ABB ACS880-01 Hardware Manual
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ABB ACS880-01 Hardware Manual

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ACS880-01 drives
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Summary of Contents for ABB ACS880-01

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-01 drives Hardware manual...
  • Page 3 ACS880-01 drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation – IEC 7. Electrical installation – North America 10. Start-up 3AUA0000078093 Rev P EFFECTIVE: 2020-07-31...

  • 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 Type designation key ..................Basic code ....................Option codes ....................4 Mechanical installation Contents of this chapter ..................Safety ........................Mounting orientations ..................Required free space .................... Examining the installation site ................Required tools ..................... Moving the drive ....................Unpacking and examining the delivery ...............
  • Page 7 Table of contents 7 Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ..............Additional requirements for braking applications ......Additional requirements for ABB high-output and IP23 motors ..Additional requirements for non-ABB high-output and IP23 motors ..
  • Page 8 8 Table of contents Implementing the Power-loss ride-through function ........... Using power factor compensation capacitors with the drive ....... Controlling a contactor between drive and motor ..........Implementing a bypass connection ..............Example bypass connection ................ Switching the motor power supply from drive to direct-on-line ..Switching the motor power supply from direct-on-line to drive ..
  • Page 9 Table of contents 9 Grounding system compatibility check ............... Corner-grounded and midpoint-grounded 525…690 V delta systems ..Connecting the power cables ................Connection diagram with conduits ............... Connection procedure for frames R1 to R3 ..........Connection procedure for frames R4 and R5 ..........Connection procedure for frames R6 to R9 ..........
  • Page 10 10 Table of contents 12 Maintenance Contents of this chapter ..................Maintenace intervals ................... Descriptions of symbols ................Recommended annual maintenance actions by the user ......Recommended maintenance intervals after start-up ........Heatsink ......................Fans ........................Replacing the main cooling fan of frames R1 to R3 ........Replacing the auxiliary cooling fan of IP55 frames R1 to R3 .......
  • Page 11 Calculating the short-circuit current of the installation ......... Calculation example ................. Fuses (UL) ......................Circuit breakers (IEC) ..................ABB miniature and molded case circuit breakers ........Circuit breakers (UL) ................... ABB inverse time circuit breakers ..............Dimensions, weights and free space requirements ..........
  • Page 12 12 Table of contents 14 Dimension drawings Contents of this chapter ..................Frame R1 (IP21, UL Type 1) ................Frame R1 (IP55, UL Type 12) ................Frame R2 (IP21, UL Type 1) ................Frame R2 (IP55, UL Type 12) ................Frame R3 (IP21, UL Type 1) ................
  • Page 13 Table of contents 13 Degree of protection and thermal constant of the resistor ......Dimensions and weights of external resistors ............ JBR-03 ......................SACE08RE44 ....................SACE15RE13 and SACE15RE2 ..............SAFUR80F500 and SAFUR90F575 ............SAFUR125F500 and SAFUR200F500 ............16 The Safe torque off function Contents of this chapter ..................
  • Page 14 14 Table of contents Sine filters ......................Selecting a sine filter for a drive ..............Definitions ....................Derating .................... Description, installation and technical data ........Further information...

  • Page 15: Safety Instructions

    Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 16: General Safety In Installation, Start-Up And Maintenance

    16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...

  • Page 17: Electrical Safety In Installation, Start-Up And Maintenance

    Safety instructions 17 • Before you activate the automatic fault reset or automatic restart functions of the drive control program, make sure that no dangerous situations can occur. These functions reset the drive automatically and continue operation after a fault or supply break.

  • Page 18: Additional Instructions And Notes

    18 Safety instructions • Disconnect all dangerous external voltages from the control circuits. • After you disconnect power from the drive, always wait 5 minutes to let the intermediate circuit capacitors discharge before you continue. 3. Protect any other energized parts in the work location against contact. 4.

  • Page 19: Optical Components

    Safety instructions 19 • External wiring can supply dangerous voltages to the relay outputs of the control units of the drive. • The Safe torque off function does not remove the voltage from the main and auxiliary circuits. The function is not effective against deliberate sabotage or misuse. Optical components WARNING! Obey these instructions.
  • Page 20 20 Safety instructions • Make a 360° grounding of the power and control cable shields at the cable entries to suppress electromagnetic disturbances. • In a multiple-drive installation, connect each drive separately to the protective earth (PE) busbar of the power supply. Note: •...

  • Page 21: General Safety In Operation

    Safety instructions 21 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. • If you have a cardiac pacemaker or other electronic medical device, keep away from the area near motor, drive, and the drive power cabling when the drive is in operation.

  • Page 22: Safety In Operation

    22 Safety instructions • Do not do work on the drive when a rotating permanent magnet motor is connected to it. A rotating permanent magnet motor energizes the drive including its input and output power terminals. Before installation, start-up and maintenance work on the drive: •...

  • Page 23: Introduction To The Manual

    The flowchart refers to chapters/sections in this manual and other manuals. Applicability This manual applies to ACS880-01 drive module units intended for user-defined cabinet installations. Target audience...

  • Page 24: Quick Installation, Commissioning And Operation Flowchart

    24 Introduction to the manual Quick installation, commissioning and operation flowchart Task Identify the frame of your drive: R1…R9. Type designation key (page 36) Plan the electrical installation and acquire the accessories Guidelines for planning the electrical needed (cables, fuses, etc.). installation (page 61) Check the ratings, required cooling air flow, input power Technical data (page 177)

  • Page 25: Terms And Abbreviations

    Introduction to the manual 25 Terms and abbreviations Term Description DC link DC circuit between rectifier and inverter DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage DPMP-01 Mounting platform for control panel (flush mounting) DPMP-02 Mounting platform for control panel (surface mounting) Drive Frequency converter for controlling AC motors Embedded fieldbus...

  • Page 26: Related Manuals

    Drive modules cabinet design and construction instruc- 3AUA0000107668 tions ACS880-01 drives hardware manual 3AUA0000078093 ACS880-01 quick installation guide for frames R1 to R3 3AUA0000085966 ACS880-01 quick installation guide for frames R4 and R5 3AUA0000099663 ACS880-01 quick installation guide for frames R6 to R9 3AUA0000099689 ACS880…+P940 and +P944 drive modules supplement...
  • Page 27 Common mode filter kit for ACS880-01, ACS880-11 and 3AXD50000015178 ACS880-31 drives (frame R6, option +E208) installation instructions Common mode filter kit for ACS880-01 frame R7, and for 3AXD50000015179 ACS880-11, ACS880-31, ACH580-31 and ACQ580-31 frame R8 (option +E208) installation instructions Common mode filter kit for ACS880-01 drives (frame R9,...
  • Page 28 28 Introduction to the manual ACS880-01 manuals...

  • Page 29: Operation Principle And Hardware Description

    Contents of this chapter This chapter briefly describes the operation principle and construction of the drive. Product overview The ACS880-01 is a drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors).

  • Page 30: Main Circuit

    30 Operation principle and hardware description ￭ Main circuit The main circuit of the drive is shown below. ACS880-01 T1/U T2/V T3/W R- UDC+ UDC- Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter.

  • Page 31: Layout

    Operation principle and hardware description 31 ￭ Layout IP21, UL Type 1 The components of the drive are shown below (view of frame R5). Control panel Front cover Cable entry box Four attaching points at the back of the unit Heatsink Lifting eyes...

  • Page 32: Ip55 (Option +B056)

    32 Operation principle and hardware description IP55 (option +B056) The components of the IP55 drive (option +B056) are shown below (view of frame R4). Control panel behind the control panel cover Front cover Four fastening points at the back of the drive Heatsink Lifting eyes...

  • Page 33: Ul Type 12 (Option +B056)

    Operation principle and hardware description 33 UL Type 12 (option +B056) The components of the UL Type 12 drive (option +B056) are shown below (view of frame R6). Control panel behind the control panel cover Front cover Four attaching points at the back of the unit Llifting eyes Heatsink Hood (included in frames R4…R9)

  • Page 34: Overview Of Power And Control Connections

    34 Operation principle and hardware description ￭ Overview of power and control connections This diagram shows the power connections and control interfaces of the drive. Slot 1 X208 Slot 2 Slot 3 U/T1 V/T2 W/T3 UDC+ UDC- Analog and digital I/O extension modules, feedback interface modules and fieldbus commu- nication modules can be inserted into slots 1, 2 and 3.

  • Page 35: Control Panel

    Note: The cover is not included with options +0J400+P940 and +0J400+P944. Control panel door mounting kits You can use a mounting platform to mount the control panel on the cabinet door. Mounting platforms for control panels are available as options from ABB. For more information, see Manual...

  • Page 36: Type Designation Label

    36 Operation principle and hardware description Manual Code (English) DPMP-02/03 mounting platform for control panels installation guide 3AUA0000136205 DPMP-04 and DPMP-05 mounting platform for control panels installation 3AXD50000308484 guide DPMP-06 / 07 mounting platform for control panels installation guide 3AXD50000289561 Type designation label Type designation, see section Type designation key (page...

