ABB ACS880-107 Series Hardware Manual
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ABB ACS880-107 Series Hardware Manual

Inverter units
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ABB INDUSTRIAL DRIVES
ACS880-107 inverter units
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Summary of Contents for ABB ACS880-107 Series

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-107 inverter units Hardware manual...
  • Page 3 ACS880-107 inverter units Hardware manual Table of contents 4. Electrical installation 6. Start-up 3AUA0000102519 Rev F EFFECTIVE: 2020-05-11...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter ................Applicability ..................Safety instructions ................. Target audience ..................Categorization by frame size, option code and item designation ......Use of component designations ..............Terms and abbreviations ................
  • Page 6 6 Table of contents Charging switch (frame R8i and multiples only) ........Type designation labels ................Inverter unit type designation label ............Inverter module type designation label ............Type designation key ................Option codes ..................3 Control units of the drive Contents of this chapter ................

  • Page 7: Table Of Contents

    Table of contents 7 Re-installing the fan carriage of an inverter module ........Re-inserting the inverter modules into the cubicle ........Connecting the motor cables – Frame size R8i and multiples with common motor terminal cubicle ....................Output busbars ................. Connection diagram ................
  • Page 8 8 Table of contents Replacing R5i inverter module (with option +C204, modules in their own compart- ments) .................... Replacing R6i and R7i inverter modules ............ Replacing R8i inverter modules .............. Removing the inverter module(s) ............Re-inserting the inverter modules into the cubicle ........Activating the reduced run of the inverter unit ..........
  • Page 9 Table of contents 9 10 Dimensions and weights Contents of this chapter ................Frames R1i…R7i ................... Frames R1i…R5i ................Weights ..................Frames R6i and R7i ................Dimension drawing, 400 mm wide cubicle ..........Frame R8i and multiples ................Dimension drawing, R8i (without +C128 or +H353), bottom cable exit ....Dimension drawing, R8i (without +C128 or +H353), top cable exit .....

  • Page 11: Introduction To The Manual

    Introduction to the manual 11 Introduction to the manual Contents of this chapter This chapter gives basic information on the manual. Applicability The manual is applicable to ACS880 multidrive inverter units that form a part of an ACS880 multidrive system. ACS880 multidrive inverter units have the basic type designation of ACS880-107.

  • Page 12: Categorization By Frame Size, Option Code And Item Designation

    12 Introduction to the manual Categorization by frame size, option code and item designation Some descriptions, instructions, technical data and dimensional drawings which concern only a certain group of units may be marked with the symbol of the frame size (such as “R2i”, “4×R8i”, etc.).

  • Page 13: Related Documents

    Introduction to the manual 13 Term Description Frame, frame size Physical size of the drive or power module FSCA Optional Modbus RTU adapter module FSE-31 Optional pulse encoder interface module for safety encoder FSO-12, FSO-21 Optional functional safety modules IGBT Insulated gate bipolar transistor Intermediate circuit DC circuit between rectifier and inverter...
  • Page 14 Lifter for air-cooled drive modules user's guide 3AXD50000332588 Manuals for I/O extension modules, fieldbus adapters, safety options etc. You can find manuals on the Internet. See www.abb.com/drives/documents. For manuals not available in the document library, contact your local ABB representative.

  • Page 15: Hardware Description

    Hardware description 15 Hardware description Contents of this chapter This chapter describes a typical drive system and the hardware of the inverter unit. The information is valid for all ACS880-107 inverter units.

  • Page 16: Overview Diagram Of The Drive System

    DC back to AC that rotates the motor. The inverter units can be used for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM).

  • Page 17: Inverter Unit Hardware

    Hardware description 17 Inverter unit hardware ￭ General An inverter unit contains the components required to control one motor. These include one or more inverter modules connected in parallel, together with the necessary auxiliary equipment such as control electronics, fusing, cabling and switchgear. ACS880-107 inverter units range from 1.5 to 5600 kW in power.

  • Page 18: Inverter Module Frame Sizes R1I To R4I

    18 Hardware description ￭ Inverter module frame sizes R1i to R4i General The motor (output) cables are connected to either detachable or non-detachable screw terminal blocks at the bottom of the cubicle. The modules have a built-in ZCU drive control unit, which contains the basic I/Os and slots for optional I/O modules.

  • Page 19: Standard Cabinet Layout

    Hardware description 19 Frame R4i (Frame R3i has a similar layout) Item Explanation Power unit DC (input) connections (under connector cover) Motor (output) connection (under connector cover). This has been wired to a separate terminal block in the lower part of the cubicle. ZCU-14 control unit mounted on top of the power unit Grounding/strain relief rail for control cables...

  • Page 20: Layout Of Cubicle With Frame R1I

    20 Hardware description Item Explanation Main DC switch fuse for all units in the cubicle (optional) or main DC fuses DC fuse disconnectors for each individual module Three frame R1i inverter modules Frame R3i inverter module Two frame R4i inverter modules Output connections Cable entries Air outlet compartment with cabinet cooling fan (not...
  • Page 21 Hardware description 21 The motor (output) connections for each module are located at the lower part of the cubicle; depending on the power of the inverter module, these are either detachable or non-detachable terminal blocks. The cubicle is equipped with cable entries for the motor cables in the floor. The picture below presents an example of a 400 mm wide cubicle with three R1i to R4i modules.

  • Page 22: Inverter Module Frame Size R5I

    Several inverter modules of frame size R5i can be installed in one cubicle. The standard cubicle widths are 300 (check availability with ABB) and 500 mm. The number of modules that can be fitted into the cubicle also depends on the optional equipment selected.

