Page 1 — ABB INDUSTRIAL DRIVES ACS880-37LC drives Hardware manual...
Page 3 ACS880-37LC drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 9. Start-up 3AXD50000251407 Rev B Original instructions EFFECTIVE: 2022-04-20...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ................Use of warnings and notes ............... General safety in installation, start-up and maintenance ........Work on the liquid cooling system ............Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ..............
Page 6 6 Table of contents Descriptions of options ................Degree of protection ................Definitions ..................Marine construction (option +C121) ............UL Listed (option +C129) ..............Plinth height (options +C164 and +C179) ..........Resistor braking (options +D150 and +D151) ..........du/dt filter ..................Common mode filter (option +E208) ............
Page 7 Availability of du/dt filter and common mode filter by drive type ..... Additional requirements for explosion-safe (EX) motors ......Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ..................Additional requirements for braking applications ........
Page 8 8 Table of contents Protecting the drive, input power cable, motor and motor cable in short circuit situations and against thermal overload ..............Protecting the input cabling and the drive upon a short-circuit ......Protecting the motor and motor cable in short-circuits ........Protecting the drive and the power cables against thermal overload ....
Page 9 Table of contents 9 Panel bus (Control of several units from one control panel) ......... Installing option modules ................. Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface modules ..................Installation of an FSO safety functions module onto BCU ....... Wiring of option modules ..............
Page 10 10 Table of contents Fans ....................Frame R8i fan replacement ..............Replacing the heat exchanger fan in the filter cubicle ........Replacing the fan in the incoming cubicle ..........Replacing the fan in the auxiliary control cubicle .......... Replacing the common motor terminal cubicle fan ........Replacing the brake chopper and resistor cubicle fans (options +D150 and +D151) .
Page 11 Table of contents 11 Derating ..................Surrounding air temperature derating ............ Coolant temperature derating ............. Antifreeze content derating ..............Altitude derating ................Switching frequency derating ............. Output frequency derating ..............Frame sizes and power module types ............Fuses ....................AC fuses ..................DC fuses ..................
Page 12 12 Table of contents 14 Dimensions Cabinet line-up dimensions ............... Dimension drawing examples ..............ACS880-37LC-0390A-7 with main contactor ........... ACS880-37LC-0600A-7 with brake chopper and resistors ......ACS880-37LC-1270A-7 with common motor terminal cubicle ....... ACS880-37LC-1940A-7 with common motor terminal cubicle .......
Page 13 Table of contents 13 16 Resistor braking Further information...
Page 15: Safety Instructions
Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start-up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 16: General Safety In Installation, Start-Up And Maintenance
16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 17 Safety instructions 17 • Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors, and brake resistors, remain hot for a while after disconnection of the electrical supply. • Make sure that debris from drilling, cutting and grinding does not enter the drive during the installation.
Page 18: Work On The Liquid Cooling System
• If you need to store the drive in temperature below -15 °C (5 °F), drain the cooling circuit, or make sure that it is filled with the coolant specified by ABB. • Drives with the cooling unit: Do not open the cooling unit pump inlet or outlet valves before filling up the coolant circuit.
Page 19: Electrical Safety In Installation, Start-Up And Maintenance
Safety instructions 19 Electrical safety in installation, start-up and maintenance Electrical safety precautions ￭ These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 20: Additional Instructions And Notes
There are electromagnetic fields present which can interfere with the function of such devices. This can cause a health hazard. • ABB does not recommend attaching the cabinet by arc welding. If you have to, obey the welding instructions in the drive manuals. Note: •...
Page 21: Optical Components
Safety instructions 21 After disconnecting the drive from the input power, these remain at a dangerous voltage until the intermediate circuit capacitors have discharged. • External wiring can supply dangerous voltages to the relay outputs of the control units of the drive. •...
Page 22: General Safety In Operation
22 Safety instructions General safety in operation These instructions are for all personnel that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Keep the cabinet doors closed when the drive is powered. With the doors open, a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists.
Page 23: Safety In Operation
Safety instructions 23 Before installation, start-up and maintenance work on the drive: • Stop the drive. • Disconnect the motor from the drive with a safety switch or by other means. • If you cannot disconnect the motor, make sure that the motor cannot rotate during work. Make sure that no other system, like hydraulic crawling drives, can rotate the motor directly or through any mechanical connection like felt, nip, rope, etc.
Page 25: Introduction To The Manual
Introduction to the manual 25 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 26: Use Of Component Designations
26 Introduction to the manual Use of component designations Some device names in the manual include the item designation in brackets, for example [Q20], to make it possible to identify the components in the circuit diagrams of the drive. Quick installation, commissioning and operation flowchart Task Plan the electrical installation and acquire the accessories needed Guidelines for planning the electrical install-...
Page 27: Terms And Abbreviations
Supply module(s) under control of one control unit, and related components. Related manuals You can find manuals and other product documents in PDF format on the Internet at www.abb.com/drives/documents. The code below opens an online listing of the manuals applicable to this product. ACS880-37LC manuals...
Page 29: Operation Principle And Hardware Description
This chapter briefly describes the operation principle and construction of the drive. The ACS880-37LC is a low-harmonic, liquid-cooled, cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance (SynRM) motors. The drive consists of several cubicles that contain •...
Page 30: Ac Voltage And Current Waveforms
30 Operation principle and hardware description AC fuses LCL filter Supply module (with IGBTs) DC capacitors with discharge resistors DC fuses AC voltage and current waveforms ￭ The AC current is sinusoidal at a unity power factor. The LCL filter suppresses the AC voltage distortion and current harmonics.
Page 31: Overview Circuit Diagram Of The Drive
Operation principle and hardware description 31 Overview circuit diagram of the drive Auxiliary voltage transformer(s) Auxiliary voltage switch [Q21] *Main switch/disconnector [Q1.1] *AC fuses [F1.x]. If the drive has multiple LCL filters, there are additional AC fuses at the input of each filter.
Page 32: Cabinet Line-Up And Layout Examples
32 Operation principle and hardware description Cabinet line-up and layout examples Frame 2×R8i+2×R8i line-up ￭ Cabinet line-up example Auxiliary control unit (ACU). Contains control electronics. Input cubicle (IPU). Contains the input power cable terminals. LCL filter cubicle (LCL). Supply module cubicle (ISU). Inverter module cubicle (INU).
Page 33: Frame 2×R8I+2×R8I Layout
Operation principle and hardware description 33 Frame 2×R8i+2×R8i layout ￭ Cabinet layout example Auxiliary control unit (ACU). Contains control electronics. Input cubicle (IPU). Contains the input power cable terminals. LCL filter cubicle (LCL). Supply module cubicle (ISU). Inverter module cubicle (INU). Contains the motor cable terminals. Supply control unit (A51) and inverter control unit (A41) Control electronics Auxiliary voltage transformers (obscured)
Page 34: Ka Input Cubicle (Option +F274)
34 Operation principle and hardware description Common mode filters IGBT supply modules of frame size R8i Coolant connections Air-to-liquid heat exchanger installed below each module (Behind the mounting plate) Fan. Forces air inside the cubicle through the heat exchanger. Mounting plate with terminal blocks for customer connections Inverter module DC fuses Inverter modules Inverter module cooling fan.
