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Related Manuals for ABB ACS880-07XT Series
Summary of Contents for ABB ACS880-07XT Series
- Page 1 ABB industrial drives Hardware manual ACS880-07XT drives (400 to 1200 kW)
- Page 2 List of related manuals Drive hardware manuals and guides Code (English) ACS880-04XT (500 to 1200 kW) hardware manual 3AXD50000025169 ACS-AP-X assistant control panels user’s manual 3AUA0000085685 Drive firmware manuals and guides ACS880 primary control program firmware manual 3AUA0000085967 Quick start-up guide for ACS880 drives with primary 3AUA0000098062 control program...
- Page 3 Hardware manual ACS880-07XT drives (400 to 1200 kW) Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 9. Start-up 2018 ABB Drive. All Rights Reserved. 3ABD00043579 Rev C EFFECTIVE: 2018-01-01...
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Page 5: Table Of Contents
Table of contents 1. Safety instructions Contents of this chapter ..........13 Use of warnings and notes . - Page 6 Additional requirements for the braking applications ..... . . 60 Additional requirements for ABB high-output and IP23 motors ....60 Additional requirements for non-ABB high-output and IP23 motors .
- Page 7 Recommended power cable types ........65 Power cable types for restricted use .
- Page 8 Wiring the Pt100 relays (options +2L506, +3L506, +5L506 and +8L506) ..82 Powering the heating(options +G300) ........83 Wiring ground fault monitoring for IT ungrounded systems (option +Q954) .
- Page 9 Warning and fault messages ..........111 11.
- Page 10 Ambient conditions ........... 140 Materials .
- Page 11 Providing feedback on ABB Drives manuals ....... . . 167...
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Page 13: Safety Instructions
Safety instructions 13 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 and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment. -
Page 14: General Safety In Installation, Start-Up And Maintenance
14 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the drive module and do maintenance work on it. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •... - Page 15 Safety instructions 15 • To prevent the drive module from falling, attach its top lifting lugs with chains to the cabinet frame before you push the module into the cabinet and pull it from the cabinet. Work carefully preferably with help from another person as shown below. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back 3AUA0000088632...
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Page 16: Electrical Safety In Installation, Start-Up And Maintenance
16 Safety instructions Electrical safety in installation, start-up and maintenance Precautions before electrical work These warnings are for all personnel that 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 17: Additional Instructions And Notes
Safety instructions 17 Additional instructions and notes WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you are not a qualified electrician, do not do installation or maintenance work. •... -
Page 18: Grounding
18 Safety instructions Grounding These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase. •... -
Page 19: Additional Instructions For Permanent Magnet Motor Drives
Safety instructions 19 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 20 20 Safety instructions...
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Page 21: Introduction To The Manual
Introduction to the manual 21 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 22: Related Manuals
22 Introduction to the manual Electrical installation gives instructions on wiring the drive. Control units of the drive contains the default I/O connection diagrams, descriptions of the terminals and technical data for the control units of both the supply and inverter units. Installation checklist contains a list for checking the mechanical and electrical installation of the drive. -
Page 23: Quick Installation, Commissioning And Operation Flowchart
Introduction to the manual 23 Quick installation, commissioning and operation flowchart Task Plan the electrical installation and acquire the accessories needed Guidelines for planning the (cables, fuses, etc.). electrical installation (page 73) Check the ratings, required cooling air flow, input power connection, Technical data (page 133) compatibility of the motor, motor connection, and other technical... -
Page 24: Terms And Abbreviations
24 Introduction to the manual Terms and abbreviations Term/ Explanation Abbreviation Drive control unit. The drive contains two BCU control units. One controls the supply unit, the other controls the inverter unit. As standard, the external I/O control signals are connected to the control unit, or optional I/O extensions mounted on it. -
Page 25: Safety Data (Sil, Pl)
Introduction to the manual 25 Safety data (SIL, PL) Abbr. Reference Description Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition, and which is achieved by the structural arrangement of the parts, fault detection and/or by their reliability. - Page 26 26 Introduction to the manual...