  • Page 37: Basic Code

    Operation principle and hardware description 37 Not all selections are available for all types. For more information, refer to the ordering instructions available separately on request. ￭ Basic code Code Description ACS880 Product series Type ACS880- When no options are selected: Wall mounted drive, IP21 (UL Type 1), ACS-AP-W 01-…...
  • Page 38 38 Operation principle and hardware description Code Description C210 Marine product certification issued by Nippon Kaiji Kyokai (NK) D150 Brake choppers E200 EMC filter for 2nd environment TN (grounded) system, category C3 E201 EMC filter for second environment IT (ungrounded) system, category C3 E202 EMC filter for 1st environment TN (grounded) system, category C2 E208...
  • Page 39 Operation principle and hardware description 39 Code Description L525 FAIO-01 analog I/O extension module L526 FDIO-01 digital I/O extension module N5000 Winder control program N5050 Crane control program N5150 Centrifuge control program N5200 PCP (Progressive Cavity Pump) control program N5250 Rod pump control program N5300 Test bench control program...
  • Page 40 40 Operation principle and hardware description Code Description R704 Danish R705 Swedish R706 Finnish R707 French R708 Spanish R709 Portuguese R711 Russian R712 Chinese R713 Polish R714 Turkish Note: Option codes R700…R714 denote full set of printed manuals in the selected language.

  • Page 41: Mechanical Installation

    Mechanical installation 41 Mechanical installation Contents of this chapter This chapter tells how to check the installation site, unpack, check the delivery and install the drive mechanically. Safety WARNING! For frame sizes R4 to R9: Use the lifting eyes of the drive when you lift the drive. Do not tilt the drive.

  • Page 42: Mounting Orientations

    42 Mechanical installation Mounting orientations The drive must be installed in an upright position with the cooling section against a wall. IP21 and IP55 frames R1 to R9 can be mounted side by side. UL Type 1 frames R1 to R9 can be mounted side by side. UL Type 12 frames R1 to R3 can be mounted side by side.

  • Page 43: Required Tools

    Mechanical installation 43 There is enough free space above the drive (200 mm [7.87 in.]) and below the drive (300 mm [11.81 in.]) when measured from the drive base without the cable box) for cooling air flow, service and maintenance. There is enough free space in front of the drive for operation, service and maintenance.

  • Page 44: Package Of Frames R1 To R5

    44 Mechanical installation Package of frames R1 to R5 IP21 (UL Type 1) Drive with factory installed options. 6…9 Cushions Control cable grounding shelf. Romex connectors in IP21 frames R1 to R3 in a plastic bag inside the cable box. Straps Printed quick guides and manuals, Top cardboard cover...
  • Page 45 Mechanical installation 45 IP55 (UL Type 12) 3AXD50000003341 Printed quick guides and manuals, 7…11 Cushions and cardboard support multilingual residual voltage warning sticker Straps Cardboard tray + top cardboard cover Hood included in frames R4 and R5. The hood is required only in UL Type 12 installations.

  • Page 46: Frame R5 Cable Box (Ip21, Ul Type 1)

    46 Mechanical installation ￭ Frame R5 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.

  • Page 47: Package Of Frames R6 And R7

    Mechanical installation 47 Package of frames R6 and R7 IP21 (UL Type 1) 3axd50000012445 Drive with factory installed options Cushions Cable box. Power and control cable Straps grounding shelves in a plastic bag, as- sembly drawing. Note: The cable entry box is mounted to the IP55 drive module frame at the factory Cardboard cover...
  • Page 48 48 Mechanical installation IP55 (UL Type 12) 3axd50000012445 Drive with factory installed options Cushions Cardboard cover Straps Stopper Hood (required only in UL Type 12 in- stallation) Pallet tray Printed quick guides and manuals and multilingual residual voltage warning sticker To unpack: Cut the straps (6).

  • Page 49: Frame R6 Cable Box (Ip21, Ul Type 1)

    Mechanical installation 49 ￭ Frame R6 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.

  • Page 50: Frame R7 Cable Box (Ip21, Ul Type 1)

    50 Mechanical installation ￭ Frame R7 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.

  • Page 51: Package Of Frames R8 And R9

    Mechanical installation 51 Package of frames R8 and R9 IP21 (UL Type 1) IP21 (UL Type 1) 3AXD50000106974 Printed quick guides and manuals and Cardboard tray multilingual residual voltage warning sticker VCI bag Cardboard sleeve Mounting template Plywood support (not in R9) Straps Pallet tray Plastic bag...
  • Page 52 52 Mechanical installation IP21 (UL Type 1) IP55 (UL Type 12) IP55 (UL Type 12) 3AXD50000106974 Printed quick guides and manuals and Cardboard sleeve multilingual residual voltage warning sticker VCI bag Not included Bubble wrap Plywood support (not in R9) Mounting template Pallet tray Straps...

  • Page 53: Frame R8 Cable Box (Ip21, Ul Type 1)

    Mechanical installation 53 ￭ Frame R8 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. There is also an assembly drawing which shows how to install the cable entry box to the drive module frame. 3aua0000112174...

  • Page 54: Frame R9 Cable Box (Ip21, Ul Type 1)

    ￭ Vibration dampers (option +C131) Marine type approval (option +C132) requires the installation of vibration dampers for frames R4 to R9 in wall installations. See Vibration dampers for ACS880-01 drives (frames R4 and R5, option +C131) installation guide (3AXD50000010497 [English]) or...

  • Page 55: Flange Mounting (Option +C135)

    Mechanical installation 55 Vibration dampers for ACS880-01 drives (frames R6 to R9, option +C131) installation guide (3AXD50000010497 [English]). The guide is included in the vibration damper package. ￭ Flange mounting (option +C135) See: Name Code (English) ACS880-01…+C135 drives with flange mounting kit supplement 3AXD50000349814 ACS880-01…+C135 frames R1 to R3 flange mounting kit quick installation...

  • Page 56: Frames R1 To R4 (Ip21, Ul Type 1)

    56 Mechanical installation ￭ Frames R1 to R4 (IP21, UL Type 1) 1. See the dimensions in chapter Dimension drawings. Mark the locations for the four mounting holes. 2. Drill the mounting holes. 3. Insert anchors or plugs into the holes and start the screws or bolts into the anchors or plugs.

  • Page 57: Frames R5 To R9 (Ip21, Ul Type 1)

    Mechanical installation 57 ￭ Frames R5 to R9 (IP21, UL Type 1) 1. See the dimensions in chapter Dimension drawings. Mark the locations for the four or six mounting holes. Note: The lowest holes/mounting screws or bolts are not necessarily needed. If you use also them, you can replace the drive module without removing the cable entry box from the wall.
  • Page 58 58 Mechanical installation...

  • Page 59: Frames R1 To R9 (Ip55, Ul Type 12)

    Mechanical installation 59 ￭ Frames R1 to R9 (IP55, UL Type 12) Note: Do not open or remove the cable box for easier installation. The gaskets do not fulfill the degree of protection if the box is opened. 1. See the dimensions in chapter Dimension drawings.
  • Page 60 60 Mechanical installation...

  • Page 61: Guidelines For Planning The Electrical Installation

    ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 62: European Union

    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: Protecting The Motor Insulation And Bearings

    Guidelines for planning the electrical installation 63 Note: • Consult the motor manufacturer before using a motor whose nominal voltage differs from the AC line voltage connected to the drive input. • The voltage peaks at the motor terminals are relative to the supply voltage of the drive, not the drive output voltage.
  • Page 64 64 Guidelines for planning the electrical installation This table shows the requirements when an ABB motor is in use. Motor type Nominal AC sup- Requirement for ply voltage Motor insu- ABB du/dt and common mode filters, in- lation sys- sulated N-end motor bearings P N <...
  • Page 65 Guidelines for planning the electrical installation 65 This table shows the requirements when a non-ABB motor is in use. Motor type Nominal AC sup- Requirement for ply voltage Motor insu- ABB du/dt and common mode filters, in- lation sys- sulated N-end motor bearings P N <...

  • Page 66: Availability Of Du/Dt Filter And Common Mode Filter By Drive Type

    If you will use an explosion-safe (EX) motor, follow the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ Use the selection criteria given for non-ABB motors.

  • Page 67: Additional Requirements For Non-Abb High-Output And Ip23 Motors

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

  • Page 68: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    68 Guidelines for planning the electrical installation Nominal AC supply Requirement for voltage Motor insulation sys- ABB du/dt and common mode filters, insu- lated N-end motor bearings P N < 100 kW or frame 100 kW < P N < 350 kW size < IEC 315 IEC 315 <...

  • Page 69: Additional Note For Sine Filters

    Guidelines for planning the electrical installation 69 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 LL /U N Relative peak line-to-line voltage (du/dt)/U N Relative du/dt value...

  • Page 70: Typical Power Cable Sizes

    70 Guidelines for planning the electrical installation Symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation, bearing currents and wear. Metal conduit reduces electromagnetic emission of the whole drive system. The protective conductor must always have an adequate conductivity.