Page 35: Overview Of Power And Control Connections
Operation principle and hardware description 35 Protective earth (ground) Inlet manifold with stop and drain valves Outlet manifold with stop and drain valves Overview of power and control connections The diagram shows the power connections and control interfaces of the drive. Drive Supply control unit [A51] Inverter control unit [A41]...
Page 36: Door Switches And Lights
36 Operation principle and hardware description Memory unit Connection for FSO safety functions module Control panel and PC connection Terminal blocks on the inverter control unit. Fiber optic link to each inverter module. Similarly, each supply module is connected to the supply control unit by fiber optic cables.
Page 37: Other Devices On The Door
Operation principle and hardware description 37 Other devices on the door ￭ • Voltmeter (option +G334); comes with a phase selector switch. Note: The voltage is measured on the supply side of the main switch or breaker. • AC current meter (option +G335) on one phase. •...
Page 38: Descriptions Of Options
38 Operation principle and hardware description Descriptions of options Note: All options are not available for all drive types, do not coexist with certain other options, or may require additional engineering. Check actual availability with ABB. Degree of protection ￭...
Page 39: Du/Dt Filter
Operation principle and hardware description 39 du/dt filter ￭ The du/dt filter protects the motor insulating system by reducing the voltage rise speed at the motor terminals. The filter also protects the motor bearings by reducing the bearing currents. More information on when the option is required: See section Examining the compatibility of the motor and drive (page 74).
Page 40: Halogen-Free Wiring And Materials (Option +G330)
40 Operation principle and hardware description When the drive is powered (and not faulted), the heater is switched off. Otherwise, the heater is controlled by the external supply voltage. The power and voltage of the heater depend on the motor. See also: •...
Page 41: Additional Wire Markings
Operation principle and hardware description 41 Additional wire markings The following additional wire markings are available. Option Additional markings +G338 Equipment pin identifiers are marked with printing (or equivalent) on conductors that connect (class A1) to equipment, or are part of the wiring between power modules. (Short, obvious connections, main circuit conductors, and conductors going to terminal blocks or plug-type connectors are not marked.) T3/S...
Page 42: Bottom Cable Entry/Exit (Options +H350 And +H352)
42 Operation principle and hardware description of nuisance DC overvoltage tripping due to disturbances caused by probable high-voltage THD in the supply voltage. Short-circuit ratio is defined as the supply network's apparent short-circuit power S k,net divided by the drive's nominal apparent power S Bottom cable entry/exit (options +H350 and +H352) ￭...
Page 43: L536, +L537
Operation principle and hardware description 43 +L536, +L537 An alternative to a thermistor relay option is the FPTC-01 (option +L536) or FPTC-02 (option +L537, also requires option +Q971) thermistor protection module. The module mounts onto the inverter control unit, and has reinforced insulation to keep the control unit PELV-compatible.
Page 44: Starter For Auxiliary Motor Fan (Options +M600
44 Operation principle and hardware description • firmware manual for parameter settings • ATEX-certified motor thermal protection functions for cabinet-built ACS880 drives (options +L513+Q971 and +L514+Q971) user's manual (3AXD50000014979 [English]) • Pt100 relay alarm and trip limit setting instructions in the start-up instructions •...
Page 45: Type Designation Label
Operation principle and hardware description 45 Type designation label The type designation label includes ratings, appropriate markings, a type designation and a serial number, which allow the identification of each unit. A sample label is shown below. Quote the complete type designation and serial number when contacting technical support..•...
Page 46: Option Codes
46 Operation principle and hardware description Option codes ￭ Code Description A012 50 Hz supply frequency A013 60 Hz supply frequency B054 IP42 (UL Type 1 Filtered) B055 IP54 (UL Type 12) C121 Marine construction. See section Marine construction (option +C121) (page 38).
Page 47 Operation principle and hardware description 47 Code Description G301 Cabinet lighting. See section Cabinet lighting (option +G301) (page 39). G304 Control (auxiliary) voltage 115 V AC Terminals for connecting external control voltage (230 V AC or 115 V AC, eg. UPS). See section G307 Terminals for external control voltage (option +G307) (page 39).
Page 48 48 Operation principle and hardware description Code Description K470 FEPL-02 Ethernet POWERLINK adapter module K473 FENA-11 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols FENA-21 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols, K475 2-port L500 FIO-11 analog I/O extension module...
Page 49 Operation principle and hardware description 49 Code Description Q965 Safely-limited speed with FSO-21 and encoder Q966 Safely-limited speed without encoder Q971 ATEX-certified safe disconnection function Q972 FSO-21 safety functions module Q973 FSO-12 safety functions module Emergency stop (configurable for category 0 or 1) with FSO safety functions module, by opening Q978 the main breaker/contactor Emergency stop (configurable for category 0 or 1) with FSO safety functions module, by activating...
Page 51: Mechanical Installation
Mechanical installation 51 Mechanical installation Contents of this chapter This chapter describes the mechanical installation procedure of the drive. Examining the installation site Examine the installation site. Make sure that: • The installation site is sufficiently ventilated or cooled to remove heat from the drive. See the technical data.
Page 52: Examining The Delivery
52 Mechanical installation Examining the delivery The drive delivery contains: • drive cabinet line-up • optional modules (if ordered) installed onto the control unit(s) at the factory • appropriate drive and optional module manuals • delivery documents. Make sure that there are no signs of damage. Before attempting installation and operation, see the information on the type designation labels of the drive to verify that the delivery is of the correct type.
Page 53: Moving And Unpacking The Drive
Mechanical installation 53 Moving and unpacking the drive Move the drive in its original packaging to the installation site as shown below to avoid damaging the cabinet surfaces and door devices. When you are using a pallet truck, check its load capacity before you move the drive. The drive cabinet is to be moved in the upright position.
Page 54: Lifting The Crate With A Crane
54 Mechanical installation Lifting the crate with a crane WARNING! Incorrect lifting can cause danger or damage. Obey the local laws and regulations applicable to lifting, such as requirements for planning the lift, for capacity and condition of lifting equipment, and for training of personnel. Lifting point Optimal position for the lifting sling: as close to the traverse board as possible...
Page 55: Moving The Crate With A Forklift
Mechanical installation 55 Mechanical installation 61 Moving the crate with a forklift Moving the crate with a forklift 750 mm (29.5'') Removing the transport package ￭ Remove the transport package as follows: Undo the screws that attach the wooden parts of the transport crate to each other. Remove the wooden parts.
Page 56: Moving The Unpacked Drive Cabinet
Removing the transport package  Remove the transport package as follows: 56 Mechanical installation 1. Undo the screws that attach the wooden parts of the transport crate together. 2. Remove the wooden parts. Moving the unpacked drive cabinet ￭ 3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws.
Page 57: Moving The Cabinet On Rollers
Mechanical installation 57 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 an LCL or L filter on its back.
