converter for controlling AC motors. The drive consists of a rectifier and an inverter connected together by the DC link. In drives up to approximately 500 kW, these are integrated into a single module (drive module).
Page 27 Introduction to the manual 27 Term/ Explanation Abbreviation Programmable logic controller Power module Common term for drive module, inverter module, supply module, brake chopper module etc. R6…R11 Frame size designation of the drive Radio-frequency interference SAFUR Series of optional brake resistor Safe acceleration range Safe brake control Safely-limited speed...
Page 28 28 Introduction to the manual...
Page 29: Operation Principle And Hardware Description
This chapter briefly describes the operation principle and construction of the drive. Product overview The ACS880-07 is an air-cooled cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors) with option N7502.
Page 30: Single-Line Circuit Diagram Of The Drive
30 Operation principle and hardware description Single-line circuit diagram of the drive  > Main switch-disconnector (switch fuse in frames R6 to R8, switch-disconnector and separate fuses in frames R9 to R11, or molded case circuit breaker and separate fuses [option +F289 for US market only]) Optional line contactor (+F250) Auxiliary voltage transformer supplying 24 V and 230 V control voltage for, eg, cabinet fan(s),...
Page 31: Block Diagram Of The Brake And Dc Options (+D150, +D151 And +H356)
Operation principle and hardware description 31 Block diagram of the brake and DC options (+D150, +D151 and  +H356) Drive module cubicle Drive module Brake resistor cubicle Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter. DC choke is included in frames R6 to R9. An AC input choke is included in frames R10 and R11.
Page 32: General Information On The Cabinet Layout
32 Operation principle and hardware description General information on the cabinet layout  IP22/IP42 IP54 Example cabinet line-up UL Type 1 / UL Type 12 Frames R6 to R8: drive module cubicle. UL Type 1 Filtered Frames R9 to R11: two cubicles with one door (main switch and power cabling cubicle and drive module cubicle) Brake resistor cubicle with option +D151...
Page 33: Cabinet Layout Of Frames R6 To R8
Operation principle and hardware description 33 Cabinet layout of frames R6 to R8  The cabinet layout without shrouds is shown below. Drive control panel Control unit, see page 137. Door switches and lights, see page 46. Optional terminal block for external control unit connections (X504, option +L504) Main switch handle Power cable connection terminals and du/dt...
Page 34: Cabinet Layout Of Frames R6 To R8 With Option +C129
34 Operation principle and hardware description Cabinet layout of frames R6 to R8 with option +C129  The cabinet layout without shrouds is shown below. Drive control panel Buffer module C22 Door switches and lights, see page 46. Swing-out frame Main switch handle Mounting plate with connection terminals for options +G300, +G307, +G313 at the back...
Page 35: Cabinet Layout Of Frames R6 To R8 With Options +C129 And +F289
Operation principle and hardware description 35 Cabinet layout of frames R6 to R8 with options +C129 and +F289  Option +C129 +F289 is available for US market only. The cabinet layout without shrouds is shown below. Drive control panel Auxiliary voltage transformer (T21) Door switches and lights, see page 46.
Page 36 36 Operation principle and hardware description Control cable entries Control unit, see page 137. Motor cable entries Optional terminal block for external control unit connections (X504, option +L504) Ground bar Common mode filter (option +E208) Motor cable connection terminals Connection terminals for options +F250, +Q951, +Q952, +Q963, +Q964+Q968, +Q954, +M600…+M605,+ L505, +L506.
Page 37: Cabinet Layout Of Frame R9
Operation principle and hardware description 37 Cabinet layout of frame R9  The cabinet layout is shown below. See also the next page. A – Main breaker and power cabling cubicle B – Drive module cubicle Drive control panel Buffer module Operating switch Swing-out frame Main switch handle...
Page 38 38 Operation principle and hardware description The cabinet layout without shrouds, with the swing-out frame open is shown below. A – Main breaker and power cabling cubicle B – Drive module cubicle Auxiliary voltage transformer (T21) Control unit, see page 137. Swing-out frame Optional terminal block for external control unit connections (X504, option +L504)
Page 39: Cabinet Layout Of Frame R9 With Options +C129 And +F289
Operation principle and hardware description 39 Cabinet layout of frame R9 with options +C129 and +F289  The cabinet layout is shown below. See also the next page. A – Main breaker and power cabling cubicle B – Drive module cubicle Drive control panel Buffer module Operating switch...
Page 40 40 Operation principle and hardware description The cabinet layout with the swing-out frame open is shown below. Control cable entry Connection terminals for external brake resistor and DC cables Swing-out frame Line contactor (option +F250) Drive module Connection terminals for options +F250, +Q951, +Q952, +Q963, +Q964+Q968, +Q954, +M600…+M605,+ L505, +L506.
Page 41: Cabinet Layout Of Frames R10 And R11 - Bottom Entry And Exit Of Cables
Operation principle and hardware description 41 Cabinet layout of frames R10 and R11 – bottom entry and exit of  cables The cabinet layout is shown below. See also the next page. A – Main breaker and power cabling cubicle B –...
Page 42 42 Operation principle and hardware description The cabinet layout without shrouds, with the swing-out frame open is shown below. A – Main breaker and power cabling cubicle B – Drive module cubicle Main fuses for control devises, IP54 fan Drive module transformer (with option +B055), V-meter (option +G334), starter for auxiliary motor fan (option +M600)
Page 43: Cabinet Layout Of Frames R10 And R11 - Top Entry And Exit Of Cables (Option +C129)
Operation principle and hardware description 43 Cabinet layout of frames R10 and R11 – top entry and exit of cables  (option +C129) The cabinet layout is shown below. A – Main breaker and power cabling cubicle B – Drive module cubicle Main fuses for control devises, IP54 fan Drive module transformer (with option +B055), V-meter...
Page 44: Overview Of Power And Control Connections
44 Operation principle and hardware description Overview of power and control connections  The diagram shows the power connections and control interfaces of the drive. Slot 1 X208 Slot 2 Slot 3 ..M 3 ~ UDC+ UDC-...
Page 45 Operation principle and hardware description 45 The layout of external control connection terminals at the side of the drive cabinet is shown below. The composition depends on the options selected. X965 X965 Terminals for X250 Auxiliary contacts of optional line contactor (+F250) X969 X969...
Page 46: Door Switches And Lights
46 Operation principle and hardware description Door switches and lights  Label in English Label in local Description language READY Ready light (option +G327) Run light (option+G328) FAULT Fault light (option +G329) MAIN CONT. Operating switch with option +F250 Opens the main contactor (Q2) and disables starting of the drive Closes the main contactor (Q2) EMERGENCY...
Page 47: Control Panel
When a PC is connected to the control panel, the control panel keypad is disabled. Descriptions of options Note: All options are not available for all drive types, do not coexist with certain other options, or may require additional engineering. Check actual availability with ABB. Degree of protection ...
Page 48: Ip42 And Ul Type 1 Filtered (Option +B054)
48 Operation principle and hardware description IP20. The live parts inside the cabinet are protected against contact with clear plastic shrouds or metallic gratings. IP42 and UL Type 1 Filtered (option +B054) This option provides the degree of protection of IP42 (UL type 1). The air inlet gratings are covered with a metallic mesh between the inner and outer metallic gratings.