  • Page 71: Power Cable Types

    Guidelines for planning the electrical installation 71 ￭ Power cable types Preferred power cable types This section presents the preferred cable types. Make sure that the selected cable type also complies with local/state/country electrical codes. Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or ar- mored) cable with three phase...

  • Page 72: Alternate Power Cable Types

    72 Guidelines for planning the electrical installation Alternate power cable types Cable type Use as input power cabling Use as motor cabling Yes with phase conductor Yes with phase conductor smaller than 10 mm 2 (8 AWG) smaller than 10 mm 2 (8 AWG) Cu, or motors up to 30 kW (40 hp).

  • Page 73: 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 recommends the use of metallic conduit.

  • Page 74: Metal Conduit

    74 Guidelines for planning the electrical installation Wiring method Notes Free air Prefer symmetrical shielded VFD cable. Enclosures, air handlers, etc. Allowed internally in enclosures when in accord- ance with UL. 1) Metallic conduit may be used as an additional ground path, provided this path is a solid path capable of handling ground currents.

  • Page 75: 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 length of the cable is 100 m (328 ft).

  • Page 76: Routing The Cables

    76 Guidelines for planning the electrical installation Routing the cables ￭ General guidelines – IEC • Route the motor cable away from other cables. Motor cables of several drives can be run in parallel installed next to each other. • Install the motor cable, input power cable and control cables on separate trays.

  • Page 77: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable

    Guidelines for planning the electrical installation 77 The following figure illustrates the cable routing guidelines with an example drive. 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 78: Separate Control Cable Ducts

    78 Guidelines for planning the electrical installation ￭ Separate control cable ducts Put 24 V DC and 230 V AC (120 V AC) control cables in separate ducts, unless the 24 V DC cable is insulated for 230 V AC (120 V AC) or insulated with an insulation sleeving for 230 V AC (120 V AC).

  • Page 79: Protecting The Motor And Motor Cable In Short-Circuits

    Guidelines for planning the electrical installation 79 ￭ 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. No additional protection devices are needed.

  • Page 80: Protecting The Drive Against Ground Faults

    These capacitors and long motor cables increase the ground leakage current and may cause nuisance faults in residual current devices. Connecting drives to a common DC system See ACS880-01 drives and ACS880-04 drive modules common DC systems application guide (3AUA0000127818 [English]).

  • Page 81: Implementing An Atex-Certified Motor Thermal Protection

    Guidelines for planning the electrical installation 81 See the appropriate manual for more information. Name Code FSO-12 safety functions module user's manual 3AXD50000015612 FSO-21 safety functions module user's manual 3AXD50000015614 Implementing an ATEX-certified motor thermal protection With option +Q971, the drive provides ATEX-certified safe motor disconnection without contactor using the drive Safe torque off function.

  • Page 82: Controlling A Contactor Between Drive And Motor

    82 Guidelines for planning the electrical installation WARNING! Do not connect power factor compensation capacitors or harmonic filters to the motor cables (between the drive and the motor). They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves. If there are power factor compensation capacitors in parallel with the input of the drive: 1.

  • Page 83: Example Bypass Connection

    Guidelines for planning the electrical installation 83 with interlocking that the contactors cannot be closed simultaneously. The installation must be clearly marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”. WARNING! Never connect the drive output to the electrical power network. The connection may damage the drive.
  • Page 84 84 Guidelines for planning the electrical installation Drive main switch S1 1 Drive main contactor on/off control Bypass circuit breaker S 4 0 Motor power supply selection (drive or dir- ect-on-line) Drive main contactor S 4 1 Start when motor is connected direct-on- line Bypass contactor S 4 2...

  • Page 85: Switching The Motor Power Supply From Drive To Direct-On-Line

    Guidelines for planning the electrical installation 85 Switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in local control mode) or with the external stop signal (drive in remote control mode). 2.

  • Page 86: Implementing A Motor Temperature Sensor Connection

    86 Guidelines for planning the electrical installation 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode Implementing a motor temperature sensor connection WARNING! IEC 60664 and IEC 61800-5-1 require double or reinforced insulation between live parts and accessible parts when: •...

  • Page 87: Connecting Motor Temperature Sensor To The Drive Via An Option Module

    Guidelines for planning the electrical installation 87 and the drive control unit. See section Connection of motor temperature sensor to the drive via an option module (page 100). 4. You can connect the sensor to a digital input of the drive via a customer’s external relay.

  • Page 88: Connection Of Motor Temperature Sensor To The Drive Via A Relay

    88 Guidelines for planning the electrical installation ￭ Connection of motor temperature sensor to the drive via a relay PTC (IEC 60800-5-1) Class A. This table shows the insulation requirement for a customer’s external relay, and the insulation requirement for the sensor to fulfill decisive voltage class A (double insulation).

  • Page 89: Electrical Installation - Iec

    Electrical installation – IEC 89 Electrical installation – IEC Contents of this chapter This chapter gives instructions on wiring 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 90: 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 91: Measuring The Insulation Of The Brake Resistor Circuit

    Electrical installation – IEC 91 U1-PE, V1-PE, W1-PE 1000 V DC, > 100 Mohm ￭ Measuring the insulation of the brake resistor circuit 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 92: Corner-Grounded And Midpoint-Grounded 525

    92 Electrical installation – IEC WARNING! Do not install the drive with EMC filter options +E200 or +E202 connected to a system that the filter is not suitable for. This can cause danger, or damage the drive. WARNING! Do not install the drive with the ground-to-phase varistor connected to a system that the varistor is not suitable for.
  • Page 93 Electrical installation – IEC 93 Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity of the shield does not meet the requirements for the PE conductor. See section Selecting the power cables (page 69).

  • Page 94: Connection Procedure For Frames R1 To R3

    94 Electrical installation – IEC ￭ Connection procedure for frames R1 to R3 1. Undo the mounting screws at the sides of the front cover. 2. Remove the cover by sliding it forward. 3. Attach the residual voltage warning sticker in the local language to the control panel mounting platform.
  • Page 95 Electrical installation – IEC 95 R1…R3 IP55 IP21...
  • Page 96 96 Electrical installation – IEC R1…R3 L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/UDC+, UDC (N·m) (N·m)

  • Page 97: Connection Procedure For Frames R4 And R5

    Electrical installation – IEC 97 ￭ Connection procedure for frames R4 and R5 1. Remove the front cover. IP21 drives: Release the retaining clip with a screwdriver (a) and lift the cover from the bottom outwards (b). 2. For IP21 drives: Remove the cable entry box cover by undoing the mounting screw. 3.
  • Page 98 98 Electrical installation – IEC Note: For cable lug installation (frame R5): Detach the connector and install a cable lug to the terminal post as follows: • Remove the combi screw that attaches the connector to its terminal post and pull the connector off.
  • Page 99 Electrical installation – IEC 99 R4, R5 IP55 IP21...
  • Page 100 100 Electrical installation – IEC R4, R5...
  • Page 101 Electrical installation – IEC 101 R4, R5 L1, L2, L3, T1/U, R-, R+/UDC+, T2/V, T3/W UDC- (N·m) (N·m) (N·m)

  • Page 102: Connection Procedure For Frames R6 To R9

    102 Electrical installation – IEC ￭ Connection procedure for frames R6 to R9 Note: For frames R6 to R9 with option +H358, see also ACS880-01, ACS580-01, ACH580-01, ACQ580-01 UK gland plate (+H358) installation guide (3AXD50000034735 [English]). 1. Remove the front cover: For IP21 drives: Release the retaining clip with a screwdriver (a) and pull the cover by the bottom outwards (b).
  • Page 103 Electrical installation – IEC 103 Note: For frames R8 and R9: • If you put only one conductor to the connector, ABB recommends that you put it under the upper pressure plate. • ABB does not recommend that you detach the connectors. If you do, detach and reinstall the connector as follows.
  • Page 104 104 Electrical installation – IEC Note: Cable lug installation (frames R6 to R9): Detach the connector and install a cable lug to the terminal post / busbar as follows: • L1, L2, L3: Undo the nut that attaches the connector to th terminal post, and pull the connector off.
  • Page 105 Electrical installation – IEC 105 R6 … R9 IP55 IP21...
  • Page 106 106 Electrical installation – IEC R6 … R9 Frame L1, L2, L3, T1/U, R-, R+/UDC+, T2/V, T3/W UDC- T (Wire screw) T (Wire screw) M… N·m M… N·m N·m 40 (30*) * for 525…690 V drives...
  • Page 107 Electrical installation – IEC 107 R6 … R9 R8, R9...

  • Page 108: Connecting The Control Cables

    108 Electrical installation – IEC Connecting the control cables See section Control units of the drive (page 141) for the default I/O connections of the Factory macro of ACS880 primary control program. For other macros and control programs, see the firmware manual. ￭...
  • Page 109 8. For connecting the fieldbus cables, see appropriate quick installation guide: Name Code (Multilin- gual) ACS880-01 quick installation guide for frames R1 to R3 3AUA0000085966 ACS880-01 quick installation guide for frames R4 and R5 3AUA0000099663 ACS880-01 quick installation guide for frames R6 to R9 3AUA0000099689 9.