Page 58: Final Placement Of The Cabinet
58 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 59: Attaching The Cabinet To The Floor And Wall Or Roof
Mechanical installation 59 Attaching the cabinet to the floor and wall or roof General rules ￭ • The drive must be installed in an upright vertical position. • Leave 250 mm (9.85”) of free space above the cabinet for maintenance, and to allow pressure relief operation.
Page 60: Attaching The Cabinet (Non-Marine Units)
60 Mechanical installation Attaching the cabinet (non-marine units) ￭ Alternative 1 – Clamping Insert the clamps (included) into the twin slots along the front and rear edges of the cabinet frame body and fasten them to the floor with a bolt. The recommended maximum distance between the clamps in the front edge is 800 mm (31.5”).
Page 61: Alternative 2 - Using The Holes Inside The Cabinet
Mechanical installation 61 Alternative 2 – Using the holes inside the cabinet Attach the cabinet to the floor through the bottom fastening holes with size M10…M12 (3/8”…1/2”) bolts. The recommended maximum distance between the front edge fastening points is 800 mm (31.5”). If the back fastening holes are not accessible, attach the top of the cabinet to the wall with L-brackets (not included in the delivery) bolted to the lifting eye/bar holes.
Page 62: Attaching The Cabinet (Marine Units)
62 Mechanical installation Attaching the cabinet (marine units) ￭ See the dimension drawing delivered with the drive for details of the fastening points. Fasten the cabinet to the floor and roof (wall) as follows: Bolt the unit to the floor through the flat bars at the base of the cabinet using M10 or M12 screws.
Page 63: Joining Cabinet Sections Together
Mechanical installation 63 Joining cabinet sections together Wide cabinet line-ups are delivered in multiple sections. The sections are to be joined on-site using a joining cubicle at the end of one section (a common motor terminal cubicle can also act as a joining cubicle). The screws required for the joining are enclosed in a plastic bag inside the cabinet.
Page 64 64 Mechanical installation Center the Axilock connectors onto the gaps between coolant pipe ends. Tighten the connector screws to the torque indicated on the connector label. Fasten the front and rear posts of the joining cubicle to the posts of the other section with 16 screws (8 per post).
Page 65 Mechanical installation 65 Connect the PE busbars using the M10 bolts included. Tighten to 35…40 N·m (25…30 lbf·ft). Side Above Plain washer Spring washer Bolt Remove the shroud covering the DC busbars in the joining cubicle.
Page 66 66 Mechanical installation 10. Connect the DC and AC busbars. Tighten the bolts to 55…70 N·m (40…50 lbf·ft). Units with single DC busbars Units with double DC busbars Joint piece Plain washer with electroplated zinc coating and blue chromate passivation Spring washer with mechanically sprayed zinc coating Nut (M12)
Page 67 Mechanical installation 67 Units with single AC busbars Units with double AC busbars Bolt (M12) Bolt (M12) Joint piece Plain washer with electroplated zinc coating and blue chromate passivation Spring washer with mechanically sprayed zinc coating Nut (M12) WARNING! Make sure you install the washers in the correct order as shown. For example, placing an unpassivated zinc-coated spring washer directly against the joint piece will cause corrosion.
Page 68: Miscellaneous
Arc welding ￭ ABB does not recommend attaching the cabinet by arc welding. However, if arc welding is the only option, connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1’6”) of the welding point.
Page 69: Lifting Lugs And Bars
Mechanical installation 69 Lifting lugs and bars Certificate of conformity ￭ The certificate is available in ABB Library at www.abb.com/drives/documents (document number 3AXD10001061361). Declarations of conformity ￭...
Page 70 70 Mechanical installation...
Page 71 Mechanical installation 71 Declaration of Conformity Supply of Machinery (Safety) Regulations 2008 Manufacturer: ABB Oy Address: Hiomotie 13, 00380 Helsinki, Finland. Phone: +358 10 22 11 declare under our sole responsibility that the following products: Lifting bars, identified with material codes...
Page 72 Supply of Machinery (Safety) Regulations 2008. Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland Helsinki, 28 May 2021 Signed for and on behalf of:...
Page 73: Guidelines For Planning The Electrical Installation
The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
Page 74: Examining The Compatibility Of The Motor And Drive
Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.
Page 75 Guidelines for planning the electrical installation 75 This table shows the requirements when an ABB motor is in use. Motor type Nominal AC line Requirement for voltage Motor insula- ABB du/dt and common mode filters, insulated tion system N-end motor bearings <...
Page 76 76 Guidelines for planning the electrical installation This table shows the requirements when a non-ABB motor is in use. Motor type Nominal AC line Requirement for voltage Motor insula- ABB du/dt and common mode filters, insulated tion system N-end motor bearings <...
Page 77: Availability Of Du/Dt Filter And Common Mode Filter By Drive Type
If you 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 Use the selection criteria given for non-ABB motors.
Page 78: Additional Note For Sine Filters
78 Guidelines for planning the electrical installation 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: • If motor power is below 350 kW: Equip the drive and/or motor with the filters and/or bearings according to the table below.
Page 79: Selecting The Power Cables
Guidelines for planning the electrical installation 79 Selecting the power cables General guidelines ￭ Select the input power and motor cables according to local regulations. • Current: Select a cable capable of carrying the maximum load current and suitable for the prospective short-circuit provided by the supply network.
Page 80: Alternate Power Cable Types
80 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or armored) cable with three phase conductors and a shield (or armor), and separ- ate PE conductor/cable 1) A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the PE use. Alternate power cable types Cable type Use as input power cabling...
Page 81: Not Allowed Power Cable Types
Guidelines for planning the electrical installation 81 Not allowed power cable types Cable type Use as input power cabling Use as motor cabling Symmetrical shielded cable with in- dividual shields for each phase conductor Power cable shield ￭ If the cable shield is used as the sole protective earth (PE) conductor, make sure that its conductivity agrees with the PE conductor requirements.
Page 82: Additional Grounding Requirements - Iec
82 Guidelines for planning the electrical installation cross-sectional area of the protective earth conductor must be determined in a manner which produces a conductance equivalent to that which results from the application of this table. Cross-sectional area of the phase conductors Minimum cross-sectional area of the corresponding protective earth conductor S (mm...
Page 83: Selecting The Control Cables
￭ Only use shielded control cables. Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable also for the pulse encoder signals. Use one individually shielded pair for each signal. Do not use common return for different analog signals.
Page 84: Routing The Cables
84 Guidelines for planning the electrical installation Routing the cables General guidelines – IEC ￭ • Route the motor cable away from other cables. Motor cables of several drives can be run in parallel installed next to each other. • Install the motor cable, input power cable and control cables on separate trays.
Page 85: Separate Control Cable Ducts
Guidelines for planning the electrical installation 85 Separate control cable ducts ￭ Put 24 V DC and 230 V AC (120 V AC) control cables in separate ducts, unless the 24 V DC cable is insulated for 230 V AC (120 V AC) or insulated with an insulation sleeving for 230 V AC (120 V AC).
