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ABB ACS880-04FXT Hardware Manual

Drive module packages
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Summary of Contents for ABB ACS880-04FXT

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-04FXT drive module packages Hardware manual...
  • Page 3 ACS880-04FXT drive module packages Hardware manual Table of contents 1. Safety instructions 6. Mechanical installation 8. Electrical installation 11. Start-up 3AXD50000274444 Rev B EFFECTIVE: 2020-03-26...

  • 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 ........Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ..............Additional instructions and notes .............
  • Page 6 6 Table of contents Limitation of liability ................Cabinet construction ................Disposition of the devices ..............Grounding of mounting structures ............Busbar material and joints ..............Shrouds ..................Tightening torques ................Electrical connections ..............Mechanical connections ..............Insulation supports ................Cable lugs ..................

  • Page 7: Table Of Contents

    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 the regenerative and low harmonics drives ...
  • Page 8 8 Table of contents Implementing the Safe torque off function ............. Implementing the functions provided by the FSO-xx safety functions module .... Using power factor compensation capacitors with the drive ......... Using a safety switch between the drive and the motor ........Implementing an ATEX-certified motor thermal protection ........
  • Page 9 Table of contents 9 AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input ........ DIIL input .................... The XD2D connector ................Safe torque off (XSTO, XSTO OUT) ............FSO-xx safety functions module connection (X12) ........... 10 Installation checklist Contents of this chapter ................
  • Page 10 10 Table of contents 15 Technical data Contents of this chapter ................Ratings ....................Output derating ..................When is derating necessary ..............Ambient temperature derating ..............Altitude derating ................Deratings for special settings in the drive control program ....... High speed mode ................Modules used ..................
  • Page 11 Table of contents 11 Mounting plate opening ................17 Example circuit diagram Contents of this chapter ................Example circuit diagram ................18 The Safe torque off function Contents of this chapter ................Description ..................Compliance with the European Machinery Directive ........Wiring ....................
  • Page 12 12 Table of contents Connection diagram ................Connection procedure ................. Start-up ....................Parameter settings ................Technical data ..................Ratings ................... SAFUR resistors ................Dimensions, weights and ordering codes ..........Terminals and cable entry data ............... 20 Filters Contents of this chapter ................du/dt filters ..................

  • 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, 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 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 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 15: Electrical Safety In Installation, Start-Up And Maintenance

    Safety instructions 15 • 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. • Vacuum clean the area around the drive before the start-up to prevent the drive cooling fan from drawing the dust inside the drive.

  • Page 16: Additional Instructions And Notes

    16 Safety instructions WARNING! Obey these instructions. 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 or maintenance work. Go through these steps before you begin any installation or maintenance work. 1.

  • Page 17: Optical Components

    Safety instructions 17 • 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. • Make sure that the electrical power network, motor/generator, and environmental conditions agree with the drive data.

  • 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. If you are not a qualified electrical professional, do not do grounding work.

  • Page 19: General Safety In Operation

    Safety instructions 19 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 20: Safety In Operation

    20 Safety instructions • 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 21: Introduction To The Manual

    The flowchart refers to chapters/sections in this manual and other manuals. Applicability This manual applies to ACS880-04FXT drive module units intended for user-defined cabinet installations. Target audience This manual is intended for people who plan the installation, install, start up and do maintenance work on the drive, or create instructions for the end user of the drive concerning the installation and maintenance of the drive.

  • Page 22: Related Documents

    Related documents Name Code Drive hardware manuals and guides Drive/converter/inverter safety instructions Multilingual code: 3AXD50000037978 ACS880-04FXT drives hardware manual 3AXD50000274444 ACS880-04F drive modules quick installation guide 3AXD50000044913 ACx-AP-x Assistant control panels user’s manual 3AUA0000085685 BCU-02/12/22 control units hardware manual 3AUA0000113605...

  • Page 23: Categorization By Frame Size And Option Code

    Introduction to the manual 23 Categorization by frame size and option code The instructions, technical data and dimension drawings which concern only certain drive frame sizes are marked with the symbol of the frame size (R11). The frame size is marked on the type designation label.

  • Page 24: Terms And Abbreviations

    24 Introduction to the manual Task Connect the external control cables to the drive control Connecting the control cables to the terminals of the unit. control unit (page 99) Check the installation. Installation checklist (page 115) Commission the drive. Start-up (page 119) Commission the brake chopper (if used).

  • Page 25: Operation Principle And Hardware Description

    Operation principle and hardware description 25 Operation principle and hardware description Contents of this chapter This chapter describes the operating principle and construction of the drive module packages.

  • Page 26: Product Overview

    26 Operation principle and hardware description Product overview The ACS880-04FXT is a drive module package (drive) for controlling asynchronous AC induction motors, permanent magnet motors and AC induction servomotors. The drive consists of two drive modules (ACS880-04F +P943) and a separate control unit.

  • Page 27: Drive Connection Examples

    Operation principle and hardware description 27 Drive connection examples 6-pulse connection 6-pulse connection No additional protection for the input and motor cables No additional protection for the input and motor cables against thermal overload is needed. against thermal overload is needed. WARNING! Make sure that both contactors close at the same time.
  • Page 28 28 Operation principle and hardware description 12-pulse connection 6-pulse connection Protection against thermal overload for the input cables Protection against thermal overload for the input cables with fuses is needed. with fuses is needed. WARNING! WARNING! Make sure that both contactors close at the Make sure that both contactors close at the same time.