  • Page 110: Connecting A Pc

    110 Electrical installation – IEC 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 111 Electrical installation – IEC 111 • Use parameter 49.06* to validate any changes. *The parameter group is 149 with supply (line-side), brake or DC/DC converter units. Repeat the above for each drive. 2. With the panel connected to one unit, link the units using Ethernet cables. 3.
  • Page 112 112 Electrical installation – IEC With FDPI-02 modules:...
  • Page 113 Electrical installation – IEC 113 ACS880-01 IP55 (UL Type 12): 20x20...

  • Page 114: Installing Option Modules

    114 Electrical installation – IEC Installing option modules Note: In frames R1 and R2, 90° connector cannot be used in Slot 1. In other frames, there is 50…55 mm free space for the connector and its cable available on Slots 1, 2 and 3.

  • Page 115: Installing Fso-Xx Safety Functions Modules

    Electrical installation – IEC 115 Note: The location of the lock depends on the module type. 3. Install the module to a free option module slot on the control unit. 4. Push in the lock. 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.

  • Page 116: Installation Procedure

    116 Electrical installation – IEC Installation procedure WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Repeat the steps described in Electrical safety precautions (page 17). 2.

  • Page 117: Electrical Installation - North America

    Electrical installation – North America 117 Electrical installation – North America Contents of this chapter This chapter gives instructions on wiring 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 118: Grounding System Compatibility Check

    118 Electrical installation – North America Grounding system compatibility check The standard drive can be installed to a symmetrically grounded TN-S system. If you install the drive to another system, you may need to disconnect the EMC filter and ground-to-phase varistor. See ACS880 frames R1 to R11 EMC filter and ground-to-phase varistor disconnecting instructions (3AUA0000125152 [English]).
  • Page 119 3 ~ M Electrical installation – North America 119 T1/U T2/V T3/W 3 ~ M Drive Drive For alternatives, see section Selecting the supply disconnecting device on page For alternatives, see section Selecting the main supply disconnecting device (page 61). Use a separate grounding PE conductor inside the conduit or a grounding cable, if the conductivity of the conduit does not meet the requirements for the PE conductor (see lecting the power cables (page...

  • Page 120: Connection Procedure For Frames R1 To R3

    120 Electrical installation – North America ￭ Connection procedure for frames R1 to R3 1. Undo the mounting screws at the sides of the front cover. 2. Remove the cover by sliding it forward. 3. Attach the residual voltage warning sticker in the local language to the control panel mounting platform.
  • Page 121 Electrical installation – North America 121 IP55 (UL Type 12) IP21 (UL Type 1) M4x16 Torx T20 2 N·m M4×16 Torx T20 2 N·m...
  • Page 122 122 Electrical installation – North America L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ UDC+, UDC (lbf·ft) (lbf·ft) 6 AWG...

  • Page 123: Connection Procedure For Frames R4 And R5

    Electrical installation – North America 123 M4×8 Torx T20 18 lbf·in ￭ Connection procedure for frames R4 and R5 In this connection procedure, the cables are connected to the power cable connectors. For cable lug installation of frame R5, see also chapter Electrical installation –...
  • Page 124 124 Electrical installation – North America...
  • Page 125 Electrical installation – North America 125 R4: M4×8 Torx T20 (2 pcs), M4×10 Torx T20 (1 pcs) 2 N·m R5: M4×8 Torx T20 2 N·m L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/UDC+, UDC- (lbf·ft) (lbf·ft)
  • Page 126 126 Electrical installation – North America...

  • Page 127: Connection Procedure For Frames R6 To R9

    Electrical installation – North America 127 ￭ Connection procedure for frames R6 to R9 In this connection procedure, the cables are connected to the power cable connectors. For cable lug installation, see also chapter Electrical installation – IEC (page 89) section UL listed cable lugs and tools (page 227).
  • Page 128 128 Electrical installation – North America 4 R6,R7,R9: M5×12 Torx T20 R8: M5×20 Torx T20 2 N·m (17 lbf·in)
  • Page 129 Electrical installation – North America 129...
  • Page 130 130 Electrical installation – North America...

  • Page 131: Connecting The Control Cables

    Electrical installation – North America 131 L1, L2, L3, R-, R+/ T1/U, T2/V, UDC+, T3/W UDC- lbf·ft lbf·ft lbf·ft 22.1 14.8 R7 29.5 (22.1 *) 14.8 29.5 29.5 51.6 51.6 525…690 V Connecting the control cables See section Control units of the drive (page 141) for the default I/O connections of the Factory macro of ACS880 primary control program.
  • Page 132 3.3 nF / 630 V. 5. Connect the conductors to the appropriate terminals of the control board. 6. Wire the optional modules if included in the delivery. For connecting the fieldbus cables, see ACS880-01 quick installation guide for frames R1 to R3 (3AUA0000099689 [English]).

  • Page 133: Connection Procedure For Frames R4 To R5

    3.3 nF / 630 V. 4. Connect the conductors to the appropriate terminals of the control board. 5. Wire the optional modules if included in the delivery. For connecting the fieldbus cables, see ACS880-01 quick installation guide for frames R4 and R5 (3AUA0000085966 [English]).

  • Page 134: Connection Procedure For Frames R6 To R9

    3.3 nF / 630 V. 5. Connect the conductors to the appropriate terminals of the control board. 6. Wire the optional modules if included in the delivery. For connecting the fieldbus cables, see ACS880-01 quick installation guide for frames R6 to R9 (3AUA0000099689 [English]).
  • Page 135 Electrical installation – North America 135 R6, R7: M4×20 Torx T20 R8, R9: M4×20 Torx T20 17 lbf·in M4×8 Torx T20 R9: M4×12 Torx T20 17 lbf·in...
  • Page 136 136 Electrical installation – North America 5 lbf·in 13 lbf·in M4×20 Torx T20 13 lbf·in M4×20 Torx T20...

  • Page 137: Connecting A Pc

    Electrical installation – North America 137 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 138 138 Electrical installation – North America • Use parameter 49.06* to validate any changes. *The parameter group is 149 with supply (line-side), brake or DC/DC converter units. Repeat the above for each drive. 2. With the panel connected to one unit, link the units using Ethernet cables. 3.
  • Page 139 Electrical installation – North America 139 With FDPI-02 modules:...

  • Page 140: Installing Option Modules

    140 Electrical installation – North America ACS880-01 IP55 (UL Type 12): Installing option modules See section Installing option modules (page 114).

  • Page 141: Control Units Of The Drive

    Control units of the drive 141 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).

  • Page 142: Zcu-12 Layout

    142 Control units of the drive ZCU-12 layout Description Analog inputs X202 Analog outputs X208 X210 Digital inputs XDIO Digital input/outputs X205 XD24 Digital input interlock (DIIL) and +24 V output XD2D Drive-to-drive link X203 XPOW External power input XRO1 Relay output RO1 XRO2 Relay output RO2...

  • Page 143: Default I/O Diagram Of The Drive Control Unit (Zcu-1X)

    Control units of the drive 143 Default I/O diagram of the drive 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 144 144 Control units of the drive 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 in = 100 ohm] or voltage [0(2)…10 V, R in > 200 kohm] input selected by switch AI2.

  • Page 145: Additional Information On The Connections

    Control units of the drive 145 Additional information on the connections ￭ External power supply for the control unit (XPOW) The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW. Using an external supply is recommended if •...

  • Page 146: Diil Input

    146 Control units of the drive 3.3 nF / 630 V. The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points. AI1+ AI1- AGND One, two or three Pt100, Pt1000 or PTC sensors;...

  • Page 147: Safe Torque Off (Xsto)

    Control units of the drive 147 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. The following diagram shows the wiring between control units.

  • Page 148: Connector Data

    148 Control units of the drive Connector data Connector pitch 5 mm, wire size 2.5 mm 2 Power supply (XPOW) 24 V (±10%) DC, 2 A External power input. Connector pitch 5 mm, wire size 2.5 mm 2 Relay outputs RO1…RO3 (XRO1…XRO3) 250 V AC / 30 V DC, 2 A Protected by varistors...
  • Page 149 Control units of the drive 149 Connector pitch 5 mm, wire size 2.5 mm 2 Analog inputs AI1 and AI2 (XAI:4 … XAI:7). Current input: –20…20 mA, R in = 100 ohm Current/voltage input mode selec- Voltage input: –10…10 V, R in > 200 kohm tion by jumpers Differential inputs, common mode range ±30 V Sampling interval per channel: 0.25 ms...

  • Page 150: Zcu-1X Ground Isolation Diagram

    150 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 151: Installation Checklist

    Installation checklist 151 Installation checklist 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. WARNING! Obey the safety instructions of the drive.
  • Page 152 152 Installation checklist Make sure that … The insulation resistance of the input power cable, motor cable and motor is measured according to local regulations and the manuals of the drive. The drive is attached securely on an even, vertical and non-flammable wall. The cooling air flows freely in and out of the drive.
  • Page 153 Installation checklist 153 Make sure that … The area in front of the drive is clean: the drive cooling fan cannot draw any dust or dirt inside. Drive covers and cover of the motor connection box are in place. The motor and the driven equipment are ready for power-up.