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Page 27: Operation Principle And Hardware Description
Operation principle and hardware description 27 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle and construction of the drive. Product overview The ACS880-07XT is an air-cooled cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors and AC induction servomotors. -
Page 28: Overview Circuit Diagram Of The Drive
28 Operation principle and hardware description Overview circuit diagram of the drive ACS880-04 +P943 UDC+ UDC- L1/U1 T1/U2 L2/V1 T2/V2 L3/W1 T3/W2 AC choke Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter Inverter. -
Page 29: 12-Pulse Connection (Option +A004)
Operation principle and hardware description 29 12-pulse connection (option +A004) The figure below illustrates the difference between 6-pulse and 12-pulse AC supply connections. 6-pulse connection is standard. If the drive has an even number of supply modules, you can order it as a 12-pulse version (option +A004). 12-pulse supply connection eliminates the fifth and seventh harmonics, which remarkably reduces the harmonic distortion of the line current and the conducted emissions. -
Page 30: Cabinet Line-Up And Layout Examples
30 Operation principle and hardware description Cabinet line-up and layout examples Example(Frame R11) Cabinet line-up example Incoming and Auxiliary control cubicle (ICU). Contains control electronics, customer I/O connections, the power input cable terminals and switchgear. Module cubicle. Contains the R11 module. Output cubicle. - Page 31 Operation principle and hardware description 31 Cabinet layout example Input cable lead-throughs, PE busbar (behind grid) Input terminals (behind grid) Main switch-disconnector (Q1.1) AC fuses (behind swing-out door) Main contactor (Q2.1) (optional, behind swing door) Control unit, BCU-02 Output cubicle cooling fan Module Bus bar Output terminals...
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Page 32: Overview Of Power And Control Connections
32 Operation principle and hardware description Overview of power and control connections The diagram shows the power connections and control interfaces of the drive. ACS880-07XT Control unit (A41) Slots 1, 2 and 3 Slot 4 X205 V1T/R… . . . M 3 ~ Option modules can be inserted into slots 1, 2, 3 and 4 as follows: Module type... - Page 33 Operation principle and hardware description 33 Bus bar link Inverter Optional brake chopper (+D150) and resistors (+D151)
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Page 34: Door Switches And Lights
34 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) RUN/ENBL Run enable signal switch for the supply unit OFF Run enable signal off (starting the supply unit not allowed) ON Run enable signal on... -
Page 35: Main Disconnecting Device (Q1.1)
Operation principle and hardware description 35 Main disconnecting device (Q1.1) Depending on the configuration of the drive, the main disconnecting device of the drive is either a switch-disconnector or a main circuit breaker. The main disconnecting device switches the main supply to the drive on and off. To disconnect the main supply, turn the switch-disconnector to the 0 (OFF) position, or rack out the main breaker (whichever device is installed). -
Page 36: Control Panel
36 Operation principle and hardware description Control panel The ACS-AP-I is the user interface of the drive. It provides the essential controls such as Start/Stop/Direction/Reset/Reference, and the parameter settings for the inverter control program. The control panel can be removed by pulling it forward from the top edge and reinstalled in reverse order. -
Page 37: Descriptions Of Cabinet Options
Operation principle and hardware description 37 Descriptions of cabinet 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 38: Terminals For External Control Voltage (Option +G307)
38 Operation principle and hardware description See also • Powering the heating(options +G300) • circuit diagrams delivered with drive for the actual wiring. Terminals for external control voltage (option +G307) The option provides terminals for connecting external uninterruptible control voltage to the control unit and control devices when the drive is not powered. -
Page 39: Pt100 Relays (Options +2L506, +3L506, +5L506, +8L506)
Operation principle and hardware description 39 See also • firmware manual for parameter settings • Wiring the thermistor relay(s) (options +L505 and +2L505) on page • circuit diagrams delivered with the drive for the actual wiring. Pt100 relays (options +2L506, +3L506, +5L506, +8L506) ... -
Page 40: Type Designation Label
40 Operation principle and hardware description Type designation label The type designation label includes ratings, appropriate markings, a type designation and a serial number, which allow identification of each unit. A sample label is shown below. Quote the complete type designation and serial number when contacting technical support. - Page 41 Operation principle and hardware description 41 CODE DESCRIPTION 380…415 V AC. This is indicated in the type designation label as typical input voltage level (3~ 400 V AC) 380…500 V AC. This is indicated in the type designation label as typical input voltage levels (3~ 400/480/500 V AC) 525…690 V AC.
- Page 42 42 Operation principle and hardware description CODE DESCRIPTION L509 RDCO-04 optical fiber communication interface module L516 FEN-21 resolver interface module L517 FEN-01 TTL pulse encoder interface module L518 FEN-11 absolute pulse encoder interface module Starter for auxiliary motor fan M602 Trip limit setting range: 2.5 …...