Page 49: Csa Approved (Option +C134)
Operation principle and hardware description 49 CSA approved (option +C134)  The option includes the following accessories and features: • bottom entry and exit of cables with US cable conduit entry (plain plate without ready- made holes) • all components UL/CSA listed/Recognized •...
Page 50: Sine Filter (Option +E206)
50 Operation principle and hardware description Sine filter (option +E206)  A sine filter provides true sinusoidal voltage waveform at the drive output by suppressing the high-frequency voltage components of the output. These high-frequency components cause stress to motor insulation as well as output transformer saturation (if present). The sine filter option consists of three single-phase reactors and delta-connected capacitors at the output of the drive.
Page 51: Cabinet Lightning (Option +G301)
Operation principle and hardware description 51 See also sections: • Powering the heating and lighting equipment (options +G300, +G301 and +G313) • Auxiliary circuit power consumption on page • circuit diagrams delivered with drive for the actual wiring. Cabinet lightning (option +G301) ...
Page 52: A-Meter In One Phase (Option +G335)
52 Operation principle and hardware description A-meter in one phase (option +G335)  The option contains an ammeter that reads the current flowing through one input phase. Additional wire markings (options +G340 and +G342)  Standard wire markings As standard, wires and terminals are marked as follows: •...
Page 53: Top Cable Entry/Exit (Options +H351 And +H353)
Operation principle and hardware description 53 Top cable entry/exit (options +H351 and +H353)  For non-UL Listed units, the default input and output cabling direction is through the bottom of the cabinet. The top entry (+H351) and top exit (+H353) options provide power and control cable entries at the roof of the cabinet.
Page 54: L536, +L537
54 Operation principle and hardware description Option +L513 is an ATEX-certified thermal protection function that has the same external connectivity as +L505. In addition, +L513 comes with +Q971 (ATEX-certified safe disconnection function) as standard and is wired at the factory to activate the Safe torque off function of the drive in an overtemperature situation.
Page 55: Starter For Auxiliary Motor Fan (Options +M600
Operation principle and hardware description 55 The output indication of the auxiliary relays can be wired by the customer for example to • the main contactor or breaker control circuit of the drive, to open it in case of motor overtemperature, •...
Page 56: Type Designation Label
56 Operation principle and hardware description The statuses of both the starter switch and the fan contactor are wired to the terminal block. See the circuit diagrams delivered with the drive for the actual wiring. Type designation label The type designation label includes ratings, appropriate markings, a type designation and a serial number, which allow identification of each unit.
Page 57: Type Designation Key
Type designation key The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (eg, ACS880-07-240A-5). The optional selections are given thereafter, separated by plus signs, eg, +E202. The main selections are described below.
Page 58 58 Operation principle and hardware description CODE DESCRIPTION Filters E200 EMC/RFI filter for second environment TN (grounded) system, category C3. See page 49. E201 EMC/RFI filter for second environment IT (ungrounded) system, category C3. See page 49. E202 EMC/RFI filter for first environment TN (grounded) system, category C2. See page 49. E205 du/dt filter (page 49) E206...
Page 59 Operation principle and hardware description 59 CODE DESCRIPTION K473 FENA-11 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols K475 FENA-21 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols, 2-port I/O extensions and feedback interfaces L500 FIO-11 analog I/O extension module L501...
Page 60 60 Operation principle and hardware description CODE DESCRIPTION Safety functions Q950 Prevention of unexpected start-up with FSO-xx safety functions module Q951 Emergency stop (category 0) with safety relays, by opening the main contactor/breaker Q952 Emergency stop (category 1) with safety relays, by opening the main contactor/breaker Q954 Ground fault monitoring for IT (ungrounded) systems Q957...
Page 61: Mechanical Installation
Mechanical installation 61 Mechanical installation Contents of this chapter This chapter describes the mechanical installation procedure of the drive. Examining the installation site Examine the installation site: • The installation site is sufficiently ventilated or cooled to transfer away the drive losses.
Page 62: Necessary Tools
62 Mechanical installation Do not install the drive on an elevated platform or a recess. The module extraction/installation ramp included with the drive is only suitable for a height difference of 50 mm maximum (ie. the standard plinth height of the drive). Necessary tools The tools required for moving the unit to its final position, fastening it to the floor and wall and tightening the connections are listed below:...
Page 63: Moving And Unpacking The Drive
Mechanical installation 63 Moving and unpacking the drive Move the drive in its original pallet, preferably in the original package to the installation site as shown below to avoid damaging the cabinet surfaces and door devices. When you are using a pallet truck, check its load capacity before you move the drive. The drive cabinet is to be moved in the upright position.
Page 64: Removing The Transport Package
64 Mechanical installation Removing the transport package  Remove the transport package as follows: 1. Undo the screws that attach the wooden parts of the transport crate to each other. 2. Remove the wooden parts. 3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws.
Page 65: Moving The Cabinet On Rollers
Mechanical installation 65 Moving the cabinet on rollers WARNING: Do not move marine versions (option +C121) on rollers. Lay the cabinet on the rollers and move it carefully until close to its final location. Remove the rollers by lifting the unit with a crane, forklift, pallet truck or jack. Moving the cabinet on its back WARNING: Do not transport the drive with a sine filter (option +E206) on its back.
Page 66: Final Placement Of The Cabinet
66 Mechanical installation Final placement of the cabinet Move the cabinet into its final position with a slate bar (spud bar). Place a piece of wood between the edge of the cabinet and the bar to protect the cabinet frame.
Page 67: Installing The Ip54 Roof
Mechanical installation 67 Installing the IP54 roof If the roof of an IP54 cabinet is delivered in a separate package, install the roof as follows. Frames R6 to R8  1. Undo the mounting screws of the front top profile of the cabinet and remove it. Undo the back mounting screws of the roof from the cabinet top.
Page 68: Frame R9
68 Mechanical installation Frame R9  1. Undo the mounting screws of the front top profile of the cabinet and remove it. Undo the back mounting screws of the roof from the cabinet top. See step 1 under section Frames R10 and R11 on page 69.
Page 69: Frames R10 And R11
Mechanical installation 69 Frames R10 and R11  1. To remove the top front and back profile of the cabinet, undo the mounting screws. 2. Connect the power supply wires to the fan. 3. Install the front top profile of the cabinet in reverse order to step 1. 4.
Page 70: Fastening The Cabinet To The Floor And Wall Or Roof (Non-Marine Units)
70 Mechanical installation Fastening the cabinet to the floor and wall or roof (non-marine units) General rules  • The drive must be installed in an upright vertical position. • The cabinet can be installed with its back against a wall (a), or back-to-back with another unit (b).
Page 71: Fastening Methods
Mechanical installation 71 Fastening methods  Fasten the cabinet to the floor by using clamps included along the edge of the cabinet bottom, or by bolting the cabinet to the floor through the holes inside (if they are accessible). Alternative 1 – Clamping ...
Page 72: Fastening The Cabinet To The Floor And Roof/Wall (Marine Units)
72 Mechanical installation Fastening the cabinet to the floor and roof/wall (marine units) Obey the general cabinet installation rules also in the installation of the marine variant. See section General rules on page 70. See the dimension drawing delivered with the drive for details of the fastening points. Top fastening brackets are included in the delivery.