  • Page 29: Layout

    Operation principle and hardware description 29 Layout ￭ Standard drive module configuration Lifting lugs Input cable connection busbars (L1/U1, L2/V1, L3/W1) and DC+ and DC- busbars Circuit board compartment Output cable connection busbars (T1/U2, T2/V2, T3/W2) and brake resistor connection busbars (R+ and R- with option +D150) Common mode filter (+E208 as standard) Auxiliary cooling fans...

  • Page 30: Drive Module Configuration With Ip20 Shrouds (Option) And Full-Size Output Cable Connection Terminals (Option)

    30 Operation principle and hardware description ￭ Drive module configuration with IP20 shrouds (option) and full-size output cable connection terminals (option) Front view Back view Drive module Upper front cover Lower front cover Clear plastic shrouds attached Heatsink cleaning hole cover Flange Hood for UL Type 12 installations External control unit...

  • Page 31: Control Unit

    Operation principle and hardware description 31 Clear plastic shroud to be attached onto the drive Metallic shroud. With option "full-size input cable module input power cabling (a). Entry shroud for connection terminals", the shroud includes a side cabling (b). ground bar. Clear plastic shrouds to be attached onto the drive PE (ground) terminal module output power cabling...

  • Page 32: Overview Of Power And Control Connections

    32 Operation principle and hardware description Overview of power and control connections The diagram below shows the power connections and control interfaces of the drive unit. XPOW ACS880-04F- V10 V20 xxxx-x+P943 BPOW BGDR t° UDC+ UDC- T1/U2 L1/U1 T2/V2 L2/V1 T3/W2 L3/W1 X3 1...
  • Page 33 Operation principle and hardware description 33 I/O terminal blocks, see chapter Control unit of the drive (page 107) Fiber optic links to the drive modules Ethernet interface – not in use Control panel Brake resistor (optional, see chapter Resistor braking (page 185) du/dt or sine filter (optional, see chapter Filters (page 193) XSTO OUT terminals are wired to BGDR connectors if Safe torque off function is taken into use.

  • Page 34: External Control Unit Connection Cables

    34 Operation principle and hardware description ￭ External control unit connection cables The cables for connecting the drive module and control panel to the control unit are shown below. The length of the cables is 3 meters (9.8 feet). See sections Connecting the control unit to the drive module (page 98) Connecting a control panel (page 100)

  • Page 35: Type Designation Labels

    Operation principle and hardware description 35 Type designation labels A type designation label is attached to the drive modules. The type designation label of the drive module package is delivered in an envelope. ￭ Drive module package label The type designation label of the drive module package includes a rating, markings, a type designation and a serial number, which allow individual recognition of each drive module package.

  • Page 36: Drive Module Label

    36 Operation principle and hardware description ￭ Drive module label The type designation label of the drive module includes a rating, markings, a type designation and a serial number, which allow individual recognition of each drive module package. An example label is shown below. Type designation, see section Type designation key (page 37).

  • Page 37: Type Designation Key

    Operation principle and hardware description 37 Type designation key The type designation contains information on the specifications and configuration of the drive module package and the drive module. The first digits from left express the basic drive type. The optional selections are given thereafter, separated by plus signs. Codes preceded by zero indicate the absence of the specified feature.

  • Page 38: Drive Module

    38 Operation principle and hardware description Code Description Specialties P904 Extended warranty 24/30 P909 Extended warranty 36/42 P911 Extended warranty 60/66 Safety functions Q971 ATEX-certified Safe Disconnection Function Full set of printed manuals in the selected language Note: The delivery may include manuals in English if the requested language is not available. R700 English R701...
  • Page 39 High speed license for > 598 Hz operation Specialties P904 Extended warranty 24/30 P909 Extended warranty 36/42 P911 Extended warranty 60/66 Drive module for parallel connection (only modules with +P943 can be connected in parallel and P943 used as spare parts for ACS880-04FXT)

  • Page 41: Generic Cabinet Planning Instructions

    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 42: Grounding Of Mounting Structures

    ￭ Shrouds The installation of shrouds (touch protection) to fulfill applicable safety regulations is the responsibility of the drive system builder. Ready-made shrouding parts are available from ABB for some cabinet designs, see the ordering information. ￭ Tightening torques Unless a tightening torque is specified in the text, the following torques can be used.

  • Page 43: Insulation Supports

    Generic cabinet planning instructions 43 Insulation supports Size Max. torque Note 5 N·m (44 lbf·in) Strength class 8.8 9 N·m (6.6 lbf·ft) Strength class 8.8 18 N·m (13.3 lbf·ft) Strength class 8.8 31 N·m (23 lbf·ft) Strength class 8.8 Cable lugs Size Max.

  • Page 44: Preventing The Recirculation Of Hot Air

    44 Generic cabinet planning instructions Note: Use an extra exhaust fan if the air outlet is on the cabinet door. Air inlet Air outlet Arrange the cooling air flow through the components according to the technical data. See the specifications for: •...

  • Page 45: Emc Requirements

    • The best galvanic connection between the steel panels is achieved by welding them together as no holes are necessary. If welding is not possible, ABB recommends to leave the seams between the panels unpainted and equipped with special conductive EMC strips to provide adequate galvanic connection.
  • Page 46 360° high-frequency grounding of the cable shields at the cable entries improves the EMC shielding of the cabinet. • ABB recommends 360° high-frequency grounding of the motor cable shields at their entries. The grounding can be implemented by a knitted wire mesh screening as shown below.