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Page 43: Mechanical Installation
Mechanical installation 43 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 44: Necessary Tools
44 Mechanical installation 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: • crane, fork-lift or pallet truck (check load capacity!), slate/spud bar, jack and rollers •... -
Page 45: Moving And Unpacking The Drive
Mechanical installation 45 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 46: Lifting The Crate With A Crane
46 Mechanical installation Lifting the crate with a crane Position each sling as close to a transverse board as possible. We recommend the use of transverse spreader bars. Lifting point... -
Page 47: Moving The Crate With A Forklift
Mechanical installation 47 Moving the crate with a forklift Free width for fork tines: 750 mm (29.5”) -
Page 48: Removing The Transport Package
48 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 together. 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 49: Moving The Cabinet On Rollers
Mechanical installation 49 Moving the cabinet 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 Support the cabinet from below alongside the cubicle seams. -
Page 50: Fastening The Cabinet To The Floor And Wall Or Roof (Non-Marine Units)
50 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 51: Fastening Methods
Mechanical installation 51 Fastening methods Fasten the cabinet to the floor by using the 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 –... -
Page 52: Fastening The Cabinet To The Floor And Roof/Wall (Marine Units)
52 Mechanical installation Fastening the cabinet to the floor and roof/wall (marine units) Follow the general rules given in section General rules. See the dimension drawing delivered with the drive for the locations of the fastening holes in the flat bars below the cabinet and for fastening points at the top of the cabinet. Top fastening brackets are included in the delivery. -
Page 53: Miscellaneous
Mechanical installation 53 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 54 54 Mechanical installation...
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Page 55: 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 obeyed, the drive can experience problems that the warranty does not cover. -
Page 56: Selecting The Supply Disconnecting Device
Examining the compatibility of the motor and drive Use an asynchronous AC induction motor, permanent magnet motor, AC induction servomotor or ABB synchronous reluctance motor (SynRM motor) with the drive. Several induction motors can be connected at a time. Select the motor size and drive type from the rating tables in chapter Technical data basis of the AC line voltage and motor load. -
Page 57: Protecting The Motor Insulation And Bearings
Guidelines for planning the electrical installation 57 Protecting the motor insulation and bearings The drive uses modern IGBT inverter technology. Regardless of frequency, the drive output has pulses of approximately the drive DC bus voltage with a very short rise time. Up to twice bus voltage can be at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals. -
Page 58: Requirements Table
The following table shows how to select the motor insulation system and when optional ABB du/dt filters, insulated N-end (non-drive end) motor bearings and ABB common mode filters are required. Failure of the motor to fulfill the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the motor warranty. - Page 59 Guidelines for planning the electrical installation 59 Motor Nominal AC supply Requirement for type voltage ABB du/dt and common mode filters, insulated N-end Motor motor bearings insulation system 100 kW < P < 350 kW > 350 kW IEC 315 < frame size <...
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Page 60: Additional Requirements For Explosion-Safe (Ex) Motors
If you use an explosion-safe (EX) motor, obey the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ Use the selection criteria given for non-ABB motors. -
Page 61: Additional Requirements For Non-Abb High-Output And Ip23 Motors
The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347:2001. The table below shows the requirements for random-wound and form-wound non-ABB motors with nominal power smaller than 350 kW. For bigger motors, consult the motor manufacturer. -
Page 62: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
62 Guidelines for planning the electrical installation Additional data for calculating the rise time and the peak line-to-line voltage The diagrams below show the relative peak line-to-line voltage and rate of change of voltage as a function of the motor cable length with and without a du/dt filter in use. To calculate the actual peak voltage for a certain cable length read the relative Û... -
Page 63: Selecting The Power Cables
Guidelines for planning the electrical installation 63 Selecting the power cables General rules Select the input power and motor cables according to local regulations: • Select a cable capable of carrying the drive nominal current. • ° ° Select a cable rated for at least 70 C (158 F) maximum permissible temperature of conductor in continuous use. -
Page 64: Typical Power Cable Sizes