  • Page 23: Layout Of Cubicle With Frame R5I Modules In Their Own Compartments (Option +C204)

    Hardware description 23 Item Explanation Main DC switch for all units in the cubicle (optional) and main DC fuses DC fuse disconnectors for each individual module R5i inverter modules (with ZCU-12 control units) Output connections Output cable entries Control cable entry Air outlet compartment with cabinet cooling fan (not shown) Layout of cubicle with frame R5i modules in their own compartments (option +C204)
  • Page 24 24 Hardware description Item Example Main DC switch-disconnector handle for both modules in the cubicle Compartment for DC fuses DC switch-disconnectors (with fuses) for each individu- al module Inverter modules Inverter control units Output connections Cable entries Compartment doors closed...

  • Page 25: Inverter Module Frame Sizes R6I And R7I

    Hardware description 25 ￭ Inverter module frame sizes R6i and R7i The inverter cubicle is equipped with cable entries for the motor cables in the floor of the cubicle. As standard, the output busbars are extended to the lower part of the cubicle for easy access.

  • Page 26: Motor Cabling

    26 Hardware description The picture below presents an example of a cubicle with an R6i/R7i inverter module. Item Explanation Air outlet DC fuses DC switch-disconnector (behind DC fuses and mounting plate) (optional) Charging contactor (R7i only) (optional) Charging resistors (R7i only) (optional) Common mode filters Inverter module Inverter module cooling fan(s)

  • Page 27: Inverter Module Frame Size R8I And Multiples

    Hardware description 27 ￭ Inverter module frame size R8i and multiples This figure shows the layout of the R8i module. R8i module, front R8i module, back DC busbars Handle LEDs and fiber optic connectors Fan (standard speed-controlled fan shown; a direct-on-line fan is available as option +C188) Quick connector (three phases).

  • Page 28: Cooling Fans

    28 Hardware description Cooling fans The cooling fan unit at the base of the inverter module contains two DC fans. The fans are PWM-controlled according to an internal temperature measurement. The fan carriage can be easily removed for fan replacement, or to allow access to the output cable connections at the back of the cubicle.
  • Page 29 Hardware description 29 Side view Front view Without DC switch-disconnector With DC switch-disconnector and charging circuit Item Explanation Inverter modules DC bus DC fuses Common mode filters DC switch-disconnector [Q2] Charging resistors Charging switch [Q10] Charging controller AC quick connector...

  • Page 30: Motor Cabling

    30 Hardware description The drawing below shows an example of a 300 mm wide control equipment cubicle. Front view Item Explanation Terminal block for auxiliary voltage distri- bution 24 V DC power supply for control circuits Circuit breakers for control voltages Space for installation of items 2 and 3 for a second inverter unit (On the left-hand side wall) Terminal...

  • Page 31: Control Interfaces

    Hardware description 31 Control interfaces ￭ Overview of control connections of the ZCU control unit The diagram shows the control connections and interfaces of the ZCU-14 control unit. It is used with module frame sizes R1i…R7i. Frame R5i modules employ a type ZCU-12 unit which has a different layout but the same connectivity as the ZCU-14.

  • Page 32: Overview Of The Control Connections Of The Bcu Control Unit

    32 Hardware description See section The ACx-AP-x control panel. ￭ Overview of the control connections of the BCU control unit The diagram shows the control connections and interfaces of the BCU control unit. Analog and digital I/O extension modules and Control panel.

  • Page 33: Control By Pc Tools

    Hardware description 33 The control panel can be mounted on a platform on the inverter cubicle door. The maximum number of platforms on one door is four, but one control panel can be used to control several units through a panel link. For details on the control panel, see ACX-AP-x Assistant control panels User’s manual (3AUA0000085685 [English]).

  • Page 34: Type Designation Labels

    34 Hardware description Note: The charging switch must be opened before the inverter unit can be started. Type designation labels ￭ Inverter unit type designation label Each inverter unit has a type designation label attached onto the inside of the cubicle door. (Note that multiple small inverter units can be installed within one cubicle, and that an inverter unit may consist of several cubicles and inverter modules.) The type designation stated on the label contains information on the specifications and...
  • Page 35 Hardware description 35 Type designation. Frame size. Degree of protection; additional UL/CSA specifications. Ratings. The labels show ratings for inverter module (INVERTER), IGBT supply module (LINE CONVERT- ER), brake chopper module (BRAKE CHOPPER), regenerative rectifier module (REGENERATIVE RECTIFIER) and DC/DC converter module (DC/DC CONVERTER). Valid markings.

  • Page 36: Type Designation Key

    36 Hardware description Type designation key The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic drive type. The optional selections are given thereafter, separated by plus signs, eg, +E202. Codes preceded by a minus sign (eg. -J400) indicate the absence of the specified feature.
  • Page 37 Hardware description 37 Code Description C179 Plinth height 200 mm C180 Seismic design C188 Direct-on-line module cooling fans C204 Modules in their own compartments Filters E205 du/dt filtering E206 Sine output filter E208 Common mode filtering (standard with frames R6i, R7i, R8i and multiples) E210 EMC/RFI filter for 2nd environment TN (grounded) or IT (ungrounded) system, category C3 Switching and grounding...
  • Page 38 38 Hardware description Code Description H359 Common motor terminal cubicle H364 Gland plate out of 3 mm thick aluminum, blind H365 Blind 6 mm brass cable gland plates H366 Common output terminals (for inverter modules mounted in the same cubicle) H367 Control cable entry through floor of cabinet H368...
  • Page 39 Hardware description 39 Code Description L516 FEN-21 resolver interface module L517 FEN-01 TTL incremental encoder interface module L518 FEN-11 TTL absolute encoder interface module L521 FSE-31 pulse encoder interface module L525 FAIO-01 analog I/O extension module L526 FDIO-01 digital I/O extension module L536 FPTC-01 thermistor protection module L537...
  • Page 40 40 Hardware description Code Description Q957 Prevention of unexpected start-up with safety relays, by activating the Safe torque off function Q963 Emergency stop (category 0) with safety relays, by activating the Safe torque off function Q964 Emergency stop (category 1) with safety relays, by activating the Safe torque off function Q965 Safely-limited speed with FSO-21 and encoder Q966...