  • Page 47: Attaching The Cabinet

    Generic cabinet planning instructions 47 Attaching the cabinet WARNING! Do not attach the cabinet by electric welding. ABB does not assume any liability for damages caused by electric welding as the welding circuit can damage electronic circuits in the cabinet.
  • Page 48 48 Generic cabinet planning instructions DPMP-01 DPMP-02 DPMP-04 IP54 / UL Type 12 when panel is IP65 / UL Type 12 when panel is IP66 (inside and outside the cabinet mounted mounted door) IP20 when panel is not mounted IP20 when panel is not mounted...

  • Page 49: Guidelines For Planning The Mechanical Installation

    Guidelines for planning the mechanical installation 49 Guidelines for planning the mechanical installation Contents of this chapter This chapter guides in planning drive cabinets and installing the drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirements around the module for cooling.

  • Page 50: Installation Principle

    50 Guidelines for planning the mechanical installation ￭ Installation principle Cool air in, max. 40 °C (104 °F) Hot air out Air guide Air flow in the cooling air channel...

  • Page 51: Cabinet Installation

    Guidelines for planning the mechanical installation 51 Cabinet installation ￭ Layout example, outside view This figure shows a cabinet layout example with the input power cable entry from top and the motor cable entry from bottom. WARNING! Attach the cabinet to the floor or prop it up from the back. The module has its center of gravity at the back and the cabinet easily topples over.

  • Page 52: Layout Example, Inside View

    Required free space (page 53). ￭ Other installation positions than vertical You can install the drive module on its back. Make sure that the hot cooling air that flows upwards from the module does not cause danger. For other installation positions, contact ABB.

  • Page 53: Required Free Space

    Guidelines for planning the mechanical installation 53 Required free space Free space around the drive module is needed to make sure that sufficient cooling air flows through the module and the module cools correctly. The required free space at the top and bottom of the drive module is shown below. The modules can be installed side by side.

  • Page 55: Mechanical Installation

    Mechanical installation 55 Mechanical installation Contents of this chapter This chapter describes how to install the drive module mechanically without the clear plastic shrouds. The shrouds are attached after the power cabling. Examining the installation site Examine the installation site. Make sure that: •...

  • Page 56: Package Drawings

    56 Mechanical installation ￭ Package drawings 3AXD50000040437_assy Standard drive module package Package with IP20 shrouds for cabling area (option) Drive module with factory installed options (for example, +E208), delivery documents, multilingual residual voltage warning sticker, printed multilingual start-up quick guide. Other printed manuals with option +R700. Cardboard lids Top box (with option "IP20 shrouds for cabling area").
  • Page 57 Mechanical installation 57 Box B1 contents (option "IP20 shrouds for cover- ing the input and motor cabling area") Paper fill Clear plastic shroud for output cabling Cardboard box cover Cardboard box bottom Support Bands Back clear plastic shroud (lower) Back clear plastic shroud (upper) Front clear plastic shroud Clear plastic shroud for input cabling Top clear plastic shroud...

  • Page 58: Examining The Delivery

    58 Mechanical installation Box B3 contents (option "Full size input cable connection terminals and PE busbar”) Metallic shroud with ground bar Paper fill Input cable connection terminal L3/W1 Input cable connection terminal L2/V1 Input cable connection terminal L1/U1 Cardboard box Screws and insulators in a plastic bag 3AXD5000009522 ￭...

  • Page 59: Attaching Alternatives

    Mechanical installation 59 Attaching alternatives ￭ Attaching the drive module by the flange See chapter Dimension drawings for the mounting point and mounting plate opening dimensions. 1. Make an opening to the mounting plate for the drive module heatsink penetration. 2.

  • Page 60: Attaching The Drive Module By The Heatsink

    60 Mechanical installation ￭ Attaching the drive module by the heatsink 1. Attach the support brackets to the heatsink back. 2. Attach the support brackets to the wall. Combi screw M8×20 20 N·m (14.8 lbf·ft) Attaching the external control unit The drive control unit can be attached on a mounting plate or onto a DIN rail.

  • Page 61: 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 62: North America

    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 63: Requirements Table

    N-end (non-drive end) motor bearings are required. Ignoring the requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty. This table shows the requirements when an ABB motor is in use. Motor Nominal AC supply...
  • Page 64 64 Guidelines for planning the electrical installation 2) For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer. This table shows the requirements when a non-ABB motor is in use. Motor Nominal AC supply Requirement for type...

  • Page 65: Availability Of Du/Dt Filter And Common Mode Filter By Drive Type

    The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: •...

  • Page 66: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    66 Guidelines for planning the electrical installation Nominal AC supply Requirement for voltage Motor insulation system ABB du/dt and common mode filters, insulated N- end motor bearings < 100 kW or frame 100 kW < P < 350 kW or size <...

  • Page 67: Additional Note For Sine Filters

    Guidelines for planning the electrical installation 67 Û du/dt -------------(1/ µs) Û -- - - -- - - - - - (1/ µs) l (m) l (m) Drive with du/dt filter Drive without du/dt filter Motor cable length Û Relative peak line-to-line voltage (du/dt)/U Relative du/dt value Note: Û...

  • Page 68: Typical Power Cable Sizes

    68 Guidelines for planning the electrical installation fault current during the disconnection time of the protective device. The cross-sectional area of the protective conductor can either be selected from the table below or calculated according to 543.1 of IEC 60364-5-54. This table shows the minimum cross-sectional area of the protective conductor related to the phase conductor size according to IEC/UL 61800-5-1 when the phase conductor and the protective conductor are made of the same metal.