64 Guidelines for planning the electrical installation Typical power cable sizes The tables below give copper and aluminum cable types with concentric copper shield for the drive modules with nominal current. Drive type input and motor cabling ACS880- Cabling per basic module Common cabling for the basic modules 07XT- Cu cable type... -
Page 65: Alternative Power Cable Types
Guidelines for planning the electrical installation 65 Alternative power cable types The recommended and not allowed power cable types to be used with the drive are presented below. Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield. -
Page 66: Motor Cable Shield
66 Guidelines for planning the electrical installation Motor cable shield If the motor cable shield is used as the sole protective earth conductor of the motor, make sure that the conductivity of the shield is sufficient. See subsection General rules above, or IEC 61439-1. -
Page 67: Signals In Separate Cables
Relay cable type The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel cable length and type In remote use, the cable connecting the control panel to the drive must not exceed three meters (10 ft). -
Page 68: Separate Control Cable Ducts
68 Guidelines for planning the electrical installation A diagram of the cable routing is shown below. Control cables min 200 mm (8 in.) 90 ° Input power cable Motor cable Drive min 300 mm (12 in.) Power cable Motor cable, brake cable min 500 mm (20 in.) Control cables Separate control cable ducts... -
Page 69: Implementing Thermal Overload And Short-Circuit Protection
The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers. There are also limitations pertaining to the short-circuit capacity of the supply network. Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known. -
Page 70: Protecting The Motor Against Thermal Overload
70 Guidelines for planning the electrical installation WARNING! If the drive is connected to multiple motors, use a separate circuit breaker or fuses for protecting each motor cable and motor against overload. The drive overload protection is tuned for the total motor load. It may not trip due to an overload in one motor circuit only. -
Page 71: Iimplementing The Power Loss Ride-Through Function
Guidelines for planning the electrical installation 71 IImplementing the Power loss ride-through function Implement the power loss ride-through function as follows: 1. Check that the power-loss ride-through function of the drive is enabled with parameter 30.31 Undervoltage control in the ACS880 primary control program. 2. -
Page 72: Using A Contactor Between The Drive And The Motor
72 Guidelines for planning the electrical installation Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate. When you have selected to use DTC motor control mode and motor ramp stop, open the contactor as follows: 1. -
Page 73: Example Bypass Connection
Guidelines for planning the electrical installation 73 Example bypass connection An example bypass connection is shown below. Drive main switch Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor Drive main contactor on/off control Motor power supply selection (drive or direct-on-line) Start when motor is connected direct-on-line Stop when motor is connected direct-on-line Switching the motor power supply from drive to direct-on-line... -
Page 74: Switching The Motor Power Supply From Direct-On-Line To Drive
74 Guidelines for planning the electrical installation Switching the motor power supply from direct-on-line to drive 1. Stop the motor with S42. 2. Switch the motor power supply from direct-on-line to the drive with S40. 3. Close the main contactor of the drive with switch S11 (-> turn to position ST for two seconds and leave to position 1). -
Page 75: Electrical Installation
Electrical installation 75 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 76: Motor And Motor Cable
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. Note: Moisture inside the motor casing will reduce the insulation resistance. -
Page 77: Connecting The Control Cables
Electrical installation 77 Connecting the control cables The default I/O connections can be different with some hardware options, see the circuit diagrams delivered with the drive for the actual wiring. For other control programs, see their firmware manuals. Control cable connection procedure ... - Page 78 78 Electrical installation Note 1: Keep the shields continuous as close to the connection terminals as possible. Secure the cables mechanically at the lead-through strain relief. Note 2: If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the bare part. Be careful not to cut the conductors or the grounding wire (if present).
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Page 79: Routing The Control Cables Inside The Cabinet
Electrical installation 79 5. Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions. 6. If more than one cable go through a grommet, seal the grommet by applying Loctite 5221 (catalogue number 25551) inside the grommet. Routing the control cables inside the cabinet Use the existing trunking in the cabinet wherever possible. -
Page 80: Connecting A 230/115 V Ac Auxiliary Voltage Supply (Ups, Option +G307)
80 Electrical installation Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) Wire the external control voltage to terminal block X91 at the back side of the mounting plate as shown below. Internal wiring of UPS supervision: circuit breaker or fuse off/fault = contact open. Connecting the emergency stop push buttons (options +Q951, +Q952, +Q963, +Q964) Connect external emergency stop push buttons according to the circuit diagrams delivered... -