  • Page 41: Control Units Of The Drive

    Control units of the drive 41 Control units of the drive Contents of this chapter This chapter • describes the connections of the control unit(s) used in the drive, • contains the specifications of the inputs and outputs of the control unit(s). General The ZCU-14 control unit is used with inverter module frame sizes R1i…R4i, R6i and R7i, while the ZCU-12 is used with frame size R5i.

  • Page 42: Layout

    42 Control units of the drive ZCU-12 layout Description Analog inputs Analog outputs X202 Digital inputs X208 XDIO Digital input/outputs XD24 Digital input interlock (DIIL) and +24 V output X205 XD2D Drive-to-drive link XPOW External power input XRO1 Relay output RO1 XRO2 Relay output RO2 X203...

  • Page 43: Layout

    Control units of the drive 43 ZCU-14 layout Description XPOW External power input Analog inputs XRO1 Analog outputs XD2D Drive-to-drive link XRO2 XRO1 Relay output RO1 XRO2 Relay output RO2 XRO3 Relay output RO3 XRO3 XD24 Digital input interlock (DIIL) and +24 V output XDIO Digital input/outputs XPOW...

  • Page 44: Default I/O Diagram Of The Inverter Control Unit (Zcu-1X)

    44 Control units of the drive Default I/O diagram of the inverter control unit (ZCU-1x) Relay outputs XRO1…XRO3 Ready 250 V AC / 30 V DC Running 250 V AC / 30 V DC Faulted(-1) 250 V AC / 30 V DC Fault External power input XPOW...
  • Page 45 Control units of the drive 45 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). Current [0(4)…20 mA, R = 100 ohm] or voltage [0(2)…10 V, R >...

  • Page 46: Bcu-X2 Layout

    46 Control units of the drive BCU-x2 layout Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface, fieldbus...
  • Page 47 Control units of the drive 47 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 48: Default I/O Diagram Of The Inverter Control Unit (A41)

    48 Control units of the drive Default I/O diagram of the inverter control unit (A41) 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.

  • Page 49: Additional Information On The Connections

    Control units of the drive 49 Notes: See section The XD2D connector (page 51). See chapter The Safe torque off function (page 183). 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 50: Ai1 Or Ai2 As A Pt100, Pt1000, Ptc Or Kty84 Sensor Input

    50 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 51: The Xd2D Connector

    (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 52: 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 53: Connector Data

    Control units of the drive 53 Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 2.5 mm 24 V (±10%) DC, 2 A External power input. Two supplies can be connected to the BCU-x2 for redundancy. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3) 250 V AC / 30 V DC, 2 A...
  • Page 54 54 Control units of the drive Analog outputs AO1 and AO2 (XAO) Connector pitch 5 mm, wire size 2.5 mm 0…20 mA, R < 500 ohm load Frequency range: 0…300 Hz (ZCU-1x), 0…500 Hz (BCU-x2) Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range XD2D connector Connector pitch 5 mm, wire size 2.5 mm...

  • Page 55: Bcu-X2 Ground Isolation Diagram

    Control units of the drive 55 ￭ BCU-x2 ground isolation diagram XPOW +24VI +24VI +VREF -VREF AGND AI1+ AI1- AI2+ AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO SGND XSTO OUT...

  • Page 56: Zcu-1X Ground Isolation Diagram

    56 Control units of the drive ￭ ZCU-1x ground isolation diagram XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- channels ±30 V AI2+ AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2...

  • Page 57: Electrical Installation

    Electrical installation 57 Electrical installation Contents of this chapter This chapter describes the electrical installation of ACS880-107 inverter units. The circuit diagrams in this chapter are simplified presentations. Refer to the diagrams delivered with the drive system for details. For more information on cable selection, protections, etc., see Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324 [English]).
  • Page 58 58 Electrical installation 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 59: General Notes

    Electrical installation 59 General notes ￭ Printed circuit boards WARNING! Use a grounding wrist band when you handle printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge. ￭ Optical components WARNING! Obey these instructions. If you ignore them, damage to the equipment can occur. •...
  • Page 60 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 61: Connecting The Motor Cable - Frame Sizes R1I To R5I

    Electrical installation 61 Connecting the motor cable – Frame sizes R1i to R5i ￭ Diagram 1. Inverter unit cubicle 2. Inverter module 1) 360° grounding at cable lead-through 2) Use a separate grounding cable if the conductivity of the cable shield is less than 50% of the conductivity of the phase conductor in a cable with no symmetrically constructed grounding conductor (see the document ACS880 multidrive cabinets and modules, Electrical planning instructions [3AUA00000102324, English]).

  • Page 62: Connecting The Motor Cable - Frame Sizes R6I And R7I

    62 Electrical installation 7. Tighten the cable gland. 8. At the motor, connect the cables according to instructions from the motor manufacturer. Pay special attention to the phase order. For minimum radio-frequency interference, ground the cable shield 360 degrees at the lead-through of the motor terminal box. Connecting the motor cable –...

  • Page 63: Motor Cable Connection Procedure

    Electrical installation 63 ￭ Motor cable connection procedure WARNING! Read and follow the instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). Ignoring the instructions can cause physical injury or death, or damage to the equipment. Refer to the illustrations below.
  • Page 64 64 Electrical installation b > 1/5 · a...