Page 86: Protecting The Motor Against Overload Without Thermal Model Or Temperature Sensors
86 Guidelines for planning the electrical installation The most common temperature sensor types are PTC or Pt100. For more information, see the firmware manual. Protecting the motor against overload without thermal model or ￭ temperature sensors Motor overload protection protects the motor against overload without using motor thermal model or temperature sensors.
Page 87: Implementing The Prevention Of Unexpected Start-Up Function
Guidelines for planning the electrical installation 87 Implementing the Prevention of unexpected start-up function You can order the drive with a Prevention of unexpected start-up (POUS) function. The POUS function disables the control voltage of the power semiconductors of the drive (inverter) output stage.
Page 88: Implementing The Power Loss Ride-Through Function
IEC/EN/UL 61800-5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”. Bypass connection is available as a factory-installed option for some cabinet-installed drive types. Consult ABB for more information. WARNING! Never connect the drive output to the electrical power network. The connection may...
Page 89: Supplying Power For The Auxiliary Circuits
Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.
Page 90: Protecting The Contacts Of Relay Outputs
90 Guidelines for planning the electrical installation WARNING! If DTC motor control mode is in use, do not open the output contactor while the drive controls the motor. The motor control operates faster than the contactor, and tries to maintain the load current. This can cause damage to the contactor. When you select the DTC motor control mode and the motor coast stop mode, you can open the contactor immediately after the drive has received the stop command.
Page 91: Implementing A Motor Temperature Sensor Connection
Guidelines for planning the electrical installation 91 Implementing a motor temperature sensor connection WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or • the accessible parts are conductive, but not connected to the protective earth. Obey this requirement when you plan the connection of the motor temperature sensor to the drive.
Page 92 92 Guidelines for planning the electrical installation Option module Temperature sensor type Temperature sensor insu- lation requirement Type Insulation/Isolation Pt100, Pt1000 FIO-21 Galvanic isolation between sensor Reinforced insulation connector and other connectors (includ- ing drive control unit connector). FEN-01 Galvanic isolation between sensor Reinforced insulation connector and drive control unit con- nector.
Page 93: Electrical Installation
Electrical installation 93 Electrical installation Contents of this chapter This chapter gives instructions on the wiring of the drive. Warnings WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
Page 94: Measuring The Insulation Resistance Of The Input Power Cable
Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.
Page 95: Connecting The Control Cables
Electrical installation 95 Connecting the control cables See chapter Control units of the drive (page 117) for the default I/O connections of the inverter unit (with the ACS880 primary control program). The default I/O connections can be different with some hardware options, see the circuit diagrams delivered with the drive for the actual wiring.
Page 96: Routing The Control Cables Inside The Cabinet
96 Electrical installation If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the peeled part. Be careful not to cut the conductors or the grounding wire. • Turn the conductive side of the shield inside out over the insulation. •...
Page 97: Connecting Control Cabling
Electrical installation 97 Connecting control cabling Connect the conductors to the appropriate terminals. Refer to the wiring diagrams delivered with the drive. Connect the inner twisted pair shields and all separate grounding wires to the grounding clamps closest to the terminals. The drawing below represents the grounding of the control cabling when connecting to a terminal block inside the cabinet.
Page 98: Connecting The Motor Cables (Units Without Common Motor Terminal Cubicle)
98 Electrical installation Connecting the motor cables (units without common motor terminal cubicle) On units without a common motor terminal cubicle, the motor cables connect to busbars located in the inverter module cubicles. To access the terminals, the cooling fans and other equipment in front of the terminals must be removed from the cubicle.
Page 99: Procedure
Electrical installation 99 Procedure ￭ The illustration below shows the parts to be removed. Inner shroud Fan retaining screws Lower front mounting plate WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Do the steps in section Electrical safety precautions (page 19) before you start the...
Page 100 100 Electrical installation 11. Remove the rubber grommets from the cable entries for the cables to be connected. Cut adequate holes into the rubber grommets. Slide the grommets onto the cables. Slide the cables into the cubicle through the conductive sleeves and attach the grommets to the holes.
Page 101 Electrical installation 101 12. Attach the conductive sleeves to the cable shields with cable ties. Tie up the unused conductive sleeves with cable ties. 13. Connect the twisted shields of the cables to the PE busbar of the cabinet. 14. Connect the phase conductors of the cables to the appropriate terminals. Tighten the screws to the torque given in section Tightening torques (page 194).
Page 102: Connecting The Motor Cables (Units With Common Motor Terminal Cubicle)
102 Electrical installation 19. Make sure there are no tools, debris or any other foreign objects in the cubicle. Close the cubicle door. 20. At the motor, connect the cables according to instructions from the motor manufacturer. Pay special attention to the phase order. For minimum radio-frequency interference, ground the cable shield 360 degrees at the cable entry of the motor terminal box, or ground the cable by twisting the shield so that the flattened shield is wider than 1/5 of its length.
Page 103: Procedure
Electrical installation 103 Procedure ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Do the steps in section Electrical safety precautions (page 19) before you start the work.
Page 104: Connecting The Input Power Cables
104 Electrical installation For the location of the terminals, refer to the dimension drawings delivered with the unit or the dimension drawing examples in this manual. Connecting the input power cables Connection diagram ￭ LCL filter IGBT supply modules Components for charging circuit ICU cubicle...
Page 105 Electrical installation 105 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. Remove rubber grommets from the cable entries for the cables to be connected. Cut adequate holes into the rubber grommets.
Page 106 106 Electrical installation Connect the twisted shields of the cables to the PE busbar of the cabinet. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals. Tighten the screws to the torque given under Tightening torques (page 194).
Page 107: Connecting Input Power Cables - Cable Entry In 100 Ka Input Cubicle (Option +F274)
Electrical installation 107 Connecting input power cables - cable entry in 100 kA input cubicle (option +F274) Connection diagram ￭ 100 kA input cubicle Incoming cubicle Note: This diagram shows the installation with shielded single core cables. The shields are grounded at both ends and they operate as the PE conductors of the drive.
Page 108 108 Electrical installation Remove the shrouding and assembly plates covering the input terminals. Remove the beams in front of the input terminals. Peel off 3 … 5 cm (1.2 … 2 in) of the outer insulation of the cables above the cable entry plate for 360°...
Page 109 Electrical installation 109 Attach the conductive sleeves to the bare cable shields with cable ties. Tie up the unused conductive sleeves with cable ties. Connect the twisted shields of the cables to the PE busbar of the cabinet. Tighten the screws to the torque given in section Tightening torques (page 194).
Page 110 110 Electrical installation...
Page 111: Connecting A Pc
Electrical installation 111 Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. A PC (with, for example, the Drive composer PC tool) can be connected as follows: Connect a ACS-AP-…...
Page 112 112 Electrical installation Switch on the bus termination on the drive that is farthest from the control panel in the chain. • With drives that have the panel mounted on the front cover, move the terminating switch into the outer position. •...
Page 113 Electrical installation 113 With FDPI-02 modules:...