Page 81: Wiring The Thermistor Relay(S) (Options +L505 And +2L505)
Electrical installation 81 Wiring the thermistor relay(s) (options +L505 and +2L505) The external wiring of option +2L505 (two thermistor relays) is shown below. For example, one relay can be used to monitor the motor windings, the other to monitor the bearings. The maximum contact load capacity is 250 V AC 10 A. -
Page 82: Wiring The Pt100 Relays (Options +2L506, +3L506, +5L506 And +8L506)
82 Electrical installation Wiring the Pt100 relays (options +2L506, +3L506, +5L506 and +8L506) External wiring of eight Pt100 sensor modules is shown below. Contact load capacity 250 V AC 10 A. For the actual wiring, see the circuit diagram delivered with the drive. X506 1 ×... -
Page 83: Powering The Heating(Options +G300)
Electrical installation 83 Powering the heating(options +G300) See the circuit diagrams delivered with drive. Connect the external power supply wires for the cabinet heater and lighting to terminal block X91 at the back of the mounting plate. Internal wiring of the cabinet heater: heater off/fault = contact open. -
Page 84: Connecting The Motor Cables (Units Without Common Motor Terminal)
84 Electrical installation Connecting the motor cables (units without common motor terminal) On units without a common motor terminal, the motor cables connect to busbars located aside of the module(s). All parallel-connected modules are to be cabled separately to the motor. 360° earthing is to be used at cable lead-throughs. -
Page 85: Connecting The Motor Cables (Units With Du/Dt And Common Motor Terminal)
Electrical installation 85 Connecting the motor cables (units with du/dt and common motor terminal) If the drive is equipped with du/dt and common motor terminal, the motor cables connect to a common motor terminal. Connection diagram Module cubicle(s) du/dt and common motor terminal The recommended cable types are given in chapter Guidelines for planning the electrical... - Page 86 86 Electrical installation 6. Connect any separate ground conductors/cables to the PE busbar in the cubicle. 7. Connect the phase conductors to the output terminals. Use the torques specified under Tightening torques. 8. Refit any shrouding removed earlier and close the cubicle doors. 9.
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Page 87: Connecting The Input Power Cables
Electrical installation 87 Connecting the input power cables Connection diagram, 6-pulse units ACS880-07XT Incoming unit (ICU) 1) Fuses or other protection means. 2) 360-degree grounding is recommended if shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board. -
Page 88: Connection Procedure
88 Electrical installation Connection procedure WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Do the steps in section Precautions before electrical work before you start the work. 2. - Page 89 Electrical installation 89...
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Page 90: Connecting A Pc
90 Electrical installation Connecting a PC A PC (with eg. the Drive composer PC tool) can be connected to the drive unit as follows: 1. Connect an ACS-AP-I control panel to the control unit either by using an Ethernet (eg. CAT5E) networking cable, or by inserting the panel into the panel holder (if present). -
Page 91: Installing Option Modules
Electrical installation 91 Installing option modules Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface modules Install the option modules as follows: WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. -
Page 92: Mechanical Installation Of An Fso-Xx Safety Functions Module
92 Electrical installation Mechanical installation of an FSO-xx safety functions module This procedure describes the mechanical installation of an FSO-xx safety functions module onto the inverter control unit. (The FSO-xx can alternatively be installed beside the control unit, which is the standard with factory-installed FSO-xx modules. For instructions, see the FSO-xx manual.) 1. -
Page 93: Wiring Of Optional Modules
Electrical installation 93 2. Tighten the FSO-xx electronics grounding screw. 3. Connect the FSO-xx data cable between FSO-xx connector X110 and to BCU-02 connector X12. Wiring of optional modules See the appropriate optional module manual for specific installation and wiring instructions. - Page 94 94 Electrical installation...
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Page 95: Control Units Of The Drive
Control units of the drive 95 Control units of the drive What this chapter contains This chapter • describes the connections of the control units used in the drive, • contains the specifications of the inputs and outputs of the control units. General The ACS880-07XT drive utilizes BCU-02 control units. -
Page 96: Control Unit Layout And Connections
96 Control units of the drive Control unit layout and connections 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... - Page 97 Control units of the drive 97 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XDIO Digital input/outputs XD24 XPOW XD2D Drive-to-drive link XD24 +24 V output (for digital inputs) XRO2 XETH Ethernet port (eg. for PC communication) XDIO XPOW External power input...