  • Page 69: Alternate Power Cable Types

    Guidelines for planning the electrical installation 69 Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or armored) cable with three phase conductors and symmetrically constructed PE conductor and a shield (or armor) Symmetrical shielded (or armored) cable with three phase conductors and a shield (or armor), and separ- ate PE conductor/cable...

  • Page 70: Not Allowed Power Cable Types

    ￭ Additional guidelines, North America ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor(s). Due to the variety of application needs, metallic and non-metallic conduit can be used. ABB prefers the use of metallic conduit.

  • Page 71: Metal Conduit

    Guidelines for planning the electrical installation 71 Wiring method Notes 1) 2) Conduit - Metallic Electrical metallic tubing: Type EMT Prefer symmetrical shielded VFD cable. Use separate conduit run for each motor. Rigid metal conduit: Type RMC Do not run input power wiring and motor wiring in the Liquid-tight flexible metal electrical conduit: Type LFMC same conduit.

  • Page 72: Selecting The Control Cables

    ￭ Relay cable The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. ￭ Control panel to drive cable Use EIA-485 with male RJ-45 connector, cable type Cat 5e or better. The maximum permitted...

  • Page 73: Pc Tool Cable

    Guidelines for planning the electrical installation 73 ￭ PC tool cable Connect the Drive composer PC tool to the drive through the USB port of the control panel. Use a USB Type A (PC) - Type Mini-B (control panel) cable. The maximum length of the cable is 3 m (9.8 ft).

  • Page 74: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable

    74 Guidelines for planning the electrical installation Input power cabling Motor cabling Conduit ￭ Continuous motor cable shield/conduit or enclosure for equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...

  • Page 75: Implementing Motor And Motor Cable Short-Circuit And Thermal Overload Protection

    Guidelines for planning the electrical installation 75 Implementing motor and motor cable short-circuit and thermal overload protection ￭ Protecting the motor and motor cable in short-circuits The drive protects the motor cable and motor in a short-circuit situation when the motor cable is sized according to the nominal current of the drive.

  • Page 76: Protecting The Drive And Input Cable In Short-Circuits And Against Thermal Overload

    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 77: Implementing A Motor Temperature Sensor Connection

    Guidelines for planning the electrical installation 77 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 78: Protecting The Drive Against Ground Faults

    78 Guidelines for planning the electrical installation • the temperature sensor types that you can connect to each option module • the temperature sensor insulation requirement in order to form, together with the insulation of the option module, a reinforced insulation between the motor live parts and the drive control unit.

  • Page 79: Implementing The Functions Provided By The Fso-Xx Safety Functions Module

    Guidelines for planning the electrical installation 79 Implementing the functions provided by the FSO-xx safety functions module You can order a safety function module from ABB. The cabinet builder can use the module for implementing various safety functions. Using power factor compensation capacitors with the drive Power factor compensation is not needed with AC drives.

  • Page 80: Implementing The Undervoltage Control (Power-Loss Ride-Through)

    80 Guidelines for planning the electrical installation Implementing the undervoltage control (Power-loss ride-through) See the firmware manual. Controlling a contactor between drive and motor The control of the output contactor depends on how you use the drive, that is, which motor control mode and which motor stop mode you select.
  • Page 81 Guidelines for planning the electrical installation 81 Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs. 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode...

  • Page 83: Electrical Installation

    Electrical installation 83 Electrical installation Contents of this chapter This chapter gives instructions on the wiring of the drive. Safety WARNING! If you are not a qualified electrical professional, do not do installation or maintenance work. Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 84: Measuring The Insulation

    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 85: Compatibility With It (Ungrounded), Corner-Grounded Delta, Midpoint-Grounded Delta And Tt Systems

    Electrical installation 85 1. Stop the drive and do the steps in section Electrical safety precautions (page 15) before you start the work. 2. Make sure that the resistor cable is connected to the resistor and disconnected from the drive output terminals. 3.
  • Page 86 86 Electrical installation...

  • Page 87: Connecting The Power Cables (Frame Size 2 X R11)

    Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor ABB recommends 360-degree grounding if shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board.
  • Page 88 88 Electrical installation Drive module Switch-disconnector and separate fuses or switch fuse, see Selecting the main supply disconnecting device (page 61) Separate fuses for each module Note: If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor ends.

  • Page 89: Power Cable Connection Diagram (6-Pulse And 12-Pulse) With Optional Filters

    Electrical installation 89 ￭ Power cable connection diagram (6-pulse and 12-pulse) with optional filters (PE) PE (PE) UDC+ UDC+ UDC- UDC- T1/ T2/ T3/ 3 ~ M Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor...
  • Page 90 90 Electrical installation 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. 360-degree grounding is required Line contactor Common mode filter (optional), see Requirements table (page 63) du/dt filter or sine filter (optional), see Filters (page 193) Use a separate grounding cable if the shield does not meet the requirements of IEC 61439-1 and there...

  • Page 91: Power Cable Connection Diagram (6-Pulse) Without Optional Filters

    Electrical installation 91 ￭ Power cable connection diagram (6-pulse) without optional filters UDC+ UDC+ UDC- UDC- T1/ T2/ T3/ 3 ~ M Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor 360-degree grounding is recommended if shielded cable is used.
  • Page 92 92 Electrical installation Separate fuses for each module Note: If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor ends. Do not use an asymmetrically constructed motor cable. Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.