  • Page 65: Connecting The Motor Cables - Frame Size R8I And Multiples Without Common Motor Terminal Cubicle Or Sine Output Filter

    Electrical installation 65 Connecting the motor cables – Frame size R8i and multiples without common motor terminal cubicle or sine output filter On units without a common motor terminal cubicle or a sine output filter, the motor cables connect to busbars located behind the inverter module(s). The location and dimensions of the busbars are visible in the dimension drawings delivered with the drive, as well as the example drawings presented in this manual in chapter Dimensions.

  • Page 66: Motor Connection Diagram (With Option +H366)

    66 Electrical installation Inverter unit cubicle(s) ￭ Motor connection diagram (with option +H366) With option +H366, the output busbars of the inverter modules within the same cubicle are connected by bridging busbars. The bridging balances the motor current between the modules, which allows more cabling options.

  • Page 67: Procedure

    Refer to the drawings below. Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. See Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).
  • Page 68 68 Electrical installation 8. Attach the module extraction/installation ramp (included) to the base of the cabinet so that the tabs on the mounting bracket enter the slots on the ramp. WARNING! Check the markings on the ramp to make sure that it is suitable for the plinth height.
  • Page 69 Electrical installation 109 Electrical installation 69...
  • Page 70 70 Electrical installation 110 Electrical installation...

  • Page 71: Removing The Fan Carriage Of An Inverter Module

    Electrical installation 111 Electrical installation 71 Removing the fan carriage of an inverter module Refer to the drawings below. WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.
  • Page 72 72 Electrical installation 5. Remove the two screws at the bottom of the fan carriage. WARNING! Before you proceed, make sure the two screws holding the top of the inverter module are in place. 6. Remove the two screws at the top of the fan carriage. (During reassembly, tighten these screws to 22 N·m [16 lbf·ft].) Note: Units with marine or seismic design have an additional transverse bracket that is attached to the module with these screws.

  • Page 73: Connecting The Motor Cables

    Electrical installation 113 Electrical installation 73 Connecting the motor cables Refer to the drawings below. WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.
  • Page 74 74 Electrical installation 3. For 360° grounding of the shield at the cable entry, remove the outer jacket of each cable where they pass through the cable entry (a). 4. Cut the cable to suitable length and strip the ends of the individual conductors. Twist the shield strands together to form a separate conductor and wrap it with tape.
  • Page 75 Electrical installation 75 360° grounding detail...

  • Page 76: Re-Installing The Fan Carriage Of An Inverter Module

    76 Electrical installation Re-installing the fan carriage of an inverter module (If the inverter module was removed completely instead of only the fan carriage, proceed to section Re-inserting the inverter modules into the cubicle (page 76)). The re-installation of the fan carriage is the removal procedure in reverse. See section Removing the fan carriage of an inverter module (page 71).
  • Page 77 Electrical installation 77 10. Reconnect the wiring and fiber optic cables to the terminals on the front of the module. 11. Repeat the procedure for the other inverter modules. 12. Reinstall the shroud near the top of the cubicle.

  • Page 78: Connecting The Motor Cables - Frame Size R8I And Multiples With Common Motor Terminal Cubicle

    78 Electrical installation Connecting the motor cables – Frame size R8i and multiples with common motor terminal cubicle ￭ Output busbars If the drive is equipped with option +H359, the motor cables connect to a common motor terminal cubicle. Similarly, if the drive is equipped with option +E206 (sine output filter), the motor cables connect to the output busbars in the sine filter cubicle.
  • Page 79 Electrical installation 79 4. Cut the cables to suitable length. Strip the cables and conductors. 5. Twist the cable screens into bundles and connect the bundles to the PE busbar in the cubicle. 6. Connect any separate ground conductors/cables to the PE busbar in the cubicle. 7.

  • Page 80: Installing Optional Modules On The Control Unit

    80 Electrical installation Installing optional modules on the control unit ￭ Installing an FSO-xx safety functions module (frame sizes R1i…R7i) In case you need to install multiple optional modules on the control unit, install the FSO-xx first. WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).

  • Page 81: Installing An Fso-Xx Safety Functions Module (Frame Sizes R8I And Multiples)

    Electrical installation 81 7. Connect the other end of the data cable to connector X110 on the FSO-xx. 8. To complete the installation, refer to the instructions in the user’s manual delivered with the FSO-xx. ￭ Installing an FSO-xx safety functions module (frame sizes R8i and multiples) WARNING! Read the safety instructions given in Safety instructions for ACS880...
  • Page 82  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, 82 Electrical installation see the FSO-xx manual.) 1.

  • Page 83: Installation Of I/O Extension, Fieldbus Adapter And Pulse Encoder Interface Modules

    Electrical installation 83 ￭ Installation of I/O extension, fieldbus adapter and pulse encoder interface modules WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Pay attention to the free space required by the cabling or terminals coming to the option modules.
  • Page 84 84 Electrical installation 5. Tighten the grounding screw to a torque of 0.8 N·m (7 lbf·in). Note: The screw tightens the connections and grounds the module. It is essential for fulfilling the EMC requirements and for proper operation of the module. WARNING! Do not use excessive force, or leave the screw too loose.

  • Page 85: Connecting The Control Cables

    Electrical installation 85 Connecting the control cables Frame R1i…R4i, R6i and R7i inverter modules use a ZCU-14 control unit, frame R5i modules use a ZCU-12 control unit, and frame R8i modules (and multiples) use a BCU control unit. The cabinet has a control cable entry that consist of grommets and two conductive grounding cushions that press against the exposed cable shields.
  • Page 86 86 Electrical installation Lead-through detail Locking screws Stripped cable Conductive surface of the shield exposed Stripped part covered with copper foil Cable shield Copper foil Shielded twisted pair Grounding wire Copper cable...