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Page 98: Default I/O Diagram Of The Control Unit (A41)
98 Control units of the drive Default I/O diagram of the control unit (A41) Drive-to-drive link XD2D Drive-to-drive link BGND Shield RS485 connection X485 Not in use BGND Shield Relay outputs XRO1…XRO3 Ready 250 V AC / 30 V DC Running 250 V AC / 30 V DC Fault... -
Page 99: External Power Supply For The Control Unit (Xpow)
Control units of the drive 99 Notes: The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (24…12 AWG). The torque is 0.5 N·m (5 lbf·in). See section Drive-to-drive link (XD2D). See chapter Safe torque off function. -
Page 100: Ai1 Or Ai2 As A Pt100, Pt1000 Or Kty84 Sensor Input
100 Control units of the drive WARNING! As the inputs pictured above are not insulated according to IEC 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. If the assembly does not fulfill the requirement, the I/O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I/O terminals. -
Page 101: 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 102: Control Unit Connector Data
102 Control units of the drive Control unit connector data Power supply Connector pitch 5 mm, wire size 2.5 mm (XPOW) 24 V (±10%) DC, 2 A External power input. Two supplies can be connected for redundancy. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3) 250 V AC / 30 V DC, 2 A... - Page 103 Control units of the drive 103 Analog outputs AO1 and AO2 Connector pitch 5 mm, wire size 2.5 mm (XAO) 0…20 mA, R < 500 ohm load Frequency range: 0…500 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm (XD2D)
- Page 104 104 Control units of the drive Ground isolation diagram XPOW +24VI +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- each AI input and AGND is AI2+ +30 V AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD...
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Page 105: Installation Checklist
Installation checklist 105 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. Checklist Do the steps in section Precautions before electrical work... - Page 106 106 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. Proper grounding has also been measured according to the regulations. There is an adequately sized protective earth (ground) conductor between the motor and the drive, and the conductor has been connected to appropriate terminal.
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Page 107: Start-Up
Start-up 107 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 108: Checks/Settings With No Voltage Connected
108 Start-up Action Safety WARNING! Obey the safety instructions during the start-up procedure. See chapter Safety instructions. Checks/Settings with no voltage connected Ensure that the disconnector of the supply transformer is locked to the off (0) position, ie. no voltage is, and cannot be connected to the drive inadvertently. -
Page 109: Setting Up The Supply Unit Parameters
Start-up 109 Action Setting up the supply unit parameters Check the voltage range setting in parameter 195.01 Supply voltage. Setting up the Main Fan fault parameters Check the 31.35 Main Fan Fault Function = Fault for better protection of cabinet. Setting up the drive parameters, and performing the first start Set up the inverter control program. - Page 110 110 Start-up Action Test and validate the operation of Prevention of unexpected start with FSO-xx (option +Q950)
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Page 111: Fault Tracing
Fault tracing 111 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs Where Color Indication Control POWER Green Control unit is powered and +15 V is supplied to the control panel panel. mounting FAULT Drive in fault state. - Page 112 112 Fault tracing...
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Page 113: Maintenance
Maintenance 113 Maintenance Contents of this chapter This chapter contains preventive maintenance instructions. Maintenance intervals The table below shows the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet. Preventive maintenance interval table ... - Page 114 Replacement of component. Required conditions: ambient temperature is below 40 °C (104 °F) and there is no cyclic heavy load or continuous nominal load. Replacement of component in demanding operation conditions: (R) if ambient temperature is higher than 40 °C (104 °F) or operation is continuous or maintenance counter indicates replacement. For replacement contact ABB.
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Page 115: Cabinet
Maintenance 115 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 116: Cleaning The Door Air Inlets (Ip54)
116 Maintenance Cleaning the door air inlets (IP54) 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 117: Heatsink
Maintenance 117 Heatsink The drive module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. When necessary, clean the heatsink as follows. WARNING! Obey the instructions in chapter Safety instructions. -
Page 118: Fans
Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the cooling fan in the auxiliary control cubicle ... -
Page 119: Replacing The Drive Module Main Fans
Maintenance 119 Replacing the drive module main 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 before you start the work. -
Page 120: Replacing A Roof Fan (Ip54)
120 Maintenance Replacing a roof fan (IP54) 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 before you start the work. -
Page 121: Replacing The Drive Module
Maintenance 121 Replacing the drive module This replacing procedure requires: 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. There are two modules in ACS880-07XT. - Page 122 122 Maintenance 7. Remove the five screws on the bar at upper side of the module. 8. Remove the four screws on the bar at lower side of the module. 9. Unplug cable and optical fiber. 10. Pull the drive module carefully out of the cabinet preferably with help from another person.
- Page 123 Maintenance 123...
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Page 125: Replacing The Left Module
Maintenance 125 Replacing the left module The Process of replacing the left module in the cabinet is as below. 1. Stop the drive and do the steps in section Precautions before electrical work before you start the work. Prepare to unplug left drive module. 2. - Page 126 126 Maintenance...