Page 73: Miscellaneous
Mechanical installation 73 Miscellaneous Cable duct in the floor below the cabinet  A cable duct can be constructed below the 500 mm wide middle part of the cabinet. The cabinet weight lies on the two 50 mm wide transverse sections which the floor must carry. Prevent the cooling air flow from the cable duct to the cabinet by bottom plates.
Page 74: Air Outlet Duct On The Cabinet Roof (Option +C130)
= 0.5 • • v = 0.5 • 1.1 • 5.5 = 17 Pa The required pressure in the exit air duct is then, 1.5…2 • 17 Pa = 26…34 Pa, below the pressure in the room. For more information, contact ABB.
Page 75: Arc Welding
Mechanical installation 75 Arc welding  Fastening the cabinet by arc welding is not recommended. However, if the arc welding is the only mounting option, proceed as follows: Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1.5 ft) of the welding point. Note: The thickness of the zinc coating of the cabinet frame is 20 micrometers (0.79 mil).
Page 76 76 Mechanical installation...
Page 77: Guidelines For Planning The Electrical Installation
ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
Page 78: Examining The Compatibility Of The Motor And Drive
Examining 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.
Page 79: Requirements Table
Motor Nominal AC Requirement for type supply voltage Motor ABB du/dt and common mode filters, insulated N-end insulation motor bearings system < 100 kW 100 kW < P < 350 kW > 350 kW and frame size <...
Page 80: Additional Requirements For Explosion-Safe (Ex) Motors
80 Guidelines for planning the electrical installation Motor Nominal AC Requirement for type supply voltage Motor ABB du/dt and common mode filters, insulated N-end insulation motor bearings system < 100 kW 100 kW < P < 350 kW > 350 kW and frame size <...
Page 81: Hx_ And Am
Guidelines for planning the electrical installation 81 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.
Page 82: 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). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: •...
Page 83: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
Guidelines for planning the electrical installation 83 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: •...
Page 84: Selecting The Power Cables
Note: When continuous metal conduit is employed, shielded cable is not required. The conduit must have bonding at both ends. ABB recommends symmetrical shielded cable for the input cabling, but a four-conductor system is also possible. 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.
Page 85: Typical Power Cable Sizes
For the cable sizes accepted by the drive cabinet entries and connection terminals, see page 210. Drive type Frame size Cu cable type Al cable type Cu cable type AWG/kcmil per phase = 400 V ACS880-07-0105A-3 3×50 3×70 ACS880-07-0145A-3 3×95 3×120 ACS880-07-0169A-3 3×120 3×150 ACS880-07-0206A-3 3×150...
Page 86: Alternative Power Cable Types
86 Guidelines for planning the electrical installation Drive type Frame size Cu cable type Al cable type Cu cable type AWG/kcmil per phase ACS880-07-0210A-7 3×185 2 × (3×95) 300 MCM ACS880-07-0271A-7 3×240 2 × (3×120) 400 MCM ACS880-07-0330A-7 2 × (3×120) 3 ×...
Page 87: Not Allowed Power Cable Types
Guidelines for planning the electrical installation 87 Not allowed power cable types 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 PE conductor, make sure that the conductivity agree with the PE conductor requirements.
Page 88: Armored Cable / Shielded Power 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.
Page 89: Control Panel Cable Length And Type
Guidelines for planning the electrical installation 89 Control panel cable length and type  In remote use, the cable connecting the control panel to the drive must not be longer than three meters (10 ft). Cable type: shielded CAT 5e or better Ethernet patch cable with RJ-45 ends.
Page 90: Continuous Motor Cable Shield Or Enclosure For Equipment On The Motor Cable
90 Guidelines for planning the electrical installation 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: •...
Page 91: Protecting The Drive And The Input Power And Motor Cables Against Thermal Overload
Guidelines for planning the electrical installation 91 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.
Page 92: Implementing The Safe Torque Off Function
92 Guidelines for planning the electrical installation Note: Pressing the stop key on the control panel of the drive, or turning the operating switch of the drive from position “1” to “0” does not generate an emergency stop of the motor or separate the drive from dangerous potential.
Page 93: Declaration Of Conformity
Guidelines for planning the electrical installation 93 Safe stop 1 (SS1), Safe stop emergency (SSE), Safely limited speed (SLS) and Safe maximum speed (SMS). The settings of the FSO-xx are at default when delivered from the factory. The connectors of the module are pre-wired to terminal block X68. The wiring of the external safety circuit and configuration of the FSO-xx module are the responsibility of the machine builder.
Page 94: Using Power Factor Compensation Capacitors With The Drive
94 Guidelines for planning the electrical installation 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.
Page 95: Implementing A Bypass Connection
IEC/EN 61800-5-1, subclause 6.5.3, for example, "THIS MACHINE STARTS AUTOMATICALLY". Bypass connection is available as a factory-installed option for certain cabinet-built drive types. Consult ABB for more information. WARNING! Never connect the drive output to the electrical power network. The connection may damage the drive.
Page 96: Implementing A Motor Temperature Sensor Connection
96 Guidelines for planning the electrical installation Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs. 230 V AC 230 V AC + 24 V DC 1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode Implementing a motor temperature sensor connection WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either...
Page 97: Drive I/O, I/O Extension And Encoder Interface Modules
Guidelines for planning the electrical installation 97 connectors of the module. See the table below for the sensor insulation requirement. For sensor connection to the extension module, see its manual. 4. You can connect a sensor to an external thermistor relay the insulation of which is rated for the main circuit voltage of the drive.
Page 98 98 Guidelines for planning the electrical installation...
Page 99: Electrical Installation
Electrical installation 99 Electrical installation Contents of this chapter This chapter gives instructions on the wiring the drive. Warnings WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.
Page 100: Motor And Motor Cable
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, consult the manufacturer’s instructions.
Page 101: (Frames R6 To R9)
Electrical installation 101 Checking the compatibility with IT (ungrounded) and corner-grounded delta systems (frames R6 to R9) EMC filter  Drive EMC filters +E200 and +E202 are not suitable for use on an IT (ungrounded) system The filters in frames R6 to R9 are also not suitable for use on corner-grounded and midpoint-grounded delta systems.
Page 102: Disconnection Table (Frames R6 To R9)
*) With option +E201, EMC AC, EMC DC and VAR screws are removed at the factory from drives manufactured after 2018-01-01. For more information, contact ABB. Note: These are the EMC filter and varistor screws of different drive frame sizes.
Page 103: Identifying Different Types Of Electrical Power Systems
Electrical installation 103 Identifying different types of electrical power systems  To identify the electrical power system type, find out the supply transformer connection. If that is not possible, measure these voltages at the distribution board before you connect power to the drive: 1.
Page 104: (Frames R10 And R11)
104 Electrical installation Checking the compatibility with IT (ungrounded) and corner-grounded delta systems (frames R10 and R11) EMC filter +E200 – 690 V drives  Drive internal EMC filter +E200 is not suitable for use on an IT (ungrounded) system section Disconnection table (frames R10 and R11) on page 105.