Page 114: Installing Option Modules
114 Electrical installation Installing option modules Mechanical installation of I/O extension, fieldbus adapter and pulse ￭ encoder interface modules See hardware description for the available slots for each module. Install the option modules as follows: WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 115 Electrical installation 115 Attach the FSO module onto slot 3 of the BCU control unit [A41] with four screws. Tighten the FSO module electronics grounding 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.
Page 116: Wiring Of Option Modules
116 Electrical installation Wiring of option modules ￭ See the appropriate optional module manual for specific installation and wiring instructions.
Page 117: Control Units Of The Drive
Control units of the drive 117 Control units of the drive Contents of this chapter This chapter • describes the connections of the control unit(s) used in the drive, • contains the specifications of the inputs and outputs of the control unit(s). General The drive utilizes BCU-x2 control units.
Page 118: Bcu-X2 Layout
118 Control units of the drive BCU-x2 layout Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface, fieldbus...
Page 119 Control units of the drive 119 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XD24 +24 V output (for digital inputs) XDIO XETH Ethernet port – Not in use XPOW External power input XRO1...
Page 120: Default I/O Diagram Of The Supply Control Unit
120 Control units of the drive Default I/O diagram of the supply control unit The diagram below shows the default I/O connections on the supply control unit (A51), and describes the use of the connections in the supply unit. Under normal circumstances, the factory-made wiring should not be changed.
Page 121 Control units of the drive 121 Terminal Description Temp fault (0 = overtemperature) Run / enable (1 = run / enable) MCB feedback (0 = main contactor/breaker open) Not in use by default. Can be used for eg, auxiliary circuit breaker fault. Not in use by default.
Page 122 122 Control units of the drive Terminal Description X205 Memory unit connection 1) Must be set to ON when the supply unit is the first or last unit on the drive-to-drive (D2D) link. On intermediate units, set termination to OFF. 2) Use of the signal in the control program.
Page 123: Default I/O Diagram Of The Inverter Control Unit (A41)
Control units of the drive 123 Default I/O diagram of the inverter control unit (A41) The table below describes the use of the connections in the inverter unit. Under normal circumstances, the factory-made wiring should not be changed. The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …...
Page 124 124 Control units of the drive Terminal Description Stop (0) / Start (1) Forward (0) / Reverse (1) Reset Acceleration & deceleration select Constant speed 1 select (1 = on) Not in use by default. DIIL Run enable XDIO Digital input/outputs DIO1 Output: Ready DIO2...
Page 125 Control units of the drive 125 Terminal Description Control panel connection X205 Memory unit connection 1) 0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use. 1 = Acceleration/deceleration ramps defined by parameters 23.14/23.15 in use. 2) Constant speed 1 is defined by parameter 22.26. 3) The DIIL input is configured to stop the unit when the input signal is removed.
Page 126 126 Control units of the drive The diagram below shows the default I/O connections on the inverter control unit (A41). XRO1…XRO3 XSTO SGND DIIL XD24 +24VD +24VD AI1+ AI1- AI2+ AI2- AGND AGND Fault If necessary, you can connect an emergency stop button to the XSTO terminal. Refer to chapter Safe torque off function.
Page 127: Additional Information On The Connections
Control units of the drive 127 Additional information on the connections External power supply for the control unit (XPOW) ￭ The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW. With a type BCU control unit, a second supply can be connected to the same terminal block for redundancy.
Page 128: Diil Input
(nominal impedance 100 … 165 ohm, for example Belden 9842) for the wiring. For best immunity, ABB recommends high quality cable. Keep the cable as short as possible. Avoid unnecessary loops and parallel runs near power cables such as motor cables.
Page 129: Safe Torque Off (Xsto, Xsto Out)
The BCU-x2 has an on-board data logger that collects real-time data from the power modules to help fault tracing and analysis. The data is stored onto the SDHC memory card inserted into the SD CARD slot and can be analyzed by ABB service personnel.
Page 130: Connector Data
130 Control units of the drive Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) Tightening torque 0.45 N·m (4 lbf·in) 24 V (±10%) DC, 2 A External power input. Two supplies can be connected to the BCU-x2 for redundancy. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 0.5 …...
Page 131 Control units of the drive 131 Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) (XAI:4 … XAI:7). Tightening torque 0.45 N·m (4 lbf·in) Current/voltage input mode selection by Current input: –20…20 mA, R = 100 ohm switches Voltage input: –10…10 V, R...
Page 132 132 Control units of the drive SDHC memory card slot (SD CARD) Memory card type: SDHC Maximum memory size: 4 GB The terminals of the control unit fulfill the Protective Extra Low Voltage (PELV) requirements. The PELV re- quirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output.
Page 133: Bcu-X2 Ground Isolation Diagram
Control units of the drive 133 BCU-x2 ground isolation diagram ￭ XPOW +24VI +24VI +VREF -VREF AGND AI1+ AI1- AI2+ AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO SGND XSTO OUT...
Page 135: Installation Checklist
Installation checklist 135 Installation checklist Contents of this chapter This chapter contains a checklist for the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
Page 136 136 Installation checklist Make sure that … There is an adequately sized protective earth (ground) conductor(s) between the drive and the switchboard, the conductor is connected to correct terminal, and the terminal is tightened to the correct torque. Proper grounding has also been measured according to the regulations. The input power cable is connected to the correct terminals, the phase order is correct, and the terminals are tightened to the correct torque.
Page 137: Start-Up
Start-up 137 Start-up Contents of this chapter This chapter contains the start-up and switch-off procedures of the drive. Start-up procedure The tasks which are needed in certain cases only are marked with underlining, and option codes are given in brackets. Default device designations (if any) are given in brackets after the name, for example “main switch-disconnector [Q1]”.
Page 138 The trip level can be set, for example, 10 °C higher than what the temperature of the machine is at maximal load in the maximum environmental temperature. ABB recommends to set the operating temperatures of the relay, typically for example, as follows: • 120…140 °C when only tripping is in use •...
Page 139: Switching Off The Drive
Start-up 139 Action Drives with a brake chopper (option +D150): See chapter Resistor braking (page 239). Drives with an fieldbus adapter module (optional): Set the fieldbus parameters. Activate the appropriate assistant (if present) in the control program, or see the user’s manual of the fieldbus adapter module, and the drive firmware manual.
Page 141: Fault Tracing
Fault tracing 141 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. Control unit LEDs Color Indication BATT OK Green Battery voltage of the real-time clock is OK (higher than 2.8 V). When the LED is not lit, •...
Page 142: Warning And Fault Messages
142 Fault tracing Location Indication Control panel Continuous green The unit is functioning normally. Flickering green Data is transferred between the PC and the unit through the USB connection of the control panel. Blinking green There is an active warning in the unit. Continuous red There is an active fault in the unit.
Page 143: Maintenance
The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (https://new.abb.com/drives/services/maintenance/preventive-maintenance). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). Description of symbols ￭ Action...
Page 144: Recommended Maintenance Intervals After Start-Up
Coolant Checking coolant antifreeze concentration Checking coolant quality Coolant draining and replacement See ACS880-1007LC liquid cooling unit user's manual ABB cooling unit (if present) (3AXD50000129607 [English]) Cooling fans Supply module cubicle fan (230 V) Supply module cubicle fan (115 V)
Page 145 Maintenance 145 • Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.