  • Page 155: Start-Up

    For drives with resistor braking (option +D150): see also section Start-up in chapter Resistor braking. • For drives with ABB sine filter, check that parameter 95.15 Special HW settings is set to ABB sine filter. For other sine filters, see Sine filter hardware manual (3AXD50000016814 [English]). •...

  • Page 157: Fault Tracing

    Fault tracing 157 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs Where Color When the LED is lit Control panel mounting POWER Green Control unit is powered platform and +15 V is supplied to the control panel.

  • Page 159: Maintenance

    (www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance.

  • Page 160: Descriptions Of Symbols

    Performance of on/off-site work (commissioning, tests, measurements or other work) Replacement ￭ Recommended annual maintenance actions by the user ABB recommends these annual inspections to ensure the highest reliability and optimum performance. Action Target Quality of supply voltage Spare parts...

  • Page 161: Fans

    Reset the running time signal after a fan replacement. Also, reset the maintenance counter, if used. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

  • Page 162: Replacing The Main Cooling Fan Of Frames R1 To R3

    162 Maintenance ￭ Replacing the main cooling fan of frames R1 to R3 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Release the retaining clip by pushing with a flat screwdriver and turning to the right. 3.

  • Page 163: Replacing The Auxiliary Cooling Fan Of Ip55 Frames R1 To R3

    Maintenance 163 ￭ Replacing the auxiliary cooling fan of IP55 frames R1 to R3 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Remove the front cover by undoing the mounting screws at the sides. 3.
  • Page 164 164 Maintenance...

  • Page 165: Replacing The Main Cooling Fan Of Frames R4 And R5

    Maintenance 165 ￭ Replacing the main cooling fan of frames R4 and R5 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Lift the fan mounting plate up from the front edge. 3.

  • Page 166: Replacing The Auxiliary Cooling Fan Of Frames R4 And R5

    166 Maintenance ￭ Replacing the auxiliary cooling fan of frames R4 and R5 This fan is included in R5 types ACS880-01-xxxx-7 and with option +B056+C135. 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work.
  • Page 167 Maintenance 167...

  • Page 168: Replacing The Main Cooling Fan Of Frames R6 To R8

    168 Maintenance ￭ Replacing the main cooling fan of frames R6 to R8 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Undo the mounting screws of the fan mounting plate (view from bottom below). 3.

  • Page 169: Replacing The Auxiliary Cooling Fan Of Frames R6 To R9 (Ip21, Ul Type 1)

    Maintenance 169 ￭ Replacing the auxiliary cooling fan of frames R6 to R9 (IP21, UL Type 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Remove the lower front cover. 3.

  • Page 170: Replacing The Auxiliary Cooling Fan Of Frames R8 And R9 (Ip55, Ul Type 12)

    170 Maintenance ￭ Replacing the auxiliary cooling fan of frames R8 and R9 (IP55, UL Type 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Remove the front cover. 3.
  • Page 171 Maintenance 171...

  • Page 172: Replacing The Main Cooling Fans Of Frame R9

    172 Maintenance ￭ Replacing the main cooling fans of frame R9 1. Stop the drive and do the steps in section Electrical safety precautions (page 17) before you start the work. 2. Undo the two mounting screws of the fan mounting plate (view from drive bottom below).
  • Page 173 Maintenance 173 4. Disconnect the power and control cables. 5. Undo the screw(s) that fasten the drive module to the cable entry box. 6. Undo the two screws or bolts that attach the drive module to the wall from top. 7.

  • Page 174: 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 175: Replacing The Zcu-12 Control Unit Battery

    Replacing the ZCU-12 control unit battery The control unit battery is of type CR2032. For instructions on how to replace the control unit battery, contact an authorized ABB service center. Replacing safety functions modules (FSO-12, option +Q973 and FSO-21, option +Q972) Do not repair safety functions modules.

  • Page 177: Technical Data

    Ratings The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the tables. ABB recommends the DriveSize dimensioning tool for selecting the drive, motor and gear combination. IEC RATINGS...
  • Page 178 178 Technical data IEC RATINGS Output ratings Input Nominal use Light-duty use Heavy-duty rating ACS880- Frame 01-… size I max I Ld P Ld I Hd P Hd 04A6-2 0.75 0.75 0.55 06A6-2 0.75 07A5-2 11.2 10A6-2 10.6 12.8 10.6 10.1 16A8-2 16.8...
  • Page 179 Technical data 179 IEC RATINGS Output ratings Input Nominal use Light-duty use Heavy-duty rating ACS880- Frame 01-… size I max I Ld P Ld I Hd P Hd 169A-3 206A-3 246A-3 293A-3 246* 363A-3 430A-3 363** U n = 400 V 02A1-5 0.75 0.55...
  • Page 180 180 Technical data IEC RATINGS Output ratings Input Nominal use Light-duty use Heavy-duty rating ACS880- Frame 01-… size I max I Ld P Ld I Hd P Hd 04A8-5 05A2-5 07A6-5 12.2 11A0-5 11.0 16.0 11.0 10.4 014A-5 021A-5 027A-5 034A-5 18.5 18.5...
  • Page 181 Technical data 181 IEC RATINGS Output ratings Input Nominal use Light-duty use Heavy-duty rating ACS880- Frame 01-… size I max I Ld P Ld I Hd P Hd 142A-7 174A-7 210A-7 271A-7 UL (NEC) RATINGS Output ratings Input Max. App. Light-duty use Heavy-duty use rating...
  • Page 182 182 Technical data UL (NEC) RATINGS Output ratings Input Max. App. Light-duty use Heavy-duty use rating cur- power ACS880- Frame rent 01-… size I max I Ld P Ld I Hd P Hd 05A2-5 07A6-5 12.2 11A0-5 16.0 014A-5 021A-5 027A-5 034A-5 18.5...

  • Page 183: Definitions

    Note 4 – ACS880-01-174A-7 amp rating: The drive can deliver 192 A continuously with no overload. Note 5 – ACS880-01-271A-7 power rating: The power rating is as per NEC Table 42.1. However, the drive can be used for a typical 4-pole motor rated to 300 hp meeting NEMA MG 1 Table 12- 11 minimum efficiency standard (EPAct efficiency electrical motors) if motor full load current is not more than 271 A.

  • Page 184: Derating

    184 Technical data Derating ￭ Surrounding air temperature derating IP21 (UL Type 1) drives and IP55 (UL Type 12) frames R1…R7 In the temperature range +40…55 °C (+104…131 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). To calculate the output current, multiply the current in the ratings table by the derating factor (k): 1.00...
  • Page 185 Technical data 185 ACS880- Derated output current (I 2 ) 01-… 35 °C 40 °C 45 °C 50 °C 55 °C Frame (95 °F) (104 °F) (113 °F) (122 °F) (131 °F) 142A-7 174A-7 210A-7 271A-7 ACS880- Derated output current (I Ld ) 01-…...

  • Page 186: Altitude Derating

    186 Technical data ￭ Altitude derating Altitude derating At altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for every 100 m (328 ft). If ambient temperature is below +40 °C (+104 °F), the derating can be reduced by 1.5% for every 1 °C reduction in temperature.

  • Page 187: Deratings For Special Settings In The Drive Control Program

    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 in chapter Filters is used and ABB Sine filter in parameter 95.15 Special HW settings is enabled •...
  • Page 188 188 Technical data ACS880- Output ratings 01-… EX motor (ABB Ex motors) ABB Sine filter Nominal use Light- Heavy- Nominal use Light- Heavy- duty duty use duty duty use I Ld I Hd I Ld I Hd 03A3-3 04A0-3 05A6-3...
  • Page 189 Technical data 189 ACS880- Output ratings 01-… EX motor (ABB Ex motors) ABB Sine filter Nominal use Light- Heavy- Nominal use Light- Heavy- duty duty use duty duty use I Ld I Hd I Ld I Hd 040A-5 18.5 31.0...

  • Page 190: Definitions

    ** Continuous rms output current allowing 25% overload for 1 minute every 5 minutes. P Hd Typical motor power in heavy-duty use Note 1: The ratings apply at an ambient temperature of 40 °C (104 °F). ACS880-01-… Output ratings with selection Low noise optimization of parameter 97.09 Switching freq mode Nominal use...
  • Page 191 Technical data 191 ACS880-01-… Output ratings with selection Low noise optimization of parameter 97.09 Switching freq mode Nominal use Light-duty use Heavy-duty use I Ld I Hd 017A-3 14.3 11.3 025A-3 20.9 15.0 032A-3 038A-3 045A-3 061A-3 072A-3 087A-3 105A-3...

  • Page 192: Definitions

    192 Technical data ACS880-01-… Output ratings with selection Low noise optimization of parameter 97.09 Switching freq mode Nominal use Light-duty use Heavy-duty use I Ld I Hd 180A-5 240A-5 260A-5 191* 302A-5 361A-5 414A-5 258** U n = 690 V...