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Page 129: 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 130: Control Units
130 Maintenance Control units BCU control unit types ACS880-07XT uses BCU-02 control unit. There are three variants of the BCU control unit used in ACS880 drives: BCU-02, BCU-12 and BCU-22. These have a different number of converter module connections (2, 7 and 12 respectively) but are otherwise identical. The three BCU types are interchangeable as long as the number of connections is sufficient. -
Page 131: Control Unit Battery
Maintenance 131 Control unit battery Replace the real-time clock battery if the BATT OK LED is not illuminated when the control unit is powered. For information on the LED, see Control unit layout and connections (page 96). 1. Do the steps in section Precautions before electrical work before you start the work. -
Page 132: Reduced Run
132 Maintenance Reduced run A “reduced run” function makes it possible to continue operation with one drive module if the other module is out of service, for example, because of maintenance work. In principle, reduced run is possible with only one module, but the physical requirements of operating the motor still apply;... -
Page 133: Technical Data
Technical data 133 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. Ratings The ratings of the drive modules with 50 Hz and 60 Hz supply are given below. IEC RATINGS Drive unit Frame... -
Page 134: Ambient Temperature Derating
The power ratings apply to most IEC 34 motors at the nominal voltage of the drive. We recommend to select the drive, motor and gear combination for the required motion profile with the DriveSize dimensioning tool available from ABB. Ambient temperature derating ... -
Page 135: Altitude Derating
Technical data 135 Altitude derating At altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for every 100 m (328 ft). If ambient temperature is below +40 °C (+104 .°F), the derating can be reduced by 1.5% for every 1 °C reduction in temperature. -
Page 136: High Speed Mode
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 137: Frame Sizes And Power Module Types
Technical data 137 Frame sizes and power module types Drive unit type Drive module type Basic module type Qty + size = 400 V ACS880-07XT-1010A-3 ACS880-04XT-1010A-3 ACS880-04-585A-3+P943 2×R10 ACS880-07XT-1190A-3 ACS880-04XT-1190A-3 ACS880-04-650A-3+P943 2×R10 ACS880-07XT-1330A-3 ACS880-04XT-1330A-3 ACS880-04-725A-3+P943 2×R11 ACS880-07XT-1610A-3 ACS880-04XT-1610A-3 ACS880-04-880A-3+P943 2×R11 = 500 V ACS880-07XT-1010A-5 ACS880-04XT-1010A-5... -
Page 138: Dimensions And Weights
138 Technical data Dimensions and weights See chapter Dimensions. Free space requirements Front* Sides* Above** 5.91 15.75 *As required by cooling. **Measured from the base plate of the cabinet top. Note: 320 mm (12.3 in.) is required for fan replacement of IP54 cabinets. -
Page 139: Electrical Power Network Specification
Technical data 139 Electrical power network specification Voltage (U ACS880-07XT-xxxxx-3: 380…415 V AC 3-phase ±10%. This is indicated in the type designation label as typical input voltage level (3~ 400 V AC). ACS880-07XT-xxxxx-5: 380…500 V AC 3-phase ± 10%. This is indicated in the type designation label as typical input voltage levels (3~ 400/480/500 V AC). -
Page 140: Efficiency
Installation site altitude 0 to 2000 m above sea level. For attitude over 2000m, contact ABB. Output derated above 1000 m (3281 ft). See section The ratings of the drive modules with 50 Hz... -
Page 141: Materials
IEC 62635 guidelines. To aid recycling, plastic parts are marked with an approppriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations. -
Page 142: Applicable Standards
142 Technical data Applicable standards The drive complies with the standards below. The compliance with the European Low Voltage Directive is verified according to standard EN 61800-5-1. EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety requirements – electrical, thermal and energy EN 60204-1:2006 +A1 Safety of machinery. -
Page 143: Tightening Torques
Technical data 143 Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Electrical connections Size Torque Note N·m Strength class 4.6...8.8 Strength class 4.6...8.8 Strength class 8.8 Strength class 8.8 Strength class 8.8 Strength class 8.8 Strength class 8.8 Strength class 8.8... -
Page 144: Disclaimers
144 Technical data Disclaimers Generic disclaimer The manufacturer shall have no obligation with respect to any product which (i) has been improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident; (iii) has been used in a manner contrary to the manufacturer’s instructions; or (iv) has failed as a result of ordinary wear and tear. -
Page 145: Category C2
Technical data 145 Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above 400 A, or intended for use in complex systems in the second environment. Category C2 The drive complies with the standard with the following provisions: 1. - Page 146 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 motor and control cables are selected as specified in the hardware manual. 4. The drive is installed according to the instructions given in the hardware manual.