Page 105: Disconnection Table (Frames R10 And R11)
Electrical installation 105 Disconnection table (frames R10 and R11)  EMC filter +E200 Check from this table if you have to disconnect the EMC filter (EMC AC screw) with option +E200 or ground-to-phase varistor (VAR screw). For instructions on how to do this, see EMC filter and ground-to-phase varistor disconnecting instructions for ACS880 frames R1 to R11 (3AUA0000125152 [English]).
Page 106: Emc Filter +E202 And (Arfi-10)
106 Electrical installation EMC filter +E202 and (ARFI-10) Check from this table if you have to remove EMC filter +E202 (ARFI-10) or ground-to- phase varistor (VAR screw). Frame size Symmetrically grounded Corner-grounded and IT systems (ungrounded or TN systems midpoint-grounded delta high-resistance-grounded (TN-S systems) systems...
Page 107: Connecting The Power Cables
Electrical installation 107 Connecting the power cables Connection diagram  ACS880-07 UDC+ R+ UDC- UDC- UDC+ (PE) (PE) 3 ~ M Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor (see page 84).
Page 108: Layout Of The Power Cable Connection Terminals And Entries (Frames R6 To R8)
108 Electrical installation 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. Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.
Page 109: Layout Of The Power Cable Connection Terminals And Entries
Electrical installation 109 Layout of the power cable connection terminals and entries (frames  R6 to R8 with option +C129 V2 W2 Power cable entries Strain relief Ground bar Input cable power connection terminals L1, L2 and L3 Motor cable connection terminals U2, V2, W2...
Page 110: Layout Of The Power Cable Connection Terminals And Entries (Frames R6 To R8 With Options +C129+F277+F289)
110 Electrical installation Layout of the power cable connection terminals and entries (frames  R6 to R8 with options +C129+F277+F289) Input power cable entry Motor cable entry Control cable entry Ground bar for motor cables Ground bar for input power cables Motor cable connection terminals U2, V2, Strain relief Input cable power connection terminals...
Page 111: Layout Of The Input And Motor Cable Connection Terminals (Frame R9)
Electrical installation 111 Layout of the input and motor cable connection terminals (frame  Strain relief L1, L2, L3 Input power cable terminals U2, V2, W2 Motor cable terminals Main switch-disconnector Cable routing from below is shown with the arrows.
Page 112: Layout Of The Power Cable Connection Terminals And Entries (Frame R9 With Option +C129)
112 Electrical installation Layout of the power cable connection terminals and entries (frame  R9 with option +C129) Power cable entry Strain relief Ground bar Input cable power connection terminals L1, L2 and L3 Motor cable connection terminals U2, V2,...
Page 113: Layout Of The Input And Motor Cable Connection Terminals (Frames R10 And R11)
Electrical installation 113 Layout of the input and motor cable connection terminals (frames  R10 and R11) Strain relief L1, L2, L3 Input power cable terminals U2, V2, W2 Motor cable terminals PE terminal Layout of the input and motor cable connection terminals (frames ...
Page 114: Entry Of External Resistor And Dc Cables
11. Fasten the conductive sleeves to the cable shields with cable ties. 12. Seal the slot between the cable and mineral wool sheet (if used) with sealing compound (eg, CSD-F, ABB brand name DXXT-11, code 35080082). 13. Tie up the unused conductive sleeves with cable ties.
Page 115 Electrical installation 115 17. Tighten the power cable screws to the torque given in Terminal and entry data for the power cables on page 210. 18. Reinstall the shroud(s) and mounting plates.
Page 116: Connection Procedure (Us)
116 Electrical installation Connection procedure (US)  WARNING! Apply grease to stripped aluminum conductors before attaching them to non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions. Aluminum-aluminum contact can cause oxidation in the contact surfaces. 1. Do the steps in section Precautions before electrical work on page before you start...
Page 117: Grounding The Motor Cable Shield At The Motor End
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...
Page 118: Grounding The Outer Shields Of The Control Cables At The Cabinet Entries
118 Electrical installation Grounding the outer shields of the control cables at the cabinet entries Applicability This section applies to drives without solid cable conduit plate (no options +C129, +H351, +H353, +H358). Procedure Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions as follows: 1.
Page 119 Electrical installation 119 Stripped cable Conductive surface of the shield exposed Stripped part covered with copper foil Cable shield Copper foil Shielded twisted pair Grounding wire Note for top entry of cables: When each cable has its own rubber grommet, sufficient IP and EMC protection can be achieved.
Page 120: Routing The Control Cables Inside The Cabinet (Frames R6 To R8)
120 Electrical installation Routing the control cables inside the cabinet (frames R6 to R8) +H351, +C129 +C129+F289...
Page 121: Routing The Control Cables Inside The Cabinet (Frame R9)
Electrical installation 121 Routing the control cables inside the cabinet (frame R9) +H351, +C129, +C129+F289...
Page 122: Routing The Control Cables Inside The Cabinet (Frames R10 And R11)
122 Electrical installation Routing the control cables inside the cabinet (frames R10 and R11) Use the existing trunking in the cabinet wherever possible. Use sleeving if cables are laid against sharp edges. When running cables to or from the swing-out frame, leave enough slack at the hinge to allow the frame to open fully.
Page 123 Electrical installation 123 Units without additional I/O terminal block (option +L504): Ground the pair-cable shields and all grounding wires to the clamp below the control unit as shown below. Units with additional I/O terminal block (option +L504): Ground the pair-cable shields and all grounding wires to the grounding clamp below the terminal block as shown below.
Page 124: Connecting The External 230 V Or 115 V Uninterruptible Control Voltage
124 Electrical installation At the other end of the cable, leave the 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.
Page 125: Wiring The Ptc Thermistor Relay(S)
Electrical installation 125 Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513 and +2L513) The external wiring of option +2L505 and +2L513 (two thermistor relays) is shown below. For example, one relay can be used to monitor the motor windings, the other to monitor the bearings.
Page 126: Wiring The Pt100 Relays (Options +Nl506)
126 Electrical installation Wiring the Pt100 relays (options +nL506) External wiring of eight Pt100 sensor modules is shown below. Contact load capacity is 250 V AC 10 A. For the actual wiring, see the circuit diagram delivered with the drive. X506 1 ×...
Page 127 Electrical installation 127 X506 1 × Pt100 Sensor 1 Sensor 2 Sensor 3 … 0/4…20 mA current output from sensor 1 0/4…20 mA current output from sensor 2 0/4…20 mA current Internal wiring for overheat indication. output from sensor 3 Overtemperature = contact open.
Page 128: Powering The Heating And Lighting Equipment
128 Electrical installation Powering the heating and lighting equipment (options +G300, +G301 and +G313) See the circuit diagrams delivered with the drive. Connect the external power supply wires for the cabinet heater and lighting to terminal block X300 at the back of the mounting plate. X300 Internal wiring of the cabinet heater: heater off/fault = contact open.
Page 129: Wiring Ground Fault Monitoring For It Ungrounded Systems (Option +Q954)
Electrical installation 129 Wiring ground fault monitoring for IT ungrounded systems (option +Q954) We recommend to connect Alarm 1 for drive tripping and Alarm 2 for alarm signals to avoid unnecessary trippings due to the ground fault monitor self testing with Alarm 2. X954 Internal wiring: Ground fault alarm 1.