  • Page 193: High Speed Mode

    95.15 Special HW settings is enabled: With output frequencies smaller than this recommended maximum output frequency, the current derating is less than the values given in the table. Contact ABB for operation above the recommended maximum output frequency or for the output current derating with output frequencies above 120 Hz and below the maximum output frequency.
  • Page 194 194 Technical data ACS880-01-… Output ratings with selection High speed mode of parameter 95.15 Special HW settings Maximum output frequency f max Nominal use Light-duty use Heavy-duty use I Ld I Hd 09A4-3 12A6-3 11.3 10.7 017A-3 14.3 11.3 025A-3 20.9...

  • Page 195: Definitions

    Technical data 195 ACS880-01-… Output ratings with selection High speed mode of parameter 95.15 Special HW settings Maximum output frequency f max Nominal use Light-duty use Heavy-duty use I Ld I Hd 096A-5 124A-5 156A-5 180A-5 240A-5 260A-5 168* 302A-5...

  • Page 196: Fuses (Iec)

    ￭ aR fuses DIN 43653 stud-mount (frames R1 to R9) ABB recommends stud-mount fuses for better cooling but blade style fuses can be used as well. Ultrarapid (aR) fuses stud-mount (one fuse per phase) ACS880-01-…...
  • Page 197 Technical data 197 Ultrarapid (aR) fuses stud-mount (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current A 2 s rent 1) Bussmann Type type 43653 061A-2 8500 170M1318 075A-2 7500 170M3013 087A-2 8500 170M3014 115A-2 15000 170M3015...
  • Page 198 198 Technical data Ultrarapid (aR) fuses stud-mount (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current A 2 s rent 1) Bussmann Type type 43653 169A-3 1800 46500 170M3017 206A-3 2210 68500 170M3018 246A-3 3010 105000 170M5009...
  • Page 199 Technical data 199 Ultrarapid (aR) fuses stud-mount (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current A 2 s rent 1) Bussmann Type type 43653 240A-5 2620 74000 170M5008 260A-5 4000 105000 170M5009 302A-5 5550 190000 170M5011...

  • Page 200: Ar Fuses Din 43620 Blade Style (Frames R1 To R9)

    200 Technical data ￭ aR fuses DIN 43620 blade style (frames R1 to R9) Ultrarapid (aR) fuses blade style (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current A 2 s rent 1) Bussmann Type DIN type...
  • Page 201 Technical data 201 Ultrarapid (aR) fuses blade style (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current A 2 s rent 1) Bussmann Type DIN type 43620 025A-3 170M1563 032A-3 1450 170M1565 038A-3 1450 170M1565 045A-3 2550...
  • Page 202 202 Technical data Ultrarapid (aR) fuses blade style (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current A 2 s rent 1) Bussmann Type DIN type 43620 040A-5 2550 170M1566 052A-5 4650 170M1567 065A-5 8500 170M1568 077A-5...

  • Page 203: Gg Fuses Din 43620 Blade Style (Frames R1 To R9)

    Technical data 203 Ultrarapid (aR) fuses blade style (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current A 2 s rent 1) Bussmann Type DIN type 43620 142A-7 2210 145000 170M5810 174A-7 2210 145000 170M5810 210A-7 3200...
  • Page 204 204 Technical data gG fuses (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current rent 1) A 2 s ABB type DIN size 206A-2 5500 710000 OFAF1H315 274A-2 7000 1100000 OFAF2H400 U n = 400 V 02A4-3...
  • Page 205 Technical data 205 gG fuses (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current rent 1) A 2 s ABB type DIN size 430A-3 10200 2800000 OFAF3H630 U n = 500 V 02A1-5 OFAF000H4 03A0-5 OFAF000H6 03A4-5...

  • Page 206: Quick Guide For Selecting Between Gg And Ar Fuses

    206 Technical data gG fuses (one fuse per phase) ACS880-01-… Min. short- Input Fuse circuit cur- current rent 1) A 2 s ABB type DIN size 414A-5 10200 2800000 OFAF3H630 U n = 690 V 07A4-7 1200 OFAA000GG16 09A9-7 2400...
  • Page 207 Technical data 207 select between gG and aR fuses or to calculate the short-circuit current of the installation as described in Calculating the short-circuit current of the installation (page 209). ACS880- Cable type Supply transformer minimum apparent power S N (kVA) 01-…...
  • Page 208 208 Technical data ACS880- Cable type Supply transformer minimum apparent power S N (kVA) 01-… Copper Alumin- Maximum cable length with Maximum cable length with gG fuses aR fuses mm 2 mm 2 10 m 50 m 100 m 10 m 100 m 200 m 145A-3...

  • Page 209: Calculating The Short-Circuit Current Of The Installation

    Technical data 209 ACS880- Cable type Supply transformer minimum apparent power S N (kVA) 01-… Copper Alumin- Maximum cable length with Maximum cable length with gG fuses aR fuses mm 2 mm 2 10 m 50 m 100 m 10 m 100 m 200 m 023A-7...

  • Page 210: Calculation Example

    + (22.19 mohm + 13.94 mohm) The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF00H160 (1700 A). -> The 500 V gG fuse (ABB Control OFAF00H160) can be used.
  • Page 211 Technical data 211 ACS880-01-… Input current UL (one fuse per phase) Bussmann UL class type 07A5-2 JJS-15 10A6-2 10.1 JJS-20 16A8-2 16.0 JJS-25 24A3-2 23.1 JJS-35 031A-2 29.3 JJS-50 046A-2 JJS-80 061A-2 JJS-80 075A-2 JJS-110 087A-2 JJS-110 115A-2 JJS-150 145A-2...
  • Page 212 212 Technical data ACS880-01-… Input current UL (one fuse per phase) Bussmann UL class type 414A-5 JJS-600 U n = 575 V 07A4-7 JJS-15 09A9-7 JJS-20 14A3-7 13.6 JJS-30 019A-7 JJS-40 023A-7 JJS-50 027A-7 JJS-50 035A-7 JJS-60 042A-7 JJS-80 049A-7...

  • Page 213: Circuit Breakers (Iec)

    (3AXD50000645015 [English]). Circuit breakers (IEC) ￭ ABB miniature and molded case circuit breakers The table below lists the circuit breakers that can be used with the drive. ACS880- Frame ABB miniature circuit ABB moulded case circuit breaker (Tmax) 01-…...
  • Page 214 214 Technical data ACS880- Frame ABB miniature circuit ABB moulded case circuit breaker (Tmax) 01-… breaker Type Type 075A-2 S 803 S-B/C 125 XT2 L 160 Ekip LS/I In=160 3p F F 087A-2 S 803 S-B/C 125 XT2 L 160 Ekip LS/I In=160 3p F F...
  • Page 215 Technical data 215 ACS880- Frame ABB miniature circuit ABB moulded case circuit breaker (Tmax) 01-… breaker Type Type 07A6-5 S 803 S-B/C 13 11A0-5 S 803 S-B/C 20 014A-5 S 803 S-B/C 25 021A-5 S 803 S-B/C 32 027A-5 S 803 S-B/C 50...

  • Page 216: Circuit Breakers (Ul)

    ABB does not assume any liability whatsoever for the correct function and protection with circuit breakers not listed. Furthermore, if the recommendations given by ABB are not obeyed, the drive can experience problems that warranty does not cover. Circuit breakers (UL) ￭...

  • Page 217: Dimensions, Weights And Free Space Requirements

    Use drive volume for all three types listed in the table when installing multiple drives in the panel. 5. ABB circuit breaker part number listed in table is a base part number. Last eight characters of the breaker "FF000XXX" represent optional accessories which can be added to the breaker.
  • Page 218 218 Technical data Frame UL type 1 Weight 16.11 14.57 6.10 8.89 16.11 14.57 6.10 9.80 18.71 16.54 6.77 10.28 22.85 19.29 7.99 10.79 28.80 23.46 7.99 10.77 28.60 22.40 9.92 14.10 34.66 24.45 11.18 14.35 38.01 27.56 11.81 15.21 37.59 27.56 14.96...

  • Page 219: Definitions

    Note 2: For dimensions and weights of option +P940 and +P944, see ACS880…+P940 and +P944 drive modules supplement (3AUA0000145446 [English]). Note 3: For dimensions of option +C135, see ACS880-01…+C135 drives with flange mounting kit supplement (3AXD50000349814 [English]). For the additional weight of the flange mounting kit, see the table below.

  • Page 220: Free Space Requirements

    220 Technical data Frame Package Length Width Height (mm) (mm) (mm) R3 IP55 R4 (IP55) R5 IP21 1145 1145 Free space requirements 200 mm (7.87 in.) free space is required at top of the drive. 300 mm (11.81 in.) free space (when measured from the drive base without the cable entry box) is required at bottom of the drive.
  • Page 221 Technical data 221 ACS880- Frame Air flow Heat dissipation Noise 01-… m 3 /h ft 3 /min dB(A) 03A3-3 04A0-3 05A6-3 07A2-3 09A4-3 12A6-3 017A-3 025A-3 032A-3 038A-3 045A-3 061A-3 072A-3 1117 087A-3 1120 105A-3 1295 145A-3 1440 169A-3 1940 206A-3 2310 246A-3...