Page 146: Cabinet
146 Maintenance Cabinet Cleaning the interior of the cabinet ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. WARNING! Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding wristband.
Page 147: Power Connections And Quick Connectors
See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Frame R8i fan replacement ￭...
Page 148 148 Maintenance...
Page 149: Replacing The Heat Exchanger Fan In The Filter Cubicle
Maintenance 149 Replacing the heat exchanger fan in the filter cubicle ￭ WARNING! Wear protective gloves and long sleeves. Some parts have sharp edges. Repeat the steps described in section Electrical safety precautions (page 19) before you start the work. Remove the shrouding in front of the fan (if any).
Page 150: Replacing The Fan In The Incoming Cubicle
150 Maintenance Replacing the fan in the incoming cubicle ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. WARNING! Use the required personal protective equipment.
Page 151 Maintenance 151...
Page 152: Replacing The Fan In The Auxiliary Control Cubicle
152 Maintenance Replacing the fan in the auxiliary control cubicle ￭ Auxiliary control cubicle has a fan in the lower part of the cubicle. WARNING! Wear protective gloves and long sleeves. Some parts have sharp edges. Repeat the steps described in section Electrical safety precautions (page 19) before you start the work.
Page 153: Replacing The Brake Chopper And Resistor Cubicle Fans (Options +D150 And +D151)
Maintenance 153 Disconnect the fan wiring. Remove the CIO module. Undo the fastening screws. Pull the fan housing up and out. Install a new fan in reverse order to the above. Replacing the brake chopper and resistor cubicle fans (options +D150 ￭...
Page 154: Supply And Inverter Modules
154 Maintenance Supply and inverter modules Assembling the service platform ￭ The service platform is included in the cabinet delivery. It can be used when installing or servicing liquid-cooled R8i modules. Fasten the triangular supports to the cabinet frame (5 × M6 screws for each support). Make sure that the guide pins are properly inserted in the holes of the frame.
Page 155: Removing The Module
Maintenance 155 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Make sure that the replacement module has exactly the same type code as the old module.
Page 156 156 Maintenance Remove the L-shaped DC busbars at the top of the module. Make note of the orientation of the screws as well as the order of the washers. Close the inlet valve (a) and outlet valve (located on the right-hand side of the cubicle). Lead the drain hoses (b, on both sides of the cubicle) into a suitable container.
Page 157: Reinstalling The Module
Maintenance 157 Remove the module retaining screws at the top and the bottom of the module. 10. Pull the module carefully out onto the service platform. Keep the module secured to a hoist or equivalent to prevent the module from falling. For information on using the lifting device, see Converter module lifting device for drive cabinets hardware manual (3AXD50000210268...
Page 158: Capacitors
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. Reforming the capacitors ￭...
Page 159: Fuses
Maintenance 159 Fuses Replacing the AC and DC fuses in cabinet ￭ This procedure instructs how to replace the drive AC and DC fuses inside the cabinet. The location of the fuses vary depending on the drive type and options. Locate the fuses to be replaced using the delivery-specific layout drawings and circuit diagrams.
Page 160: Replacing Ac Fuses - 100 Ka Input Cubicle (Option +F274)
160 Maintenance • Bussmann fuses: 50 N·m (37 lbf·ft) • Mersen (Ferraz-Shawmut): 46 N·m (34 lbf·ft) • Other: Refer to the fuse manufacturer’s instructions. Reinstall the shroud and close the door. Replacing AC fuses - 100 kA input cubicle (option +F274) ￭...
Page 161: Control Panel
Maintenance 161 Check the condition of the fuses. If a fuse is blown, replace all fuses with similar fuses as follows: • Loosen the nuts of the fuses and pull the fuses out. Do not remove the nuts completely. If you remove the nuts completely, there is a risk that they fall inside the cubicle.
Page 162: Replacing The Memory Unit
162 Maintenance Replacing the memory unit ￭ After replacing a control unit, you can keep the existing parameter settings by transferring the memory unit from the defective control unit to the new control unit. WARNING! Do not remove or insert the memory unit when the control unit is powered. Stop the drive and do the steps in section Electrical safety precautions (page 19) before...
Page 163: Functional Safety Components
Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information.
Page 165: Internal Cooling Circuit
Each cubicle has an inlet and an outlet manifold, fitted with a stop valve and a drain valve. The stop valves can be closed to isolate all modules in the cubicle from the main cooling circuit. In cabinet line-ups built by ABB, valves are color-coded: • Blue – Open during operation •...
Page 166 166 Internal cooling circuit Supply modules. The drawing shows the configuration of a diode supply unit with two modules, ie. there is a common air-to-liquid exchanger in the cubicle. With an IGBT supply unit, each module has a dedicated air-to-liquid exchanger as shown for item 2. Inverter modules To/From cooling unit Air-to-liquid heat exchanger...
Page 167: Connection To A Cooling Unit
Internal cooling circuit 167 Connection to a cooling unit Connection to an ACS880-1007LC cooling unit ￭ Refer to ACS880-1007LC cooling unit user’s manual (3AXD50000129607 [English]). Connection to a custom cooling unit ￭ General requirements Equip the system with an expansion vessel to damp pressure rise due to volume changes when the temperature varies.
Page 168: Filling Up And Bleeding The Internal Cooling Circuit
168 Internal cooling circuit Filling up and bleeding the internal cooling circuit Both the drive and coolant must be at room temperature before filling up the cooling circuit. WARNING! Make sure that the maximum permissible operating pressure is not exceeded. When necessary regulate the pressure to appropriate level by draining excess coolant out of the system.
Page 169 Internal cooling circuit 169 12. Re-check the pressure and add coolant if necessary. 13. Start the coolant pump. Let any air remaining in the system out through the bleed valve at the cooling unit. 14. After one to two minutes, stop the pump or block the coolant flow with a valve. 15.
Page 170: Draining The Internal Cooling Circuit
Coolant type Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% mixture, available from Clariant distributors and ABB Service representatives. Note: Do not dilute the coolant. It is ready to use. Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F).
Page 171 Internal cooling circuit 171 Freeze protection: The freezing point of the coolant is determined by the concentration of heat transfer fluid in the mixture. The higher the concentration of heat transfer fluid, the higher the viscosity of the coolant. This results in a higher pressure loss in the system. See Pressure limits (page 172).
Page 172: Pressure Limits
172 Internal cooling circuit Condensation is not permitted. The minimum coolant temperature to avoid condensation (at an atmospheric pressure of 1 bar) is shown below as a function of relative humidity (RH) and ambient temperature (T Min. T (°C) coolant (°C) RH = 95% RH = 80%...
Page 173 Internal cooling circuit 173 • stainless steel AISI 316L (UNS 31603) • heavy gauge aluminum • plastic materials such as PA, PEX and PTFE Note: PVC hoses are not suitable for use with antifreeze. • rubber gasketing NBR (nitrile rubber). WARNING! If you connect external piping to the internal cooling circuit, use only materials that are specified above.