Page 130: Connecting A Pc
130 Electrical installation Connecting a PC A PC (with eg. the Drive composer PC tool) can be connected to the drive as follows: 1. Connect an ACS-AP-I control panel to the drive either by using an Ethernet (eg. CAT5E) networking cable, or by inserting the panel into the panel holder (if present). WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage.
Page 131: Installing Option Modules
Electrical installation 131 Installing option modules Mechanical installation of I/O extension, fieldbus adapter and pulse  encoder interface modules See page for the available slots for each module. Install the option modules as follows: WARNING! Obey the instructions in chapter Safety instructions.
Page 132: Installation Of Safety Functions Modules (Frames R6 To R9)
132 Electrical installation Installation of safety functions modules (frames R6 to R9)  Mount the safety functions module next to the control unit as described below. WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1.
Page 133: Installation Of Safety Functions Modules (Frames R10 And R11)
Electrical installation 133 Installation of safety functions modules (frames R10 and R11)  Install the safety functions module next to the control unit as described below. Change the mounting plate of the module as shown in FSO-12 safety functions module user’s manual (3AXD50000015612 [English]).
Page 134 134 Electrical installation...
Page 135: Case 2: Fso-Xx Safety Functions Module Above The Control Unit
Electrical installation 135 Case 2: FSO-xx safety functions module above the control unit Install the safety functions module next to the control unit as described below. Change the original mounting plate of the module to the alternative plate included in the module package.
Page 136 136 Electrical installation...
Page 137: Control Unit Of Frames R6 To R9
Control unit of frames R6 to R9 137 Control unit of frames R6 to R9 Contents of this chapter This chapter contains the default I/O connection diagram, descriptions of the terminals and technical data for the control unit (ZCU-12) of drive frames R6 to R9.
Page 138: Layout
138 Control unit of frames R6 to R9 Layout The layout of external control connection terminals of the control unit is shown below. Description XPOW External power input Analog inputs X202 Analog outputs X208 XD2D Drive-to-drive link XRO1 Relay output 1 X205 XRO2 Relay output 2...
Page 139: Default I/O Connection Diagram Of Frames R6 To R9
Control unit of frames R6 to R9 139 Default I/O connection diagram of frames R6 to R9 XPOW External power input +24VI 24 V DC, 2 A Reference voltage and analog inputs +VREF 10 V DC, R 1…10 kohm -VREF -10 V DC, R 1…10 kohm AGND Ground AI1+...
Page 140: Notes
140 Control unit of frames R6 to R9 Notes: Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R > 200 kohm] input selected with jumper J1. Change of setting requires reboot of control unit. Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R >...
Page 141: Ai1 And Ai2 As Pt100, Pt1000, Ptc And Kty84 Sensor Inputs (Xai, Xao)
Control unit of frames R6 to R9 141 AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI,  XAO) Three Pt100/Pt1000 or PTC 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 FIO-11 or FAIO-01 analog I/O extension module or FEN-xx encoder interface module.) At the sensor end of the cable, leave the shields unconnected or ground them indirectly via a high-frequency capacitor with a few...
Page 142: Di6 (Xdi:6) As Ptc Sensor Input
142 Control unit of frames R6 to R9 DI6 (XDI:6) as PTC sensor input  A PTC sensor can be connected to this input for motor temperature measurement as follows. The sensor resistance must not exceed the threshold resistance of the digital input at the motor normal operating temperature.
Page 143: Safe Torque Off (Xsto)
Control unit of frames R6 to R9 143 This diagram shows the wiring of the drive-to-drive link for frames R6 to R9... . . 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.
Page 144 144 Control unit of frames R6 to R9 Digital inputs/outputs DIO1 Connector pitch 5 mm (0.2 in), wire size 2.5 mm (14 AWG) and DIO2 As inputs: (XDIO:1 and XDIO:2) 24 V logic levels: “0” < 5 V, “1” > 15 V : 2.0 kohm Input/output mode selection Filtering: 0.25 ms...
Page 145 Control unit of frames R6 to R9 145 Ground isolation diagram XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- channels +30 V AI2+ AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2...
Page 146 146 Control unit of frames R6 to R9...
Page 147: Contents Of This Chapter
Control unit of frames R10 and R11 147 Control unit of frames R10 and Contents of this chapter This chapter contains the default I/O connection diagram, descriptions of the terminals and technical data for the control unit (ZCU-14) of drive frames R10 and R11.
Page 148: Layout
148 Control unit of frames R10 and R11 Layout The layout of external control connection terminals of the control unit is shown below. Description XPOW External power input XRO1 Analog inputs Analog outputs XRO2 XD2D Drive to drive link XRO1 Relay output RO1 XRO3 XRO2...
Page 149: Default I/O Connection Diagram Of Frames R10 And R11
Control unit of frames R10 and R11 149 Default I/O connection diagram of frames R10 and R11 Relay outputs XRO1…XRO3 Ready 250 V AC / 30 V DC Running 250 V AC / 30 V DC Faulted(-1) 250 V AC / 30 V DC Fault External power input XPOW...
Page 150: Notes
150 Control unit of frames R10 and R11 Notes: Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R > 200 kohm] input selected with jumper J1. Change of setting requires reboot of control unit. Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R >...
Page 151 Control unit of frames R10 and R11 151 This diagram shows the wiring of the drive-to-drive link for frames R10 and R11.
Page 152: Ground Isolation Diagram
152 Control unit of frames R10 and R11 Ground isolation diagram XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- AI2+ channels +30 V AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2...
Page 153: Contents Of This Chapter
Installation checklist 153 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before you start up the drive. Warnings WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Do the steps in section Precautions before electrical work on page...
Page 154 154 Installation checklist Check that … There is an adequately sized protective earth (ground) conductor between the drive and the switchboard, and the conductor has been connected to appropriate terminal, and the terminal has been tightened. (Pull the conductor to check.) Proper grounding has also been measured according to the regulations.
Page 155: Contents Of This Chapter
Start-up 155 Start-up Contents of this chapter This chapter contains the start-up procedure of the drive. Start-up procedure The tasks which are needed in certain cases only are marked with underlining, and option codes are given in brackets. Default device designations (if any) are given in brackets after the name, for example “main switch-disconnector (Q1)”.
Page 156: Checks/Settings With No Voltage Connected
+N7502) for ACS880-01, ACS880-07, ACS850-04 and ACQ810-04 drives supplement (3AXD50000026332 [English]). For drives with ABB sine filter, check that bit 1 (ABB sine filter) of parameter 95.15 Special HW settings is activated. For other sine filters, see Sine filter hardware manual (3AXD50000016814 [English]).
Page 157: On-Load Checks
Start-up 157 Action Drives with an encoder interface module (optional): Set the encoder parameters. Activate the appropriate assistant (if present) in the control program, or see the user’s manual of the encoder interface module, and the drive firmware manual. On-load checks Check that the cooling fans rotate freely in the right direction, and the air flows upwards.
Page 158 158 Start-up...
Page 159: Contents Of This Chapter
Fault tracing 159 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs This table shows the LEDs visible on the control panel mounting platform on cabinet door. Where Color Indication Control POWER Green Control unit is powered and +15 V is supplied to the control panel...