  • Page 222: Cooling Air Flow And Heat Dissipation For Flange Mounting (Option +C135)

    222 Technical data ACS880- Frame Air flow Heat dissipation Noise 01-… m 3 /h ft 3 /min dB(A) 124A-5 1440 156A-5 1940 180A-5 2310 240A-5 3300 260A-5 3900 302A-5 1150 4200 361A-5 1150 4800 414A-5 1150 6000 U n = 690 V 07A4-7 09A9-7 14A3-7...
  • Page 223 Technical data 223 ACS880- Frame Air flow (option +C135) Heat dissipation (option +C135) 01-… Heatsink Front Heatsink Front m 3 /h m 3 /h 16A8-2 24A3-2 031A-2 046A-2 061A-2 075A-2 087A-2 115A-2 145A-2 170A-2 1089 206A-2 1305 274A-2 1845 U n = 400 V 02A4-3 03A3-3 04A0-3...
  • Page 224 224 Technical data ACS880- Frame Air flow (option +C135) Heat dissipation (option +C135) 01-… Heatsink Front Heatsink Front m 3 /h m 3 /h 02A1-5 03A0-5 03A4-5 04A8-5 05A2-5 07A6-5 11A0-5 014A-5 021A-5 027A-5 034A-5 040A-5 052A-5 065A-5 077A-5 096A-5 1121 124A-5 1251...

  • Page 225: Connector And Entry Data For The Power Cables

    Technical data 225 ACS880- Frame Air flow (option +C135) Heat dissipation (option +C135) 01-… Heatsink Front Heatsink Front m 3 /h m 3 /h 119A-7 2034 142A-7 2925 174A-7 3465 210A-7 1150 3735 271A-7 1150 4275 Connector and entry data for the power cables ￭...
  • Page 226 226 Technical data Frame Cable entries R-, R+/UDC+ and UDC- terminals Ø * Wire size T (wire screw) mm 2 M… N·m 0.5…35 6…70 25…95 25…150 2 × (50…150) 2 × (95…240) * maximum cable diameter accepted. For the entry plate hole diameters, see chapter Dimension drawings.

  • Page 227: Ul Listed Cable Lugs And Tools

    Technical data 227 Frame Cable entries L1, L2, L3, T1/U, T2/V, T3/W Grounding ter- minals Ø * Wire size T (Wire screw) Max. wire lbf·ft size kcmil/AWG M… lbf·ft 1.77 2 × (1/0…300 29.5 1.18 2× MCM) 2.13 2 × (3/0…400 51.6 1.18 2×...

  • Page 228: Connector Data For The Control Cables

    228 Technical data Wire size Compression lug Crimping tool kcmil/AWG Manufacturer Type Manufacturer Type No. of crimps Thomas & 54140 Thomas & TBM4S Betts Betts Burndy YA4C-L4BOX Burndy MY29-3 Ilsco CCL-4-38 Ilsco MT-25 Thomas & 54143TB Thomas & TBM4S Betts 54142TB Betts TBM4S...
  • Page 229 Technical data 229 IEC 1) UL (NEC) 2) Drive type Frame ACS880- size Cu cable type Al cable type Cu cable type Al cable type 01-… mm 2 mm 2 AWG/kcmil AWG/kcmil 07A5-2 3×1.5 10A6-2 3×1.5 16A8-2 3×6 24A3-2 3×6 031A-2 3×10 046A-2...
  • Page 230 230 Technical data IEC 1) UL (NEC) 2) Drive type Frame ACS880- size Cu cable type Al cable type Cu cable type Al cable type 01-… mm 2 mm 2 AWG/kcmil AWG/kcmil 430A-3 2 × (3x150) 2 × (3x240) 2 × 250 MCM 2 ×...

  • Page 231: Electrical Power Network Specification

    Electrical power network specification Voltage (U 1 ) ACS880-01-xxxx-2 drives: 208 … 240 V AC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage level 3~230 V AC.

  • Page 232: Motor Connection Data

    Motor connection data Motor types Asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors) Voltage (U 2 ) 0 to U 1 , 3-phase symmetrical. This is indicated in the type designation label as typical output voltage level as 3 0…U 1 , U max at the field weak-...

  • Page 233: Efficiency

    7, ACS880-01-14A2-7 and ACS880-01-018A-7: 150 m (492 ft). For ACS880-01-xxxx-2, ACS880-01-xxxx-3 and ACS880-01-xxxx-5 frames R4 to R9 and for types from ACS880-01-022A-7 to ACS880-01- 271A-7: 300 m (984 ft). Note 1: With motor cables longer than 150 m (492 ft) or switching fre- quencies higher than default, the EMC Directive requirements may not be fulfilled.
  • Page 234 234 Technical data Relative humidity 5 to 95% Max. 95% Max. 95% No condensation allowed. Maximum allowed relative humidity is 60% in the presence of corrosive gases. Contamination IEC/EN 60721-3- IEC 60721-3-1:1997 IEC 60721-3-2:1997 (IEC 60721-3-3, IEC 3:2002: Classification 60721-3-2, IEC 60721- of environmental condi- 3-1) tions- Part 3-3: Classific-...

  • Page 235: Materials

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

  • Page 236: Applicable Standards

    236 Technical data Applicable standards The drive complies with the following standards. The compliance with the European Low Voltage Directive is verified according to standard EN 61800-5-1. EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety require- ments – Electrical, thermal and energy IEC 61800-5-2:2016 Adjustable speed electrical power drive systems.

  • Page 237: Markings

    Technical data 237 Markings These markings are attached to the drive: CE mark Product complies with the applicable European Union legislation. For fulfilling the EMC requirements, see the additional information concerning the drive EMC compliance (IEC/EN 61800-3). TÜV Safety Approved mark (functional safety) Product contains Safe Torque Off and possibly other (optional) safety functions which are certified by TÜV according to the relevant functional safety standards.

  • Page 238: Compliance With The En 61800-3:204 + A1:2012

    238 Technical data Compliance with the EN 61800-3:204 + A1:2012 ￭ Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality.

  • Page 239: Category C3

    Technical data 239 Note: Note: Do not install a drive with the EMC filter +E202 connected to a system that the filter is not suitable for. This can cause danger, or damage the drive. Note: Do not install a drive with the ground-to-phase varistor connected to a system that the varistor is not suitable for.

  • Page 240: Ul And Csa Checklist

    240 Technical data Medium voltage network Equipment Neighboring network Supply transformer Point of measurement Static screen Low voltage Drive Equipment (victim) 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available in Technical guide No. 3 EMC compliant installation and configuration for a power drive system (3AFE61348280 (English)).

  • Page 241: Approvals

    • The drive provides motor overload protection. This feature is not enabled when the drives leaves the ABB factory. For enabling this motor overload protection, see the firmware manual. • The drive overvoltage category according to IEC 60664-1 is III.

  • Page 242: Design Lifetime Expectancy

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

  • Page 243: Dimension Drawings

    Dimension drawings 243 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the standard drive (IP21, UL Type 1) and drive with option +B056 (IP55, UL Type 12). For dimension drawings with options +P940 and +P944 (IP20, UL Open Type), see ACS880…+P940 and +P944 drive modules supplement (3AUA0000145446 [English]).

  • Page 244: Frame R1 (Ip21, Ul Type 1)

    244 Dimension drawings Frame R1 (IP21, UL Type 1)

  • Page 245: Frame R1 (Ip55, Ul Type 12)

    Dimension drawings 245 Frame R1 (IP55, UL Type 12)

  • Page 246: Frame R2 (Ip21, Ul Type 1)

    246 Dimension drawings Frame R2 (IP21, UL Type 1)

  • Page 247: Frame R2 (Ip55, Ul Type 12)

    Dimension drawings 247 Frame R2 (IP55, UL Type 12)

  • Page 248: Frame R3 (Ip21, Ul Type 1)

    248 Dimension drawings Frame R3 (IP21, UL Type 1)

  • Page 249: Frame R3 (Ip55, Ul Type 12)

    Dimension drawings 249 Frame R3 (IP55, UL Type 12)

  • Page 250: Frame R4 (Ip21, Ul Type 1)

    250 Dimension drawings Frame R4 (IP21, UL Type 1)

  • Page 251: Frame R4 (Ip55, Ul Type 12)

    Dimension drawings 251 Frame R4 (IP55, UL Type 12)

  • Page 252: Frame R5 (Ip21, Ul Type 1)

    252 Dimension drawings Frame R5 (IP21, UL Type 1)

  • Page 253: Frame R5 (Ip55, Ul Type 12)

    Dimension drawings 253 Frame R5 (IP55, UL Type 12)

  • Page 254: Frame R6 (Ip21, Ul Type 1)

    254 Dimension drawings Frame R6 (IP21, UL Type 1)

  • Page 255: Frame R6 (Ip55, Ul Type 12)

    Dimension drawings 255 Frame R6 (IP55, UL Type 12)

  • Page 256: Frame R7 (Ip21, Ul Type 1)

    256 Dimension drawings Frame R7 (IP21, UL Type 1)

  • Page 257: Frame R7 (Ip55, Ul Type 12)

    Dimension drawings 257 Frame R7 (IP55, UL Type 12)

  • Page 258: Frame R8 (Ip21, Ul Type 1)

    258 Dimension drawings Frame R8 (IP21, UL Type 1)

  • Page 259: Frame R8 (Ip55, Ul Type 12)

    Dimension drawings 259 Frame R8 (IP55, UL Type 12)

  • Page 260: Frame R9 (Ip21, Ul Type 1)

    260 Dimension drawings Frame R9 (IP21, UL Type 1)

  • Page 261: Frame R9 (Ip55, Ul Type 12)

    Dimension drawings 261 Frame R9 (IP55, UL Type 12)

  • Page 263: Resistor Braking

    Resistor braking 263 Resistor braking Contents of this chapter This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains technical data Operation principle and hardware description Frames R1 to R4 have a built-in brake chopper as standard. Frames R5 and up can be equipped with optional built-in brake chopper (+D150).