  • Page 87: Connecting A Pc

    Electrical installation 87 SHIELD* Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. A PC (with eg, the Drive composer PC tool) can be connected as follows: 1.
  • Page 88 88 Electrical installation holder; those that do not require the installation of an FDPI-02 module (available separately). For further information, see the hardware description and FDPI-02 diagnostics and panel interface user’s manual (3AUA0000113618 [English]). The maximum allowed length of the cable chain is 100 m (328 ft). 1.
  • Page 89 Electrical installation 89 With FDPI-02 modules:...

  • Page 91: Installation Checklist Of The Drive

    Installation checklist of the drive 91 Installation checklist of the drive Contents of this chapter This chapter contains a checklist of 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.
  • Page 92 92 Installation checklist of the drive Make sure that … The cooling air flows freely in and out of the drive. If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground- to-phase varistor).

  • Page 93: Start-Up

    Start-up 93 Start-up Contents of this chapter This chapter describes the hardware commissioning of the inverter unit. For information on setting up the control program, refer to the appropriate firmware manual. For information on commissioning the supply unit, refer to its hardware manual. Start-up procedure The tasks which are needed in certain cases only are marked with underlining, and option codes are given in brackets.
  • Page 94 94 Start-up Action Pre-requisites The mechanical and electrical installation of the drive has been inspected and approved. See Installation checklist of the drive (page 91). The insulation resistance of the assembly has been checked according to instructions. See Electrical installation (page 57).
  • Page 95 Start-up 95 Action Powering up the main circuit of the drive Start the supply unit according to the instructions in its hardware manual. On-load checks Start the motor to perform the ID run. Check that the cooling fans rotate freely in the right direction, and the air flows upwards. Check that the motor starts.

  • Page 97: Maintenance

    (3AUA0000102301 [English]). 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 98: Maintenance Timers And Counters

    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 99: Cabinet

    Maintenance 99 Cabinet ￭ Cleaning the interior of the cabinet WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 100: Replacing The Inlet Door Filters (Ip54)

    100 Maintenance ￭ Replacing the inlet door filters (IP54) 1. Stop the drive and do the steps in section Electrical safety precautions (page 57) before you start the work. 2. Remove the fasteners at the top of the grating. 3. Lift the grating and pull it away from the door. 4.

  • Page 101: Cooling 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.

  • Page 102: Module Cooling Fans

    102 Maintenance ￭ Module cooling fans Replacing the R1i and R2i module cooling fan WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 103: Replacing The R3I And R4I Module Cooling Fan

    Maintenance 103 Replacing the R3i and R4i module cooling fan WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 104: Replacing The R5I Module Main Cooling Fan (With Option +C204)

    104 Maintenance The main cooling fan is located at the top of the module. The replacement of the main cooling fan requires that the module is pulled outwards far enough to create room above the module. 1. Stop the drive and do the steps in section Electrical safety precautions (page 57) before you start the work.

  • Page 105: Replacing The R5I Module Auxiliary Cooling Fan

    Maintenance 105 1. Stop the inverter. 2. Switch off the DC switch-disconnector of the compartment and open the door. You can completely remove the door for easier access. 3. Remove the fuses from the DC switch-disconnector of the compartment. 4. Remove the air baffle above the module. 5.
  • Page 106 106 Maintenance 3. Push the two locking tabs gently inwards to release the fan. 4. Remove the fan. Install new fan in reverse order. Make sure that the fan blows upwards (the arrows on the fan frame and the fan holder point in the same direction).

  • Page 107: Replacing The R6I And R7I Module Cooling Fan

    Maintenance 107 Replacing the R6i and R7i module cooling fan Frame R6i modules have one fan, R7i modules have two. WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 108: Replacing R8I Module Cooling Fan (Speed-Controlled Version)

    108 Maintenance Replacing R8i module cooling fan (speed-controlled version) The module is equipped with a fan unit that contains two cooling fans. WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 109: Replacing R8I Module Cooling Fan (Direct-On-Line Version)

    Maintenance 109 Replacing R8i module cooling fan (direct-on-line version) WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
  • Page 110 110 Maintenance...

  • Page 111: Replacing The Circuit Board Compartment Fan

    Maintenance 111 Replacing the circuit board compartment fan Frame R8i modules are equipped with a fan blowing air through the circuit board compartment. The fan is accessible from the front of the module. WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]).

  • Page 112: Cabinet Cooling Fans

    112 Maintenance 8. Put the fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder. 9. Install and tighten the four nuts removed earlier. 10. Connect the fan cable. 11. Align and push the fan holder into the module. 12.

  • Page 113: Replacing The Control Cubicle Fan (Frame R8I And Multiples)

    Maintenance 113 WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 57) before you start the work.

  • Page 114: Inverter Modules

    114 Maintenance 4. Remove the fastening screws (a) and finger guard (b) of the fan. 5. Install the new fan in reverse order. Make sure that the arrow indicating the air flow direction points upwards (floor fan) or inward (door fan). Inverter modules ￭...

  • Page 115: Replacing R5I Inverter Module (Without Option +C204)

    Maintenance 115 Refit the module in reverse order. ￭ Replacing R5i inverter module (without option +C204) Replacing the R5i module main cooling fan (without option +C204) (page 103) ￭ Replacing R5i inverter module (with option +C204, modules in their own compartments) WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).

  • Page 116: Replacing R6I And R7I Inverter Modules

    (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. Note: A lifting device is available from ABB. See Converter module lifting device for drive cabinets hardware manual (3AXD50000210268 [English]).
  • Page 117 Maintenance 117 11. Pull the module outwards until the lifting eyes (e) at each side of the module are accessible. 12. Attach a hoist to the lifting eyes and pull the module out. Refit the module in reverse order.
  • Page 118 118 Maintenance...