Page 160 160 Fault tracing...
Page 161: Contents Of This Chapter
(www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). The maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance.
Page 162: Descriptions Of Symbols
Performance of on/off-site work (commissioning, tests, measurements or other work) Replacement Recommended annual maintenance actions by the user  ABB recommends these annual inspections to ensure the highest reliability and optimum performance. Recommended annual actions by the user Annually Connections and environment...
Page 163: Cabinet
Maintenance 163 Cabinet Cleaning the interior of the cabinet  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use a vacuum cleaner with an antistatic hose and nozzle, and wear a grounding wristband.
Page 164: Inlet (Door) Filters (Ip54 / Ul Type 12)
164 Maintenance Inlet (door) filters (IP54 / UL Type 12) 1. Remove the fasteners at the top of the grating. 2. Lift the grating and pull it away from the door. 3. Remove the air filter mat. 4. Place the new filter mat in the grating the metal wire side facing the door. 5.
Page 165: Heatsink
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.
Page 166: Replacing The Cabinet "Door" Fans
166 Maintenance Replacing the cabinet “door” fans  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 167: Replacing The Cabinet Fans (Frames R6 To R9)
Maintenance 167 Replacing the cabinet fans (frames R6 to R9)  1. For removing the fan mounting plate, see section Replacing the drive module (frames R6 to R8) on page (steps 1 to 3 and 13) or section Replacing the drive module (frame R9) on page (steps 1, 9 and 10).
Page 168: Replacing The Drive Module Main Fans (Frames R6 To R8)
168 Maintenance Replacing the drive module main fans (frames R6 to R8)  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 169: Replacing The Auxiliary Cooling Fan Of The Drive Module (Frames R6 To R9)
Maintenance 169 Replacing the auxiliary cooling fan of the drive module (frames R6  to R9) WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 170: Replacing The Drive Module Main Fans (Frame R9)
170 Maintenance Replacing the drive module main fans (frame R9)  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 171: Replacing The Drive Module Main Fans (Frames R10 And R11)
Maintenance 171 Replacing the drive module main fans (frames R10 and R11)  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 172: Replacing The Circuit Board Compartment Cooling Fan (Frames R10 And R11)
172 Maintenance Replacing the circuit board compartment cooling fan (frames R10  and R11) WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 173: Replacing The Ip54 (Ul Type 12) Roof Fan Of Frames R6 To R8
Maintenance 173 Replacing the IP54 (UL type 12) roof fan of frames R6 to R8  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 174: Replacing The Ip54 (Ul Type 12) Roof Fan Of Frame R9
174 Maintenance Replacing the IP54 (UL type 12) roof fan of frame R9  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 175: Replacing The Ip54 (Ul Type 12) Roof Fan Of Frames R10 And R11
Maintenance 175 Replacing the IP54 (UL type 12) roof fan of frames R10 and R11  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 176: Replacing The Drive Module (Frames R6 To R8)
Required in this replacing procedure: preferably two persons, lifting chains, lifting device, a set of screw drivers and torque wrench with extension bar. A lifting device for ACS880-07 drive modules is available from ABB. For its installation and use, see ACS880-07 lifting device user’s manual (3AUA0000131337 [English]).
Page 177 Maintenance 177 14. Unplug the cabinet fan power supply cables and remove the fan assembly above the drive module. 15. Remove the slide extension rails from the left-hand side of the cabinet by undoing the mounting screws. 16. Install the extension rails at the end of the sliding bars. 17.
Page 178 178 Maintenance R6 to R8...
Page 179 Maintenance 179 R6 to R8 +D150, +D151 +H356 UDC- UDC+...
Page 180 180 Maintenance R6 to R8...
Page 181: Replacing The Drive Module (Frame R9)
Required in the replacing procedure: preferably two persons, lifting chains, lifting device, a set of screw drivers and torque wrench with extension bar. A lifting device for ACS880-07 drive modules is available from ABB. For its installation and use, see ACS880-07 lifting device user’s manual (3AUA0000131337 [English]).
Page 182 182 Maintenance 14. Undo the lower mounting nuts of the drive module. 15. Remove the two mounting screws of the top right mountig plate. Turn the plate to the horizontal position. 16. Slide the drive module towards the end of the sliding bars. 17.
Page 183 Maintenance 183...
Page 184 184 Maintenance...
Page 185 Maintenance 185...
Page 186: Replacing The Drive Module (Frames R10 And R11)
186 Maintenance Replacing the drive module (frames R10 and R11) This replacing procedure requires: preferably two persons, installation ramp, a set of screw drivers and a torque wrench with an extension bar. The drawings show frame R11. The details in frame R10 are slightly different. WARNING! Obey the instructions in chapter Safety instructions.
Page 187 Maintenance 187 R10 and R11...
Page 188 188 Maintenance R10 and R11...
Page 189 Maintenance 189 R10 and R11...
Page 190 190 Maintenance R10 and R11...
Page 191: Capacitors
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.
Page 192: Cleaning
192 Maintenance Cleaning  See ACX-AP-x assistant control panels user’s manual (3AUA0000085685 [English]). Replacing the control unit battery 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work. To replace the control unit battery: 1.
Page 193: Memory Unit
Maintenance 193 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 or 148. Transferring the memory unit ...
Page 194 194 Maintenance...
Page 195: Technical Data
The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table. IEC RATINGS Drive type Frame Input Output ratings size rating ACS880-07- No-overload use Light-overload Heavy-duty use = 400 V 0105A-3 0145A-3 0169A-3 0206A-3...
Page 196 196 Technical data IEC RATINGS Drive type Frame Input Output ratings size rating ACS880-07- No-overload use Light-overload Heavy-duty use 0585A-3 0650A-3 0725A-3 1020 0820A-3 1020 0880A-3 1100 725*** At 25 °C (77 °F) ambient temperature the current is 451 A.
Page 197 Technical data 197 NEMA RATINGS Drive type Frame Input Max. App. Output ratings size rating current power ACS880-07- Light-overload use Heavy-duty use = 460 V 0096A-5 0124A-5 0156A-5 0180A-5 0240A-5 0302A-5 0361A-5 0414A-5 361** 0503A-5 0583A-5 0635A-5 0715A-5 0820A-5 1020...
Page 198: Definitions
Note 3 – ACS880-07-0174A-7 amp rating: The drive can deliver 192 A continuously with no overload. Note 4 – ACS880-07-0271A-7 power rating: The power rating is as per NEC Table 42.1. However, the drive can be used for a typical 4-pole motor rated to 300 hp meeting NEMA MG 1 Table 12-11 minimum efficiency standard (EPAct efficiency electrical motors) if motor full load current is not more than 271 A.
Page 199: Altitude Derating
+95 °F +104 °F Ambient temperature Derating factor 1.00 Derating factor 0.95 Derating factor 0.9 Derating factor 0.85 Derating factor 0.80 Switching frequency derating  Switching frequencies other than default can require output current derating. Contact ABB for more information.
Page 200: Deratings For Special Settings In The Drive Control Program
Ex motor, sine filter, low noise The table below gives the deratings for these cases: • drive is used with an ABB motor for explosive atmospheres (Ex) and EX motor in Parameter 95.15 Special HW settings is enabled • sine filter option +E206 is selected and ABB sine filter in Parameter 95.15 Special HW settings is enabled •...