Page 175: Technical Data
Technical data 175 Technical data Contents of this chapter This chapter contains the technical specifications of the drive, for example, the ratings, fuse data, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Ratings The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table.
Page 176: Definitions
Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.
Page 177: Coolant Temperature Derating
Technical data 177 1.00 0.95 0.90 +45 °C +55 °C +113 °F +131 °F Coolant temperature derating See section Temperature limits (page 170). Antifreeze content derating See section Temperature limits (page 170). Altitude derating At altitudes above 1000 m (3281 ft) above sea level, the output current derating is 1 percentage point for every added 100 m (328 ft).
Page 178: Fuses
178 Technical data Supply module(s) used LCL filter(s) used Inverter modules used ACS880- Frame size Type Type 37LC-… Type ACS880-104LC-… ACS880-104LC-… 1170A-7 2×R8i + 2×R8i 0600A-7 BLCL-24LC-7 0600A-7+E205 1270A-7 2×R8i + 2×R8i 0670A-7 BLCL-24LC-7 0670A-7+E205 1470A-7 2×R8i + 2×R8i 0750A-7 BLCL-25LC-7 0750A-7+E205 1620A-7...
Page 179: Dc Fuses
Technical data 179 AC fuses ACS880- s at 37LC-… Manufacturer Type 660 V 2180A-7 2000 3950000 Bussmann 170M7062 2390A-7 2880A-7 2500 7800000 Bussmann 170M7063 3160A-7 3580A-7 2000 3950000 Bussmann 170M7062 4050A-7 1600 2050000 Bussmann 170M7061 4700A-7 2000 3950000 Bussmann 170M7062 5650A-7 2500 7800000...
Page 180: Charging Circuit Fuses
180 Technical data DC fuses at inverter module input ACS880- (Clearing 37LC-… Manufacturer Type at 1000 2180A-7 6 + 6 2390A-7 2880A-7 8 + 8 3160A-7 3580A-7 10 + 10 1400 6000000 1100 Bussmann 170M6501 4050A-7 12 + 10 4700A-7 12 + 12 5650A-7 16 + 14...
Page 181 Technical data 181 Heat dissipa- Coolant volume Coolant flow Noise tion ACS880-37LC-… US gal l/min US gal/min dB(A) 0600A-7 18.0 0670A-7 18.0 0750A-7 18.0 0830A-7 18.0 1000A-7 31.7 1170A-7 31.7 1270A-7 31.7 1470A-7 31.7 1620A-7 31.7 1940A-7 2180A-7 2390A-7 2880A-7 10.0 3160A-7 10.0...
Page 182: Typical Power Cable Sizes
182 Technical data Typical power cable sizes The tables below give current carrying capacity (I ) for aluminum and copper PVC/XLPE Lmax insulated cables. A correction factor K = 0.70 is used. Time const is the temperature time constant of the cable. The cable sizing is based on max.
Page 183 Technical data 183 Copper cable PVC insulation XLPE insulation Conductor temperature 70 °C Conductor temperature 90 °C Size ⌀ [mm] Time const. [s] Time const. [s] Lmax Lmax 3 × 1.5 + 1.5 3 × 2.5 + 2.5 (3 × 4 + 4) 3 ×...
Page 184: Terminal And Cable Entry Data For The Power Cables
100 kA input unit (option Note: Options +F259 and +F274 are mutually exclusive for some drive types. +F274) (IEC/EN 61439-1) Consult ABB for availability. Short-circuit current protec- The drive is suitable for use on a circuit capable of delivering not more than tion (UL 508A, CSA C22.2...
Page 185: Motor Connection Data
, 3-phase symmetrical, U at the field weakening point Frequency (f 0…500 Hz • For higher operational output frequencies, please contact your local ABB repres- entative. • Operation outside the range of 12…150 Hz requires derating. See the derating information.
Page 186: K3 Contact Data
186 Technical data The contacts of both relays are wired to a terminal block in the drive cubicle; see the drive-specific circuit diagrams for details. The external voltage switched by the contacts is to be connected to the same terminal block. K3 contact data ￭...
Page 187: Energy Efficiency Data (Ecodesign)
Maximum long-term tensile load: 1 N (3.6 ozf) • Flexing: Max. 1000 cycles ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components from Avago Technologies’ Versatile Link range. Note that the optical component type is not directly related to the actual communication speed.
Page 188: Ambient Conditions
Installation site altitude 0…2000 m (0…6562 ft) above sea level. For alti- tudes over 2000 m, contact ABB. Output derated above 1000 m (3281 ft). Air temperature 0 … +45 °C -40 to +70 °C -40 to +70 °C...
Page 189: Materials
IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.
Page 190: Applicable Standards
*IEC 61800-3 ed. 2.1 (2007 + ments and specific test methods Amd1:2011) *For compliance with IEC 61800-3 ed. 3.0 (2017), please contact ABB. IEC 60533:2015 Electrical and electronic installations in ships - Electromagnetic compat- ibility (EMC) - Ships with a metallic hull...
Page 191: Emc Compliance (Iec/En 61800-3)
Technical data 191 EAC (Eurasian Conformity) mark Product complies with the technical regulations of the Eurasian Customs Union. EAC mark is required in Russia, Belarus and Kazakhstan. Electronic Information Products (EIP) symbol including an Environment Friendly Use Period (EFUP) Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364- 2014) about hazardous substances.
Page 192: Category C4
192 Technical data WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network. Category C4 ￭...
Page 193: Ul Checklist
• The drive provides motor overload protection. The protection is not enabled when the drive leaves the ABB factory. For enabling the protection, see the firmware manual. • The drive overvoltage category according to IEC 60664-1 is III, except for auxiliary power connections (fan, control, heating, lighting, cooling unit pump etc) which are of category II.
Page 194: Tightening Torques
194 Technical data Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Electrical connections ￭ Size Torque Strength class 0.5 N·m (4.4 lbf·in) 4.6...8.8 1 N·m (9 lbf·in) 4.6...8.8 4 N·m (35 lbf·in) 9 N·m (6.6 lbf·ft) 22 N·m (16 lbf·ft) 42 N·m (31 lbf·ft)
Page 195: Cybersecurity Disclaimer
Notwithstanding any other provision to the contrary and regardless whether the contract is terminated or not, ABB and its affiliates are under no circumstances liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.
Page 197: Dimensions
The table is followed by selected dimension drawing examples. The dimensions are in millimeters (for inches, divide by 25.4). The data given is preliminary. ABB reserves the right to modify the design at any time without notice. Consult ABB for up-to-date, drive-specific information.
Page 198 198 Dimensions Width Weight ACS880-37LC-… 3580A-7 4600 4750 10470 4050A-7 5800 6170 13600 4700A-7 6000 6340 13980 5650A-7 7300 7720 17020 6260A-7 7600 7980 17590 Note: The 100 kA input cubicle (option +F274) adds 600 mm to the width.
Page 199: Dimension Drawing Examples
Dimensions 199 Dimension drawing examples ￭ ACS880-37LC-0390A-7 with main contactor...