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Page 147: Dimensions
Dimensions 147 Dimensions What this chapter contains This chapter contains the following dimension data: • Composition of cabinet line-ups in tabular form for each frame size with options • Approximate weights of basic line-ups • Dimension drawing examples of selected line-ups... -
Page 148: Cabinet Line-Up Dimensions
The standard depth of the cabinet line-up is 644 mm (25.35”) excluding equipment such as handles and air inlet gratings. • 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. Weights ... -
Page 149: Dimension Drawing Examples
Dimensions 149 Dimension drawing examples Frame 2×R11/R10 (with brake chopper) - Page 150 150 Dimensions Frame 2×R11/R10 (without brake chopper)
- Page 151 Dimensions 151 Location of input terminals (ACS880-07XT-0810A-7, ACS880-07XT-0960A-7, ACS880- 07XT-1010A-3, ACS880-07XT-1010A-5, ACS880-07XT-1190A-3, ACS880-07XT-1160A- 5, ACS880-07XT-1080A-7)
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Page 152: Location Of Input Terminals (Acs880-07Xt-1310A-5, Acs880-07Xt-1320A-7, Acs880-07Xt-1330A-3, Acs880-07Xt-1610A-3, Acs880-07Xt-1610A-5)
152 Dimensions Location of input terminals (ACS880-07XT-1310A-5, ACS880-07XT-1320A-7, ACS880- 07XT-1330A-3, ACS880-07XT-1610A-3, ACS880-07XT-1610A-5) - Page 153 Dimensions 153 Location of input terminals (ACS880-07XT, 12 pulse)
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Page 154: Location Of Output Terminals (Acs880-07Xt, R10, With Du/Dt)
154 Dimensions Location of output terminals (ACS880-07XT, R10, with du/dt) -
Page 155: Location Of Output Terminals (Acs880-07Xt, R10, Without Du/Dt)
Dimensions 155 Location of output terminals (ACS880-07XT, R10, without du/dt) -
Page 156: Location Of Output Terminals (Acs880-07Xt, R11, With Du/Dt)
156 Dimensions Location of output terminals (ACS880-07XT, R11, with du/dt) -
Page 157: Location Of Output Terminals (Acs880-07Xt, R11, Without Du/Dt)
Dimensions 157 Location of output terminals (ACS880-07XT, R11, without du/dt) -
Page 158: Location Of Pe Terminals (Acs880-07Xt)
158 Dimensions Location of PE terminals (ACS880-07XT) -
Page 159: Location Of Resistor Terminals (Acs880-07Xt, R10)
Dimensions 159 Location of resistor terminals (ACS880-07XT, R10) -
Page 160: Location Of Resistor Terminals (Acs880-07Xt, R11)
160 Dimensions Location of resistor terminals (ACS880-07XT, R11) -
Page 161: Resistor Braking
Resistor braking 161 Resistor braking Contents of this chapter This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. Operation principle and hardware description The dive can be equipped with optional built-in brake chopper (+D150). Brake resistors are available as add-on kits. -
Page 162: Selecting A Custom Resistor
162 Resistor braking Selecting a custom resistor If you use a resistor other than the default resistor, make sure that: 1. The resistance of the custom resistor is greater or equal than the resistance of the default resistor in the rating table: R >... -
Page 163: Maximum Cable Length
The maximum length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user- defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer. -
Page 164: Mechanical Installation Of External Brake Resistors
164 Resistor braking Mechanical installation of external brake resistors All brake resistors must be installed outside the drive. Obey the resistor manufacturer’s instructions. Electrical installation Checking the insulation of the assembly Obey the instructions given in section Brake resistor and resistor cable. -
Page 165: Technical Data
Short energy pulse that the resistor assembly withstands every 400 seconds Continuous power (heat) dissipation of the resistor when placed correctly Rcont The ratings apply at an ambient temperature of 40 °C (104 °F). For 690 V data, please contact your local ABB representative. SAFUR resistors ... -
Page 166: Dimensions And Weights
25 kg (55 lb) SAFUR200F500 30 kg (66 lb) 5 5 Ø 7 codes Ordering Brake resistor type ABB ordering code SAFUR125F500 68759285 SAFUR200F500 68759340 Terminals and cable lead-through data See section Terminal and lead-through data for the power cables. -
Page 167: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels. - Page 168 Contact us www.abb.com/drives www.abb.com/drivespartners 3ABD00043579 Rev C (EN) 2018-01-01...