  • Page 93: Power Cable Connection Diagram (6-Pulse And 12-Pulse) Without Optional Filters

    Electrical installation 93 ￭ Power cable connection diagram (6-pulse and 12-pulse) without optional filters (PE) PE (PE) UDC+ UDC+ UDC- UDC- T1/ T2/ T3/ 3 ~ M Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor...
  • Page 94 94 Electrical installation 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. 360-degree grounding is required Line contactor Drive module Switch-disconnector and separate fuses or switch fuse, see Selecting the main supply disconnecting device (page 61) Use a separate grounding cable if the shield does not meet the requirements of IEC 61439-1 and there...

  • Page 95: Preparing The Cable Ends And Making 360-Degree Grounding At The Cable Entry

    Electrical installation 95 ￭ Preparing the cable ends and making 360-degree grounding at the cable entry 1. Peel off 3…5 cm (1 1/4 … 2 in) of the outer insulation of the cables at the cable entries with the conductive sleeves for the 360° high-frequency grounding. 2.

  • Page 96: Power Cable Connection Procedure

    96 Electrical installation 5. Remove rubber grommets from the entry plate for the cables to be connected. Cut adequate holes into the rubber grommets. Slide the grommets onto the cables. Slide the cables through the entry plate and attach the grommets to the holes. 6.
  • Page 97 Electrical installation 97 4. Connect the UDC terminals of the drive modules together. For the tightening torques, see the technical data. If the DC cables are run outside the cabinet, ground the cable shield 360° at one end only. L1 / L3 / L3 / L1 /...

  • Page 98: Connecting The Control Unit To The Drive Module

    98 Electrical installation Connecting the control unit to the drive module WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt.

  • Page 99: Connections To The Control Unit

    Electrical installation 99 ￭ Connections to the control unit Connect the fiber optic, power supply and BGDR cables to the control unit as follows: BPOW BCU control unit ZINT/SOIA BCU control unit X3:1 XPOW:1 (+24VI) Drive module 1 X3:2 XPOW:2 (GND) ZINT: V1;...

  • Page 100: Connecting A Control Panel

    100 Electrical installation +24VD DIIL Connecting a control panel With control panel door mounting platform, connect the control panel as follows: 1. Connect an Ethernet cable to the RJ-45 connector of the control panel. 2. Connect the other end of the cable to the X13 connector of the control unit. Note: When a PC is connected to the control panel, the control panel keypad is disabled.
  • Page 101 Electrical installation 101 3. 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 102: Connecting A Pc

    102 Electrical installation With FDPI-02 modules: Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage.

  • Page 103: Installing Optional Modules

    Electrical installation 103 A PC (with eg, the Drive composer PC tool) can be connected as follows: 1. Connect an ACx-AP-x control panel to the unit either • by inserting the control panel into the panel holder or platform, or •...
  • Page 104  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, 104 Electrical installation see the FSO-xx manual.) 1.

  • Page 105: Installation Of Fso-Xx Beside The Control Unit

    Electrical installation 105 ￭ Installation of FSO-xx beside the control unit To reserve the slots of the control unit for other modules, you can install the FSO-xx separate from the control unit using mounting kit 3AXD50000025495. The kit contains the parts for mounting the FSO-xx either onto a DIN rail nearby the control unit or onto the grounding/clamping plate of a ZCU-14 (used in frames R1i…R4i) control unit.

  • Page 107: Control Unit Of The Drive

    Control unit of the drive 107 Control unit of the drive Contents of this chapter This chapter describes the control unit used in the drive module package. See BCU-02/12/22 control units hardware manual (3AUA0000113605 [English]) for the following information: • hardware description •...

  • Page 108: Bcu-X2 Layout

    108 Control unit 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 109 Control unit of the drive 109 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 110: Default I/O Connection Diagram

    110 Control unit of the drive Default I/O connection diagram The diagram below shows the default I/O connections on the inverter control unit (A41), and 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 111: External Power Supply For The Control Unit (Xpow)

    Control unit of the drive 111 Notes: See section The XD2D connector (page 113). See chapter The Safe torque off function (page 167). 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. Constant speed 1 is defined by parameter 22.26.

  • Page 112: Ai1 Or Ai2 As A Pt100, Pt1000, Ptc Or Kty84 Sensor Input

    112 Control unit of the drive +24VD 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 113: Diil Input

    (nominal impedance 100 to 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 114: Fso-Xx Safety Functions Module Connection (X12)

    114 Control unit of the drive FSO-xx safety functions module connection (X12) See the user manual of the FSO-xx module.

  • Page 115: Installation Checklist

    Installation checklist 115 Installation checklist Contents of this chapter This chapter contains a list for examining 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.
  • Page 116 116 Installation checklist Make sure that … The placement of optional modules and other equipment inside the cabinet and on the cabinet door is correct. The mounting of optional modules and other equipment is correct. Internal cabling of the cabinet assembly Main circuit: •...
  • Page 117 Installation checklist 117 Make sure that … The enclosures of the equipment in the cabinet have proper galvanic connection to the cabinet protective earth (ground) busbar; The connection surfaces at the fastening points are bare (unpainted) and the connections are tight, or separate grounding conductors have been installed. The supply voltage matches the nominal input voltage of the drive.

  • Page 119: Start-Up

    Start-up 119 Start-up Contents of this chapter This chapter describes the start-up procedure of the drive. Start-up procedure WARNING! Only qualified electricians are allowed to start-up the drive. 1. Make sure that the installation of the drive module has been done according to the checklist in chapter Installation checklist (page 115), and that the motor and driven...
  • Page 120 Start-up (page 190). • For drives with ABB du/dt filter: Make sure that bit 13 of parameter 95.20 HW options word 1 is switched on. • For drives with sine filter: Make sure that parameter 95.15 Special HW settings is set to ABB sine filter.