Page 200: Acs880-37Lc-0600A-7 With Brake Chopper And Resistors
200 Dimensions ACS880-37LC-0600A-7 with brake chopper and resistors The brake resistor cubicle is air-cooled, and is to be installed separately.
Page 201: Acs880-37Lc-1270A-7 With Common Motor Terminal Cubicle
Dimensions 201 ACS880-37LC-1270A-7 with common motor terminal cubicle...
Page 202: Acs880-37Lc-1940A-7 With Common Motor Terminal Cubicle
202 Dimensions ACS880-37LC-1940A-7 with common motor terminal cubicle...
Page 203: Cabinet Height And Depth
Dimensions 203 Cabinet height and depth Side view, bottom cable exit Side view, marine construction (option +C121), bottom cable exit...
Page 204 204 Dimensions Side view, top cable exit with common motor terminal Side view, top cable exit without common motor terminal cubicle cubicle...
Page 205: Location And Size Of Input Terminals
Dimensions 205 Location and size of input terminals Contact ABB for details.
Page 206: Ka Input Cubicle (Option +F274)
206 Dimensions 100 kA input cubicle (option +F274) ￭...
Page 207: Location And Size Of Output Terminals
Dimensions 207 Location and size of output terminals Units without common motor terminal cubicle ￭ Inverter module cubicle with one R8i module, bottom cable exit...
Page 208: Inverter Module Cubicle With Two R8I Modules, Bottom Cable Exit
208 Dimensions Inverter module cubicle with two R8i modules, bottom cable exit...
Page 209: Inverter Module Cubicle With Three R8I Modules, Bottom Cable Exit
Dimensions 209 Inverter module cubicle with three R8i modules, bottom cable exit...
Page 210: Brake Chopper Cubicle
210 Dimensions Brake chopper cubicle...
Page 211: Units With Common Motor Terminal Cubicle (+H359)
Dimensions 211 Units with common motor terminal cubicle (+H359) ￭ Cubicle width 300 mm, bottom cable exit...
Page 212: Cubicle Width 300 Mm, Top Cable Exit
212 Dimensions Cubicle width 300 mm, top cable exit...
Page 213: Cubicle Width 400 Mm, Bottom Cable Exit
Dimensions 213 Cubicle width 400 mm, bottom cable exit...
Page 214: Cubicle Width 400 Mm, Top Cable Exit
214 Dimensions Cubicle width 400 mm, top cable exit...
Page 215: Cubicle Width 600 Mm, Bottom Cable Exit
Dimensions 215 Cubicle width 600 mm, bottom cable exit...
Page 216: Cubicle Width 600 Mm, Top Cable Exit
216 Dimensions Cubicle width 600 mm, top cable exit...
Page 217: The Safe Torque Off Function
The Safe torque off function 217 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description WARNING! In case of parallel-connected drives or dual-winding motors, the STO must be activated on each drive to remove the torque from the motor.
Page 218: Compliance With The European Machinery Directive And The Uk Supply Of Machinery (Safety) Regulations
218 The Safe torque off function Standard Name IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards – Im- munity requirements for equipment intended to perform functions in a safety-related system (functional safety) in industrial locations IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC requirements –...
Page 219: Wiring
The Safe torque off function 219 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. Activation switch ￭ In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC.
Page 220: Dual-Channel Connection With Internal Power Supply
220 The Safe torque off function Dual-channel connection with internal power supply ￭ XSTO +24 V SGND XSTO OUT STO IN (X52) 24VDC CH1 SGND GND CH1 24VDC CH2 SGND GND CH2 STO IN (X52) STO OUT (X51) 24VDC CH1 24VDC CH1 GND CH1 GND CH1...
Page 221: Single-Channel Connection Of Activation Switch
The Safe torque off function 221 Single-channel connection of activation switch ￭ +24 V SGND Note: • 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 cable. For measures for fault exclusion of wiring, see eg.
Page 222: Multiple Drives
222 The Safe torque off function Multiple drives ￭ Internal power supply XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * Terminal designation may vary depending on drive type...
Page 223: External Power Supply
The Safe torque off function 223 External power supply 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * Terminal designation may vary depending on drive type...
Page 224: Operation Principle
224 The Safe torque off function Operation principle The Safe torque off activates (the activation switch is opened, or safety relay contacts open). The STO inputs of the drive control unit de-energize. The control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).
Page 225: Start-Up Including Validation Test
The Safe torque off function 225 Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed •...
Page 226 226 The Safe torque off function Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...
Page 227: Use
The Safe torque off function 227 Open the activation switch, or activate the safety functionality that is wired to the STO connection. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).
Page 228 228 The Safe torque off function 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.
Page 229: Maintenance
If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 225). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...
Page 230: Fault Tracing
See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.
Page 231: Safety Data
The Safe torque off function 231 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. MTTF Frame = 20 a)
Page 232: Terms And Abbreviations
232 The Safe torque off function • The following temperature profile is used in safety value calculations: • 670 on/off cycles per year with ΔT = 71.66 °C • 1340 on/off cycles per year with ΔT = 61.66 °C • 30 on/off cycles per year with ΔT = 10.0 °C •...
Page 233: Tüv Certificate
Dangerous failure rate (per hour) of the diagnostics function of STO Diag_d λ IEC 61508-6 Safe failure rate (per hour) of the diagnostics function of STO Diag_s TÜV certificate ￭ The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
Page 234: Declarations Of Conformity
234 The Safe torque off function Declarations of conformity ￭ EU Declaration of Conformity Machinery Directive 2006/42/EC Manufacturer: ABB Oy Address: Hiomotie 13, 00380 Helsinki, Finland. Phone: +358 10 22 11 declare under our sole responsibility that the following products:...
Page 235 The products referred in this Declaration of conformity fulfil the relevant provisions of other European Union Directives which are notified in Single EU Declaration of conformity 3AXD10000497305. Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland Helsinki, 28 May 2021 Signed for and on behalf of:...
Page 236 236 The Safe torque off function Declaration of Conformity Supply of Machinery (Safety) Regulations 2008 Manufacturer: ABB Oy Address: Hiomotie 13, 00380 Helsinki, Finland. Phone: +358 10 22 11 declare under our sole responsibility that the following products: Frequency converters and frequency converter components...
Page 237 The products referred in this declaration of conformity fulfil the relevant provisions of other UK statutory requirements, which are notified in a single declaration of conformity 3AXD10001346556. Authorized to compile the technical file: ABB Limited, Daresbury Park, Cheshire, United Kingdom, WA4 4BT Helsinki, 28 May 2021 Signed for and on behalf of:...
Page 239 Resistor braking 239 Resistor braking The brake units available for the drive are: • Single-phase, on/off-controlled brake chopper indicated by option codes +D150 (chopper) and +D151 (resistors) • Three-phase ACS880-607LC 3-phase dynamic brake units with control of current and power by modulation. For more information, refer to •...
Page 241 Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.

ABB ACS880-37LC-0390A-7 Hardware Manual

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