  • Page 119: Replacing R8I Inverter Modules

    Refer to the drawings below. Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. See Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).
  • Page 120 120 Maintenance 10. Remove the two retaining screws at the top front of the module. 11. Pull the module carefully out along the ramp. While pulling on the handle with your right hand, keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back.
  • Page 121 Maintenance 121 110 Electrical installation...

  • Page 122: Re-Inserting The Inverter Modules Into The Cubicle

    Electrical installation 111 122 Maintenance Re-inserting the inverter modules into the cubicle WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 123: Activating The Reduced Run Of The Inverter Unit

    Maintenance 123 3. Push the module up the ramp and back into the cubicle. • Keep your fingers away from the edge of the module front plate to avoid pinching. • Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back.
  • Page 124 124 Maintenance Refer to the drawing below. 1. Stop the drive and do the steps in section Electrical safety precautions (page 57) before you start the work. 2. Remove the shrouding above the module bay (in front of the DC fuses). 3.

  • Page 125: Replacing Dc Fuses (Frame R8I And Multiples)

    Maintenance 125 The maximum current is now automatically limited according to the new inverter configuration. A mismatch between the number of detected modules and the value set in 95.13 will generate a fault. Returning the module 1. Install the module in reverse order. Use the following tightening torques: •...
  • Page 126 126 Maintenance 3. Loosen the nuts (b) of the blown fuse. 4. Loosen the mounting screws of the top busbar (c) so that you can adjust the gap for the fuse block. Without DC switch With DC switch (+F286) 5. Slide out the fuse block. 6.

  • Page 127: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. ￭...

  • Page 128: Replacing The Zcu-14 Control Unit Battery

    128 Maintenance 3. Remove the fastening screw and pull the memory unit out. 4. Install a memory unit in reverse order. ￭ Replacing the ZCU-14 control unit battery WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 129: Replacing The Bcu Control Unit Battery

    Maintenance 129 ￭ Replacing the BCU control unit battery Replace the real-time clock battery if the BATT OK LED is not illuminated when the control unit is powered. 1. Stop the drive and do the steps in section Electrical safety precautions (page 57) before you start the work.

  • Page 131: Technical Data

    Technical data 131 Technical data Contents of this chapter This chapter contains the technical specifications of the inverter unit, for example, the ratings, technical specifications and requirements, and provisions for fulfilling the requirements for CE and other markings. Ratings Output ratings Input Inverter Light-overload...
  • Page 132 132 Technical data Output ratings Input Inverter Light-overload ratings unit No-overload use Heavy-duty use Fame type size ACS880- 107- … 0094A-3 0100A-3 0140A-3 0170A-3 0210A-3 0250A-3 0300A-3 0350A-3 0470A-3 0640A-3 0760A-3 0900A-3 1013 1080 1250A-3 2×R8i 1406 1630 1250 1200 1480A-3 2×R8i 1665...
  • Page 133 Technical data 133 Output ratings Input Inverter Light-overload ratings unit No-overload use Heavy-duty use Fame type size ACS880- 107- … 0200A-5 0240A-5 0300A-5 0340A-5 0440A-5 0590A-5 0740A-5 0810A-5 1060 1150A-5 2×R8i 1294 1500 1150 1104 1450A-5 2×R8i 1631 1890 1450 1000 1256 1392...

  • Page 134: Definitions

    To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. • The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.

  • Page 135: Derating

    1 percentage point for every added 100 m (328 ft). For example, the derating factor for 1500 m (4921 ft) is 0.95. For altitudes above 2000 m (6562 ft), contact ABB. If surrounding air temperature is below +40 °C, the derating can be reduced by 1.5 percentage points for every 1 °C reduction in temperature.

  • Page 136: Inverter Modules Used, Dc Fuses, Dc Capacitances

    136 Technical data 4000 m 13123 ft 0.80 3500 m 11429 ft 0.85 3000 m 0.90 9842 ft 0.95 2500 m 8202 ft 1.00 2000 m 6562 ft 1500 m 4921 ft 1000 m 3300 ft +20 °C +25 °C +30 °C +35 °C +40 °C...
  • Page 137 Technical data 137 DC capacit- Inverter module(s) used Module-specific DC fuses ance Inverter unit type Type Type μF ACS880-107-0078A-3 ACS880-104-0078A-3 *Mersen 6,921 CP URQ 27x60/160 2355 ACS880-107-0094A-3 ACS880-104-0094A-3 *Mersen 6,921 CP URQ 27x60/200 2355 ACS880-107-0100A-3 ACS880-104-0100A-3 *Mersen 6,921 CP URQ 27x60/200 2355 ACS880-107-0140A-3 ACS880-104-0140A-3...
  • Page 138 138 Technical data DC capacit- Inverter module(s) used Module-specific DC fuses ance Inverter unit type Type Type μF ACS880-107-0240A-5 ACS880-104-0240A-5 Cooper Bussmann 170M4414 6750 ACS880-107-0300A-5 ACS880-104-0300A-5 Cooper Bussmann 170M4416 9000 ACS880-107-0340A-5 ACS880-104-0340A-5 Cooper Bussmann 170M4417 9000 ACS880-107-0440A-5 ACS880-104-0440A-5 Cooper Bussmann 170M6413 11250 ACS880-107-0590A-5 ACS880-104-0590A-5...