  • Page 121: Fault Tracing

    Fault tracing 121 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs The table below describes the LEDs of the drive module with option DPMP-01. Where Color When the LED is lit Control panel POWER Green...

  • Page 123: Maintenance

    This chapter contains maintenance instructions of the drive modules. 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 (www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels).
  • Page 124 Replacement 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. Note: Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 125: Cabinet

    Maintenance 125 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 or maintenance work.

  • Page 126: Cleaning The Interior Of The Heatsink

    126 Maintenance ￭ Cleaning the interior of the heatsink WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding wristband.

  • Page 127: Fans

    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. ￭ Replacing the circuit board compartment cooling fans WARNING! Obey the safety instructions of the drive.

  • Page 128: Replacing The Main Cooling Fans

    128 Maintenance ￭ Replacing the main cooling fans The main cooling fans can be replaced from the front side and the back side. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. To replace the main cooling fans from the front side: 1.
  • Page 129 Maintenance 129 To replace the main cooling fans from the back side: 1. Stop the drive and do the steps in section Electrical safety precautions (page 15) before you start the work. 2. Undo the locking screw. 3. Push the fan cassette to the left. 4.

  • Page 130: Replacing The Standard Drive Module

    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. ￭...

  • Page 131: Replacing The Control Unit

    2. If the control unit is powered from the faulty module, connect the control unit to another 24 V DC power supply. ABB recommends using an external power supply with parallel-connected drive modules. 3. Disconnect all cables from the module to be serviced and remove it from its bay. See...

  • Page 133: Ordering Information

    This chapter gives ordering information on additional components available from ABB for the drive module installation. Note: This chapter lists only the installation accessories available from ABB. All other parts must be sourced from a third party by the system integrator. For a listing, refer to the kit-specific installation instructions available at https://www151.abb.com/spaces/lvacdrivesengineeringsupport/content.

  • Page 134: Brake Resistors

    134 Ordering information Type Description Ordering code Illustration ACS-AP-I Control panel 3AUA0000088311 DPMP-01 Door mounting kit 3AUA0000108878 The door mounting kit contains: • front cover • flat cable (between DDPI-01 board and the panel) • DDPI-01 board, cover and M4×8 combi screw for the cover •...

  • Page 135: Fso Accessories Kit

    Ordering information 135 FSO accessories kit Kit code Ordering code Illustration A-X-X-279 3AXD50000025495 Instruction code: 3AXD50000025583 Accessory kits Ordering code Full size input cable connection terminals and PE busbar 3AXD50000024518 Full size output cable connection terminals 3AXD50000024519 IP20 shrouds for covering the input and motor cabling area 3AXD50000019538 Support brackets for attaching the drive module by the heatsink 3AXD50000303533...

  • Page 137: Technical Data

    Technical data 137 Technical data Contents of this chapter This chapter contains the technical specifications of the drive, for example the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Ratings The ratings of the drive module packages with 50 Hz and 60 Hz supply are given below. IEC RATINGS Drive Frame...
  • Page 138 138 Technical data IEC RATINGS Drive Frame Input Output ratings type size current Nominal use Light-duty use Heavy-duty use ACS880- 04FXT-… max_start 0808A-7 2×R11 1017 1356 678*** 0960A-7 2×R11 1260 1674 1147 1080A-7 2×R11 1080 1472 1858 1080 1000 1291 1051 1000 1320A-7...

  • Page 139: Output Derating

    The power ratings apply to most IEC 34 motors at the nominal voltage of the drive. ABB recommends to select the drive, motor and gear combination for the required motion profile with the DriveSize dimensioning tool available from ABB.

  • Page 140: Deratings For Special Settings In The Drive Control Program

    Ex motor, sine filter, low noise Table below gives the deratings for these cases: • drive is used with an ABB motor for explosive atmospheres (Ex) and EX motor in parameter 95.15 Special HW settings is enabled • sine filter given in the selection table (see section...

  • Page 141: High Speed Mode

    The power ratings apply to most IEC 34 motors at the nominal voltage of the drive. ABB recommends to select the drive, motor and gear combination for the required motion profile with the DriveSize dimensioning tool available from ABB.
  • Page 142 142 Technical data current derating with output frequencies above 120 Hz and below the maximum output frequency. Deratings with selection High speed mode of parameter 95.15 Special HW settings 120 Hz output frequency Maximum output frequency Drive Light- Heavy- Maxim- Light- Heavy- type...

  • Page 143: Modules Used

    Technical data 143 Modules used Drive module Drive module package type Type Qty + size = 400 V ACS880-04FXT-1008A-3 ACS880-04F-584A-3+P943 2×R11 ACS880-04FXT-1188A-3 ACS880-04F-649A-3+P943 2×R11 ACS880-04FXT-1330A-3 ACS880-04F-725A-3+P943 2×R11 ACS880-04FXT-1610A-3 ACS880-04F-880A-3+P943 2×R11 = 500 V ACS880-04FXT-1008A-5 ACS880-04F-582A-5+P943 2×R11 ACS880-04FXT-1158A-5 ACS880-04F-634A-5+P943 2×R11 ACS880-04FXT-1310A-5 ACS880-04F-715A-5+P943 2×R11...