Page 201 Technical data 201 Drive type Output ratings for special settings ACS880-07- Ex motor (ABB Ex motor) ABB sine filter Low noise mode Nominal Light- Heavy- Nominal Light- Heavy- Nominal use Light- Heavy- duty duty duty duty duty duty 0635A-5 0715A-5...
Page 202: High Speed Mode
HW settings is enabled. With output frequencies smaller than the recommended maximum output frequency, the current derating is less than the values given in the table. Contact ABB for operation above the recommended maximum output frequency or for the output current derating with output frequencies above 120 Hz and below the maximum output frequency.
Page 203 Technical data 203 Drive type Deratings with selection High speed mode of parameter 95.15 Special HW settings ACS880-07- 120 Hz output frequency Maximum output frequency Nominal use Light- Heavy- Nominal use Light- Heavy- duty use duty use duty duty use...
Page 204 204 Technical data Fuses (IEC) The drive is equipped with aR fuses listed below. Drive Input Ultrarapid (aR) fuses (one fuse per phase) type cur- Bussmann Mersen type Type with option +F289 Size ACS880- rent type Bussmann Mersen type type = 400 V 0105A-3 8250...
Page 205: Fuses (Ul)
Technical data 205 Drive Input Ultrarapid (aR) fuses (one fuse per phase) type cur- Bussmann Mersen type Type with option +F289 Size ACS880- rent type Bussmann Mersen type type 0470A-7 465000 170M6412 170M6412 0522A-7 465000 170M6412 170M6412 0590A-7 670000 170M6413 170M6413 0650A-7 1000...
Page 206: Dimensions And Weights
206 Technical data Drive Input Fuse (one fuse per phase) type current Bussmann Mersen type With option +F289 ACS880- type class Bussmann Mersen type / Size type = 600 V 0061A-7 DFJ-250 170M3412 0084A-7 DFJ-250 170M3414 0098A-7 DFJ-250 170M3414 0119A-7 DFJ-250 170M3416 0142A-7...
Page 207: Dimensions And Weights Of Sine Filter Cubicle (Option +E206)
Technical data 207 Dimensions and weights of sine filter cubicle (option +E206)  Frame size Height Width Depth Weight IP22/42 IP54 2145 84.43 2315 91.16 23.62 25.43 280 to 617 to 330 * 728 * 2145 84.43 2315 91.16 23.62 25.43 310 to 683 to...
Page 208: Losses, Cooling Data And Noise
208 Technical data Losses, cooling data and noise Drive type Frame Air flow Heat Noise dissipation dB (A) /min = 400 V ACS880-07-0105A-3 1750 1130 1795 ACS880-07-0145A-3 1750 1130 1940 ACS880-07-0169A-3 1750 1130 2440 ACS880-07-0206A-3 1750 1130 2810 ACS880-07-0246A-3 1750...
Page 209: Cooling Data And Noise For Drives With Sine Filter (Option +E206)
Technical data 209 Drive type Frame Air flow Heat Noise dissipation dB (A) /min ACS880-07-0370A-7 2950 1837 6371 ACS880-07-0430A-7 2950 1837 7570 ACS880-07-0470A-7 2950 1837 6611 ACS880-07-0522A-7 2950 1837 7388 ACS880-07-0590A-7 2950 1837 8971 ACS880-07-0650A-7 3170 1978 9980 ACS880-07-0721A-7 3170...
Page 210: Terminal And Entry Data For The Power Cables
5170 ACS880-07-0721A-7 NSIN0900-6 3170 2000 5170 * Natural convection Sine filter is not available for ACS880-07-0302A-5. Terminal and entry data for the power cables  Frame Number of holes Terminals L1, L2, L3, U2, V2, W2, UDC+/R+, Grounding terminals size...
Page 211 Technical data 211  Frame Terminals L1, L2, L3, U2, V2, W2, UDC+/R+, UDC- and R- Grounding terminals size Max. phase Busbar bolt Tightening torque Bolt size Tightening torque conductor size size – Hole spacing AWG/kcmil bf·ft bf·ft 350 MCM M10 (3/8”) ×...
Page 212 212 Technical data Power cable terminal dimensions of frame R8 Top entry and exit:...
Page 213 Technical data 213 Motor cable terminal dimensions of frame R9 – Units with optional du/dt filter (+E205): Motor cable terminal dimensions of frame R9 – Units without optional du/dt filter (+E205): Input cable terminal dimensions of frame R9: Resistor and DC cable terminal dimensions of frames R9...
Page 214 214 Technical data Input and motor cable terminal dimensions of frame R10 Bottom entry and exit:...
Page 215 Technical data 215 Input and motor cable terminal dimensions of frame R11 Bottom entry and exit:...
Page 216 216 Technical data Input and motor cable terminal dimensions of frames R10 and R11 Top entry and exit (options +H351 and +H353):...
Page 217: Terminal Data For The Control Cables
Technical data 217 Input and motor cable terminal dimensions of frames R10 and R11 Top entry and exit: +C129+F277+F289 Terminal data for the control cables See chapter Control unit of frames R6 to R9 on page Control unit of frames R10 and R11 on page 147.
Page 218: Electrical Power Network Specification
218 Technical data Electrical power network specification Voltage (U ACS880-07-xxxxx-3 drives: 380…415 V AC 3-phase +10%…-10%. This is indicated in the type designation label as typical input voltage level 400 V AC ACS880-07-xxxxx-5 drives: 380…500 V AC 3-phase +10%…-10%. This is...
Page 219: Control Unit Connection Data
Installation site altitude 0…2000 m (0…6562 ft) above sea level. For altitudes over 2000 m, contact ABB. Output derated above 1000 m (3281 ft). See section Derating. Air temperature -0 to +40 °C (32 to -40 to +70 °C...
Page 220: Auxiliary Circuit Power Consumption
Tin-plated copper Air filters of IP54 drives Inlet (door): airComp 300-50 288 mm x 521 mm (ABB code: 64640194) 688 mm x 521 mm (ABB code 64748017) Outlet (roof): airTex G150 2 pcs: 398 mm x 312 mm (ABB code: 64722166)
Page 221: Applicable Standards
IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.
Page 222: Ce Marking
222 Technical data IEC/EN 61800-3:2004 Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific test methods UL 508A 1st edition:2001 Industrial Control Panels UL 50 12th edition:2007 Enclosures for Electrical Equipment, Non-Environmental Considerations CSA C22.2 No. 14- Industrial control equipment 13:2013 CSA C22.2 No.
Page 223: Declaration Of Conformity (Safe Torque Off)
Technical data 223 Declaration of Conformity (Safe torque off) See also chapter Safe torque off function on page and section Implementing the ATEX-certified safe motor disconnection function (option +Q971) on page 92.
Page 224 224 Technical data...
Page 225: Compliance With The En 61800-3:2004
Technical data 225 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.
Page 226: Category C3
Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The input power cables, motor cables and control cables are selected as specified in the appropriate drive manual(s).