  • Page 139: Noise And Cooling Characteristics

    Technical data 139 DC capacit- Inverter module(s) used Module-specific DC fuses ance Inverter unit type Type Type μF ACS880-107-1540A-7 ACS880-104-0530A-7 Cooper Bussmann 170M6548 27000 ACS880-107-1740A-7 ACS880-104-0600A-7 Cooper Bussmann 170M6549 27000 ACS880-107-2300A-7 ACS880-104-0600A-7 Cooper Bussmann 170M6549 36000 ACS880-107-2860A-7 ACS880-104-0600A-7 Cooper Bussmann 170M6549 45000 ACS880-107-3420A-7 ACS880-104-0600A-7...
  • Page 140 140 Technical data Heat dissipation Air flow Inverter unit Noise Sine filter type Inverter Sine filter level (option Total Inverter unit Total ACS880- unit (option +E206) +E206) 107-… dB(A) /h (ft /min) /h (ft /min) /h (ft /min) 0470A-3 **72 **1300 (765) 2000 (1180) 3300 (1940)
  • Page 141 Technical data 141 Heat dissipation Air flow Inverter unit Noise Sine filter type Inverter Sine filter level (option Total Inverter unit Total ACS880- unit (option +E206) +E206) 107-… dB(A) /h (ft /min) /h (ft /min) /h (ft /min) 1150A-5 **74 **2600 (1530) 2000 (1180) 4600 (2710)

  • Page 142: Sine Output Filter Data

    Sine output filters are available as option +E206. The table below shows the types and technical data of the filters and filter cubicles used. The standard filters listed require no current derating. For availability of sine output filters for other inverter unit types, contact your local ABB representative. Sine filter(s) used...
  • Page 143 Technical data 143 Sine filter(s) used Dimensions Cooling data Nominal Inverter unit Heat current type ACS880- Width weight Air flow dissipation Type 107… kg (lbs) /h (ft /min) 0440A-5 NSIN-0485-6 340 (750) 0590A-5 NSIN-0900-6 1000 840 (1850) 0740A-5 NSIN-0900-6 1000 840 (1850 0810A-5 NSIN-1380-6...

  • Page 144: Input Power (Dc) Connection

    Note: Longer 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 145 Technical data 145 Output terminals U2, V2, W2, PE (terminal block X1) (Frames R1i to R5i) Frame Max. wire size Tightening torque Type size N·m lbf·in 6 (stranded) Detachable R1i, R2i 0.7 … 0.8 6.2 … 7.1 10 (solid) screw terminal block R3i, R5i 1.7 …...
  • Page 146 146 Technical data Output terminals (Frame R8i) – Side view Screw size: M12 or ½″. Tightening torque: 70 N·m (52 lbf·ft) Busbar material: Tin-plated copper...

  • Page 147: Typical Power Cable Sizes

    Technical data 147 Typical power cable sizes The tables below give current carrying capacity (I ) for aluminum and copper PVC/XLPE Lmax insulated cables. A correction factor K = 0.70 is used. Time const is the temperature time constant of the cable. The cable sizing is based on max.

  • Page 148: Control Connections

    148 Technical data Copper cable PVC insulation XLPE insulation Conductor temperature 70 °C Conductor temperature 90 °C Size ⌀ [mm] Time const. [s] Time const. [s] Lmax Lmax 3 × 1.5 + 1.5 3 × 2.5 + 2.5 (3 × 4 + 4) 3 ×...

  • Page 149: Efficiency

    Maximum long-term tensile load: 1 N (3.6 ozf) • Flexing: Max. 1000 cycles ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components from Avago Technologies’ Versatile Link range. Note that the optical component type is not directly related to the actual communication speed.

  • Page 150: Cooling

    Installation site altitude 0…2000 m (0…6562 ft) above sea level. For alti- tudes over 2000 m, contact ABB. Output derated above 1000 m (3281 ft). Air temperature 0 … +40 °C -40 to +70 °C -40 to +70 °C...

  • Page 151: Cabinet Finish

    IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.

  • Page 152: Tightening Torques

    152 Technical data Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. ￭ Electrical connections Size Torque Note 0.5 N·m (4.4 lbf·in) Strength class 4.6...8.8 1 N·m (9 lbf·in) Strength class 4.6...8.8 4 N·m (35 lbf·in) Strength class 8.8 9 N·m (6.6 lbf·ft)

  • Page 153: Cybersecurity Disclaimer

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

  • Page 155: Circuit Diagrams

    Circuit diagrams 155 Circuit diagrams Refer to the circuit diagrams delivered with the unit.

  • Page 157: Dimensions And Weights

    Dimensions and weights 157 Dimensions and weights Contents of this chapter This chapter contains information on the dimensions and weights of ACS880-107 inverter cubicles. Frames R1i…R7i ￭ Frames R1i…R5i Because of the modularity of the design, the width of the cubicle varies between 400…1000 mm according to the number and size of the modules.

  • Page 158: Frames R6I And R7I

    158 Dimensions and weights Cubicle width Estimated max. weight Frame size *500 **500 *Without option +C204, **with option +C204. ￭ Frames R6i and R7i Each frame R6i and R7i inverter unit is housed in a 400 mm wide cubicle such as the one pictured below.

  • Page 159: Dimension Drawing, 400 Mm Wide Cubicle

    Dimensions and weights 159 ￭ Dimension drawing, 400 mm wide cubicle R1i…R4i (400 mm) R6i, R7i...

  • Page 160: Frame R8I And Multiples

    160 Dimensions and weights Frame R8i and multiples The standard cubicle widths are 400 mm (frame R8i), 600 mm (2×R8i) and 800 mm (3×R8i). The approximate weights of the cubicles are 320, 510 and 660 kg (705, 1125 and 1455 lbs) respectively.

  • Page 161: Dimension Drawing, R8I (Without +C128 Or +H353), Bottom Cable Exit

    Dimensions and weights 161 ￭ Dimension drawing, R8i (without +C128 or +H353), bottom cable exit...