  • Page 144: Fuses (Ul)

    144 Technical data Ultrarapid (aR) fuses per drive module Fuse Type DIN 43620 Input current Drive type Size ACS880-04FXT-0960A-7 1250 2150000 170M8554D ACS880-04FXT-1080A-7 1080 1400 2700000 170M8555D ACS880-04FXT-1320A-7 1320 1500 3350000 170M8556D 3AXD10000363510 Note: See also section Protecting the drive and input cable in short-circuits and against thermal overload (page 76).

  • Page 145: Circuit Breakers

    Circuit breakers Circuit breakers must not be used without fuses. Maximum allowed rated conditional short-circuit current (IEC 61439-1) of the electrical power network Contact your local ABB representative Dimensions, weights and free space requirements Standard drive module configuration (including flange) Frame...

  • Page 146: Losses, Cooling Data And Noise

    146 Technical data Losses, cooling data and noise Air flow per Heat dissipation per Noise drive module drive module Drive type Frame ACS880- size Heatsink Front Heatsink Front Drive module Drive 04FXT- dB(A) dB(A) = 400 V 1008A-3 2×R11 1400 5800 1188A-3 2×R11...
  • Page 147 Technical data 147 1610A-5 3×(3×240) 4×(3×240) 6×(3×240) 7×(3×240) = 690 V 0808A-7 3×(3×95) 3×(3×120) 4×(3×150) 4×(3×240) 0960A-7 3×(3×120) 3×(3×185) 4×(3×185) 5×(3×185) 1080A-7 3×(3×150) 3×(3×185) 4×(3×240) 5×(3×240) 1320A-7 3×(3×185) 4×(3×185) 5×(3×240) 6×(3×240) The cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one on top of the other, ambient temperature 30 °C (86 °F) PVC insulation, surface temperature 70 °C (158 °F) (EN 60204-1 and IEC 60364-5-52).
  • Page 148 148 Technical data Drive type UL/NEC input and motor cabling ACS880- Cabling per drive module Common cabling for the drive modules 04FXT-… Cu cable type Al cable type Cu cable type Al cable type AWG/kcmil AWG/kcmil AWG/kcmil AWG/kcmil = 400 V 1008A-3 2×600 or 3×300 3×400 or 4×250...

  • Page 149: Terminal And Entry Data For The Power Cables

    ACS880-04FXT-xxxx-3 drives: 380…415 VAC 3-phase +10%…-15%. This is in- dicated in the type designation label as typical input voltage level 3~400 V AC. ACS880-04FXT-xxxx-5 drives: 380…500 V AC 3-phase +10%…-15%. This is in- dicated in the type designation label as typical input voltage levels 3~400/480/500 V AC.

  • Page 150: Motor Connection Data

    Note: Long cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and characteristics. Contact ABB for more information. Note that a sine filter (optional) at the drive output also causes a voltage decrease.

  • Page 151: Control Unit Connection Data (Bcu-02)

    Technical data 151 Control unit connection data (BCU-02) See BCU-02/12/22 control units hardware manual (3AUA0000113605 [English]). Control panel type ACS-AP-I assistant control panel (to be ordered separately). Efficiency Approximately 98% at nominal power level. Protection classes Degrees of protection Front: IP20 (IEC/EN 60529) Front with option +0B051: IP00 Heatsink: IP55...

  • Page 152: Materials

    152 Technical data Chemical gases Class 3C2 Class 1C2 Class 2C2 Solid particles Class 3S2. No conductive Class 1S3. (packing must Class 2S2 dust allowed. support this, otherwise 1S2) Pollution degree IEC 62109-1 Atmospheric pressure 70…106 kPa 0.7 … 1.05 70…106 kPa 0.7 …...

  • Page 153: Applicable Standards

    Technical data 153 Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations. Applicable standards The drive complies with the following standards. EN 61800-5-1:2007 Adjustable speed electrical power drive systems.

  • Page 154: Emc Compliance (Iec/En 61800-3:2004)

    154 Technical data EMC compliance (IEC/EN 61800-3:2004) ￭ Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes.

  • Page 155: Category C4

    Technical data 155 ￭ Category C4 The drive complies with the C4 category with these provisions: 1. It is ensured that no excessive emission is propagated to neighboring low-voltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply transformer with static screening between the primary and secondary windings can be used.

  • Page 156: Ul And Csa Checklist

    Canadian Electrical Code). Obey also any other applicable local or provincial codes. Note: Circuit breakers must not be used without fuses in the USA. For suitable circuit breakers, contact your local ABB representative. WARNING! The opening of the branch-circuit protective device may be an indication that a fault current has been interrupted.

  • Page 157: Cybersecurity Disclaimer

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized...

  • Page 159: Dimension Drawings

    Dimension drawings 159 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules.

  • Page 160: Standard Configuration - Ip00 (Ul Type Open)

    160 Dimension drawings Standard configuration – IP00 (UL Type Open)

  • Page 161: Drive Module With Optional Support Brackets - Ip00 (Ul Type Open)

    Dimension drawings 161 Drive module with optional support brackets – IP00 (UL Type Open)

  • Page 162: Drive Module With Optional Full Size Input And Output Power Cable Terminals And Ip20 Shrouds

    162 Dimension drawings Drive module with optional full size input and output power cable terminals and IP20 shrouds...

  • Page 163: Mounting Plate Opening

    Dimension drawings 163 Mounting plate opening...
  • Page 164 164 Dimension drawings...