Page 227: Ul Marking
• Protect the input cable with fuses. Circuit breakers must not be used without fuses in the USA. For suitable circuit breakers, contact your local ABB representative. Suitable IEC (class aR) fuses for drive protection are listed on page and UL fuses on page 205.
Page 228: Rcm Marking
ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any...
Page 229: Dimension Drawings
Dimension drawings 229 Dimension drawings Example dimension drawings with dimensions in millimeters and [inches] are shown below.
Page 230: Frames R6 To R8 (Ip22, Ip42 [+B054], Ul Type 1) - Standard And Options +C129, +H350, +H352
230 Dimension drawings Frames R6 to R8 (IP22, IP42 [+B054], UL Type 1) – standard and options +C129, +H350, +H352...
Page 231: Frames R6 To R8 (Ip54 / Ul Type 12 [+B055]) - Standard And Options +C129, +H350, +H352
Dimension drawings 231 Frames R6 to R8 (IP54 / UL Type 12 [+B055]) – standard and options +C129, +H350, +H352...
Page 232 232 Dimension drawings Frame R9 (IP22 and IP42 [+B054], UL Type 1) – standard and options +C129, +H350, +H352...
Page 233 Dimension drawings 233 Frame R9 (IP54 / UL Type 12 [+B055]) – standard and options +C129, +H350, +H352...
Page 234 234 Dimension drawings Frame R9 marine (option +C121) – standard and options +C129, +H350, +H352...
Page 235 Dimension drawings 235 Frames R6 to R8 with options +F289, +C129, +H350, +H352 (UL Type 1)
Page 236 236 Dimension drawings Frames R6 to R8 with options +F289, +C129, +H350, +H352 (UL Type 12 [+B055])
Page 237 Dimension drawings 237 Frames R10 and R11 (IP22, IP42 [+B054], UL Type 1) – standard and options +C129, +H350, +H352...
Page 238 238 Dimension drawings Frames R10 and R11 (IP54 / UL Type 12) – standard and options +C129, +H350, +H352...
Page 239: Safe Torque Off Function
Safe torque off function 239 Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description 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).
Page 240: Compliance With The European Machinery Directive
240 Safe torque off function Standard Name IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 1: General requirements IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 2: Requirements for electrical/electronic/programmable electronic safety-related systems IEC 61511-1:2016 Functional safety –...
Page 241: Cable Types And Lengths
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)  Dual-channel connection ACS880-07 OUT1 +24 V SGND Control logic UDC+ T1/U, T2/V, T3/W...
Page 242: Single-Channel Connection
242 Safe torque off function Single-channel connection ACS880-07 OUT1 +24 V SGND Notes: • Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL classification is given. • Pay special attention to avoiding any potential failure modes for the wiring. For example, use shielded...
Page 243: Multiple Drives (Internal Power Supply)
Safe torque off function 243 Multiple drives (internal power supply)  ACS880-07 XSTO OUT1 +24 V SGND ACS880-07 XSTO OUT1 SGND ACS880-07 XSTO OUT1 SGND...
Page 244: Multiple Drives (External Power Supply)
244 Safe torque off function Multiple drives (external power supply)  ACS880-07 24 V DC – XSTO OUT1 +24 V SGND ACS880-07 XSTO OUT1 SGND ACS880-07 XSTO OUT1 SGND...
Page 245: Operation Principle
Safe torque off function 245 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs on the drive control unit de-energize. 3. The control unit cuts off the control voltage from the drive IGBTs. 4.
Page 246 246 Safe torque off function Action 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 wiring diagram. Close the disconnector and switch the power on. Test the operation of the STO function when the motor is stopped.
Page 247: Use
Safe torque off function 247 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 drive IGBTs. 3.
Page 248: Competence
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.
Page 249: Abbreviations
Safe torque off function 249 Frame SIL/ MTTF Cat. HFT Lifetime size SILCL = 20 a) = 2 a) = 5 a) (1/h) 99.1 3.20E-09 2.66E-4 6.65E-05 10333 > 90 99.1 3.20E-09 2.66E-4 6.65E-05 10333 > 90 > 90 99.63 3.91E-09 3.43E-5 8.56E-05...
Page 250 250 Safe torque off function Abbr. Reference Description IEC 61508 Failure in time: 1E-9 hours IEC 61508 Hardware fault tolerance MTTF EN ISO 13849-1 Mean time to dangerous failure: (The total number of life units) / (the number of dangerous, undetected failures) during a particular measurement interval under stated conditions IEC 61508 Average probability of dangerous failure on demand...
Page 251: Contents Of This Chapter
Resistor braking 251 Resistor braking Contents of this chapter This chapter tells how to select, protect and wire brake choppers and resistors. The chapter also contains the related technical data. Operation principle and hardware description The drive can be equipped with an optional built-in brake chopper (+D150). Brake resistors are available as add-on kits or factory installed (+D151).
Page 252: Selecting A Custom Resistor
252 Resistor braking Note: If the E value of the resistor is not sufficient, it is possible to use a four-resistor assembly in which two resistors are connected in parallel, two in series. The E value of the four-resistor assembly is four times that of a single resistor. Selecting a custom resistor ...
Page 253: Minimizing Electromagnetic Interference
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 custom brake resistors and cabling. The customer must consider EMC compliance of the complete installation.
Page 254: Protecting The Resistor Cable Against Short-Circuits
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.
Page 255 Resistor braking 255 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.
Page 256: Technical Data
256 Resistor braking Technical data Ratings  Drive type Internal brake Example brake resistor(s) chopper Type brcont Rcont = 400 V ACS880-07-0105A-3 SAFUR80F500 2400 ACS880-07-0145A-3 SAFUR80F500 2400 ACS880-07-0169A-3 SAFUR125F500 3600 ACS880-07-0206A-3 SAFUR125F500 3600 ACS880-07-0246A-3 SAFUR200F500 5400 13.5 ACS880-07-0293A-3 SAFUR200F500 5400 13.5...
Page 257: Degree Of Protection Of Safur Resistors
Resistor braking 257 Drive type Internal brake Example brake resistor(s) chopper Type brcont Rcont = 690 V ACS880-07-0061A-7 SACE15RE13 13.0 ACS880-07-0084A-7 SACE15RE13 13.0 ACS880-07-0098A-7 SAFUR90F575 1800 ACS880-07-0119A-7 SAFUR90F575 1800 ACS880-07-0142A-7 SAFUR80F500 2400 ACS880-07-0174A-7 SAFUR80F500 2400 ACS880-07-0210A-7 SAFUR125F500 3600 ACS880-07-0271A-7 SAFUR125F500...
Page 258 258 Resistor braking...
Page 259: Product And Service Inquiries
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.
Page 260 Contact us www.abb.com/drives www.abb.com/drivespartners 3AUA0000105718 Rev F (EN) 2017-12-11...

ABB ACS880-07 Hardware Manual

Safety Instructions

Introduction to the Manual

Operation Principle and Hardware Description

Mechanical Installation

Guidelines for Planning the Electrical Installation

Electrical Installation

Control Unit of Frames R6 to R9

8 Control Unit of Frames R10 and R11

12 Maintenance

11 Fault Tracing

Quick Links

Related Manuals for ABB ACS880-07

Summary of Contents for ABB ACS880-07