  • Page 162: Dimension Drawing, R8I (Without +C128 Or +H353), Top Cable Exit

    162 Dimensions and weights ￭ Dimension drawing, R8i (without +C128 or +H353), top cable exit...

  • Page 163: Dimension Drawing, 2×R8I (Without +C128 Or +H353), Bottom Cable Exit

    Dimensions and weights 163 ￭ Dimension drawing, 2×R8i (without +C128 or +H353), bottom cable exit...

  • Page 164: Dimension Drawing, 2×R8I (Without +C128 Or +H353), Top Cable Exit

    164 Dimensions and weights ￭ Dimension drawing, 2×R8i (without +C128 or +H353), top cable exit...

  • Page 165: Dimension Drawing, 3×R8I (Without +C128 Or +H353), Bottom Cable Exit

    Dimensions and weights 165 ￭ Dimension drawing, 3×R8i (without +C128 or +H353), bottom cable exit...

  • Page 166: Dimension Drawing, 3×R8I (Without +C128 Or +H353), Top Cable Exit

    166 Dimensions and weights ￭ Dimension drawing, 3×R8i (without +C128 or +H353), top cable exit...

  • Page 167: Dimension Drawing, Drive Control Unit (Dcu) (300 Mm)

    Dimensions and weights 167 ￭ Dimension drawing, drive control unit (DCU) (300 mm)

  • Page 168: Location And Size Of Output Terminals

    168 Dimensions and weights ￭ Location and size of output terminals Units without common motor terminal cubicle Inverter module cubicle with one R8i module, bottom cable exit...
  • Page 169 Dimensions and weights 169 Inverter module cubicle with one R8i module, top cable exit...
  • Page 170 170 Dimensions and weights Inverter module cubicle with two R8i modules, bottom cable exit...
  • Page 171 Dimensions and weights 171 Inverter module cubicle with two R8i modules, top cable exit...
  • Page 172 172 Dimensions and weights Inverter module cubicle with three R8i modules, bottom cable exit...
  • Page 173 Dimensions and weights 173 Inverter module cubicle with three R8i modules, top cable exit...
  • Page 174 174 Dimensions and weights Sine filter cubicle, 1000 mm, bottom cable exit...
  • Page 175 Dimensions and weights 175 Sine filter cubicle, 1000 mm, top cable exit...

  • Page 176: Units With Common Motor Terminal Cubicle (+H359)

    176 Dimensions and weights Units with common motor terminal cubicle (+H359) Cubicle width 300 mm, bottom cable exit...
  • Page 177 Dimensions and weights 177 Cubicle width 300 mm, top cable exit...
  • Page 178 178 Dimensions and weights Cubicle width 400 mm, bottom cable exit...
  • Page 179 Dimensions and weights 179 Cubicle width 400 mm, top cable exit...
  • Page 180 180 Dimensions and weights Cubicle width 600 mm, bottom cable exit...
  • Page 181 Dimensions and weights 181 Cubicle width 600 mm, top cable exit...

  • Page 183: The Safe Torque Off Function

    The Safe torque off function 183 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the inverter 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 184: Compliance With The European Machinery Directive

    184 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 185: Wiring

    The Safe torque off function 185 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Activation switch In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC.

  • Page 186: Dual-Channel Connection With Internal Power Supply

    186 The Safe torque off function ￭ Dual-channel connection with internal power supply Frames R1i…R7i +24 V SGND UDC+ UDC– Inverter unit Control unit Control logic To motor Activation switch * "OUT1" with frame R5i...

  • Page 187: Frame R8I And Multiples

    The Safe torque off function 187 Frame R8i and multiples XSTO +24 V SGND XSTO OUT STO IN (X52) 24VDC CH1 SGND GND CH1 24VDC CH2 SGND GND CH2 STO IN (X52) STO OUT (X51) 24VDC CH1 24VDC CH1 GND CH1 GND CH1 24VDC CH2 24VDC CH2...

  • Page 188: Single-Channel Connection Of Activation Switch

    188 The Safe torque off function ￭ 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 189: Multiple Drives

    The Safe torque off function 189 ￭ Multiple drives Internal power supply XSTO +24 V SGND XSTO SGND XSTO SGND Drive/Inverter unit Control unit Activation switch * Terminal designation may vary depending on drive/inverter unit type...

  • Page 190: External Power Supply

    190 The Safe torque off function External power supply 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive/Inverter unit Control unit Activation switch * Terminal designation may vary depending on drive/inverter unit type...

  • Page 191: Operation Principle

    The Safe torque off function 191 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the inverter control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.

  • Page 192: Start-Up Including Acceptance Test

    192 The Safe torque off function 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 193 The Safe torque off function 193 Action Test the operation of the STO function when the motor is running. • Start the inverter and make sure the motor is running. • Open the STO circuit. The motor should stop. The inverter generates an indication if one is defined for the 'running' state in parameter 31.22 (see the firmware manual).

  • Page 194: Use

    194 The Safe torque off function 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the inverter control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. 3.

  • Page 195: 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 192). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...

  • Page 196: Fault Tracing

    See the firmware manual of the inverter control program for the indications generated by the inverter, 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 197: Safety Data

    The Safe torque off function 197 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 198: Abbreviations

    198 The Safe torque off function • STO response times: • STO reaction time (shortest detectable break): 1 ms • STO response time: Frames R1i…R7i: 2 ms (typical), 5 ms (maximum) Frame R8i and multiples: 2 ms (typical), 25 ms (maximum) •...

  • Page 199: Tüv Certificate

    The Safe torque off function 199 ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.

  • Page 201: 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 202 3AUA0000102519F © Copyright 2020 ABB. All rights reserved. Specifications subject to change without notice.

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