  • Page 165: Example Circuit Diagram

    Example circuit diagram 165 Example circuit diagram Contents of this chapter This chapter shows an example circuit diagram for a cabinet-installed drive module package. Example circuit diagram This diagram is an example for the main wiring of a drive cabinet. Note that the diagram includes components which are not included in a basic delivery (* option, ** to be acquired by the customer).
  • Page 166 166 Example circuit diagram Cabinet *ACS-AP-W control panel 24 V DC supply **Main contactor **Motor temperature supervision **Switch fuse disconnector Common mode filter *du/dt filter or sine filter Drive module Alarm Supply 360 degree grounding recommended **Brake resistor For BCU input and output signals, see the Default I/O connection diagram (page 110).

  • Page 167: The Safe Torque Off Function

    The Safe torque off function 167 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 168: Compliance With The European Machinery Directive

    168 The Safe torque off function Standard Name IEC 60204-1:2016 Safety of machinery – Electrical equipment of machines – Part 1: General requirements EN 60204-1:2006 + A1:2009 + AC:2010 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...

  • Page 169: Wiring

    The Safe torque off function 169 Wiring For the electrical specifications of the STO connection, see the BCU-02/12/22 control units hardware manual (3AUA0000113605 [English]). ￭ 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 170: With Internal Power Supply

    170 The Safe torque off function ￭ With internal power supply Dual-channel connection Drive module Control unit Activation switch...

  • Page 171: Single-Channel Connection Of Activation Switch

    The Safe torque off function 171 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 172: With External Power Supply

    172 The Safe torque off function ￭ With external power supply 24 V DC Drive module Control unit Activation switch...

  • Page 173: Safe Torque Off Function Not In Use

    The Safe torque off function 173 ￭ Safe torque off function not in use If STO is not in use, close the circuit as shown. Otherwise the drive will not start. Drive module Control unit...

  • Page 174: Operation Principle

    174 The Safe torque off function Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.

  • Page 175: Start-Up Including Acceptance Test

    The Safe torque off function 175 Start-up including acceptance 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 an acceptance test. The acceptance test must be performed •...
  • Page 176 176 The Safe torque off function Action Test the operation of the STO function when the motor is running. • Start the drive and make sure the motor is running. • Open the STO circuit. The motor should stop. The drive generates an indication if one is defined for the 'running' state in parameter 31.22 (see the firmware manual).

  • Page 177: Use

    The Safe torque off function 177 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs.

  • Page 178: Maintenance

    If any wiring or component change is needed after start up, or the parameters are restored, do the test given in section Acceptance test procedure (page 175). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...

  • Page 179: 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 180: Safety Data

    180 The Safe torque off function 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 SIL/ Frame size...

  • Page 181: Tüv Certificate

    Mission time: the period of time covering the intended use of the safety function/device. After the mission time elapses, the safety device must be replaced. Note that any T values given cannot be regarded as a guarantee or warranty. ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.

  • Page 182: Declaration Of Conformity

    182 The Safe torque off function ￭ Declaration of conformity...
  • Page 183 The Safe torque off function 183...

  • Page 185: Resistor Braking

    Resistor braking 185 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. When is resistor braking necessary? Resistor braking is necessary for high capacity braking if a regenerative drive cannot be used.

  • Page 186: Resistor Cables

    IGBT semiconductors of the brake chopper. Note: ABB has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling. The customer must consider the EMC compliance of the complete installation.

  • Page 187: Placing The Brake Resistors

    Note: If an external brake chopper (outside the drive module) is used, ABB always requires a main contactor.

  • Page 188: Selecting A Custom Brake Resistor

    188 Resistor braking ￭ Selecting a custom brake resistor If you use other than ABB resistor, 1. make sure that the resistance of the custom resistor is greater than or equal to the resistance of the default ABB resistor. where...

  • Page 189: Mechanical Installation Of Resistors

    Resistor braking 189 3. make sure that the resistor can dissipate the energy transferred to it during the braking: • Braking energy is not greater than the resistor heat dissipation capacity (E ) during the period specified. See the custom resistor specification. •...

  • Page 190: Connection Procedure

    190 Resistor braking ￭ Connection procedure • Connect the resistor cables to the R+ and R- terminals in the same way as the other power cables. If a shielded three-conductor cable is used, cut the third conductor and ground the twisted shield of the cable (protective earth conductor of the resistor assembly) at both ends.

  • Page 191: Technical Data

    Resistor braking 191 Technical data ￭ Ratings The table below gives the ratings for resistor braking. Internal brake Drive Drive module chopper per drive Example brake resistor(s) per drive module type type module Frame size ACS880- ACS880- brcont Rcont 04FXT-… 04F-…...

  • Page 192: Dimensions, Weights And Ordering Codes

    192 Resistor braking Dimensions, weights and ordering codes 5 5 Ø 7 Brake resistor type Weight ABB ordering code SAFUR125F500 25 kg (55 lb) 68759285 SAFUR200F500 30 kg (66 b) 68759340 ￭ Terminals and cable entry data See section Terminal and entry data for the power cables (page...

  • Page 193: Filters

    In addition to the requirements given in Examining the compatibility of the motor and drive (page 62), ABB requires du/dt filters or sine filters at the outputs of the drive modules for equalization of drive module currents. See...

  • Page 194: Ordering Codes

    194 Filters ￭ Ordering codes Filter type ABB ordering code FOCH0610-70 68550505 FOCH0875-70 3AUA0000129544 ￭ Description, installation and technical data of the FOCH filters See FOCH du/dt filters hardware manual (3AFE68577519 [English]). Sine filters ￭ When is a sine filter necessary? Examining the compatibility of the motor and drive (page 62).

  • Page 195: 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 196 3AXD50000274444B © 2020 ABB. All rights reserved. Specifications subject to change without notice.

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