  • Page 264: Selecting A Custom Resistor

    264 Resistor braking Note: If the E value is not sufficient, it is possible to use a four-resistor assembly in which two standard resistors are connected in parallel, two in series. The E value of the four-resistor assembly is four times the value specified for the standard resistor. ￭...

  • Page 265: Selecting And Routing The Brake Resistor Cables

    The maximum length of the resistor cable(s) is 10 m (33 ft). ￭ EMC compliance of the complete installation ABB has not verified that the EMC requirements are fulfilled with external user-defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.

  • Page 266: Protecting The System Against Thermal Overload

    An example wiring diagram is shown below. ABB resistors are equipped with a thermal switch (1) inside the resistor assembly as standard. The switch indicates overtemperature and overload. ABB recommends that you also wire the thermal switch to a digital input of the drive L2 L3 Θ...

  • Page 267: Protecting The Resistor Cable Against Short-Circuits

    Note: If an external brake chopper (outside the drive module) is used, a main contactor is always required. A thermal switch (standard in ABB resistors) is required for safety reasons. The thermal switch cable must be shielded and may not be longer than the resistor cable. Wire the switch to a digital input on the drive control unit as shown in the figure below.

  • Page 268: Start-Up

    268 Resistor braking Start-up Note: Protective oil on the brake resistors will burn off when the brake resistor is used for the first time. Make sure that the airflow is sufficient. Set the following parameters (ACS880 primary control program): • Disable the overvoltage control of the drive by parameter 30.30 Overvoltage control.
  • Page 269 Resistor braking 269 ACS880- Internal brake chopper Example brake resistor(s) 01-… P brcont R min Type P Rcont 046A-2 SACE15RE13 061A-2 SACE15RE13 075A-2 18.5 SAFUR90F575 1800 087A-2 SAFUR90F575 1800 115A-2 SAFUR125F500 3600 145A-2 SAFUR125F500 3600 170A-2 SAFUR200F500 5400 13.5 206A-2 SAFUR200F500 5400 13.5...
  • Page 270 270 Resistor braking ACS880- Internal brake chopper Example brake resistor(s) 01-… P brcont R min Type P Rcont 04A8-5 JBR-03 0.14 05A2-5 JBR-03 0.14 07A6-5 JBR-03 0.14 11A0-5 JBR-03 0.14 014A-5 SACE08RE44 021A-5 SACE08RE44 027A-5 SACE15RE22 034A-5 18.5 SACE15RE22 040A-5 SACE15RE13 052A-5 SACE15RE13...

  • Page 271: Degree Of Protection And Thermal Constant Of The Resistor

    Resistor braking 271 ACS880- Internal brake chopper Example brake resistor(s) 01-… P brcont R min Type P Rcont 061A-7 SACE15RE13 084A-7 SACE15RE13 098A-7 SAFUR90F575 1800 119A-7 SAFUR90F575 1800 142A-7 SAFUR80F500 2400 174A-7 SAFUR80F500 2400 210A-7 SAFUR125F500 3600 271A-7 SAFUR125F500 3600 P brcont Maximum continuous braking power.

  • Page 272: Dimensions And Weights Of External Resistors

    272 Resistor braking Dimensions and weights of external resistors ￭ JBR-03 JBR-03 brake resistor Dimension A 340 mm (13.39 in)

  • Page 273: Sace08Re44

    Resistor braking 273 JBR-03 brake resistor Dimension B 200 mm (7.87 in) Dimension C 170 mm (6.69 in) Weight 0.8 kg (1.8 lb) 10 mm 2 (AWG6) Maximum wire size of main terminals Tightening torque of main terminals 1.5 … 1.8 N·m (13 … 16 lbf·in) 4 mm 2 (AWG12) Wire size of thermal switch terminals Tightening torque of thermal switch terminals...

  • Page 274: Sace15Re13 And Sace15Re2

    274 Resistor braking ￭ SACE15RE13 and SACE15RE2 SACE15RExx Ø 6 Weight: 6 kg (13 lb) ￭ SAFUR80F500 and SAFUR90F575 Ø 7 Brake resistor type Weight SAFUR80F500 14 kg (31 lb) SAFUR90F500 12 kg (26 lb)

  • Page 275: Safur125F500 And Safur200F500

    Resistor braking 275 ￭ SAFUR125F500 and SAFUR200F500 5 5 Ø 7 Brake resistor type Weight SAFUR125F500 25 kg (55 lb) SAFUR200F500 30 kg (66 lb)

  • Page 277: The Safe Torque Off Function

    The Safe torque off function 277 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 278: Compliance With The European Machinery Directive

    278 The Safe torque off function Standard Name IEC 60204-1:2016 Safety of machinery – Electrical equipment of machines – Part 1: EN 60204-1:2018 General requirements IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic stand- ards – Immunity requirements for equipment intended to perform functions in a safety-related system (functional safety) in indus- trial locations IEC 61326-3-1:2017...

  • Page 279: Wiring

    The Safe torque off function 279 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 280: Single Drive (Internal Power Supply)

    280 The Safe torque off function ￭ Single drive (internal power supply) Dual-channel connection OUT1 +24 V SGND UDC+ UDC– Drive Control unit Control logic To motor Activation switch...

  • Page 281: Single-Channel Connection

    The Safe torque off function 281 Single-channel connection OUT1 +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.

  • Page 282: Multiple Drives

    282 The Safe torque off function ￭ Multiple drives Internal power supply XSTO OUT1 +24 V SGND XSTO OUT1 SGND XSTO OUT1 SGND Drive Control unit Activation switch...

  • Page 283: External Power Supply

    The Safe torque off function 283 External power supply 24 V DC – XSTO OUT1 +24 V SGND XSTO OUT1 SGND XSTO OUT1 SGND Drive Control unit Activation switch...

  • Page 284: Operation Principle

    284 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 285: Start-Up Including Acceptance Test

    The Safe torque off function 285 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 286 286 The Safe torque off function Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...

  • Page 287: Use

    The Safe torque off function 287 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. 3.

  • Page 288: 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 285). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...

  • Page 289: 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 290: Safety Data

    290 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. PFD avg PFD avg Frame...
  • Page 291 The Safe torque off function 291 PFD avg PFD avg Frame SIL/ (T 1 = 20 MTTF D (T 1 = 2 (T 1 = 5 Cat. size SILCL (1/h) 3.21E- 2.66E- 6.66E- 99.1 10008 ≥90 3AXD10000006217 K, 3AXD10000083197 H •...

  • Page 292: Abbreviations

    292 The Safe torque off function ￭ Abbreviations Abbr. Reference Description Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition, and which is achieved by the structural arrangement of the parts, fault detection and/or by their reliability.

  • Page 293: Tüv Certificate

    The Safe torque off function 293 ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.

  • Page 294: Declaration Of Conformity

    294 The Safe torque off function ￭ Declaration of conformity...

  • Page 295: Filters

    Examining the compatibility of the motor and drive (page 62). A common mode filter kits are available from ABB. The kits includes three wound cores. For installation instructions of the cores, see the instruction included in the core package. Common mode filters Common mode filter kits are available from ABB.

  • Page 296: Du/Dt Filters

    296 Filters du/dt filters ￭ du/dt filter types ACS880-01-… du/dt filter ACS880-01-… du/dt filter ACS880-01-… du/dt filter type type type U N = 400 V U N = 500 V U N = 690 V 02A4-3 NOCH0016-6X 02A1-5 NOCH0016-6X 07A4-7...

  • Page 297: Sine Filters

    Filters 297 Sine filters ￭ Selecting a sine filter for a drive Check housing of sine filters from the manufacturer’s internet pages. Go to https://en.tdk.eu ACS880-01-… Sine filter type I cont. P cont. Heat dissipation Noise Drive Filter Total U N = 400 V...
  • Page 298 298 Filters ACS880-01-… Sine filter type I cont. P cont. Heat dissipation Noise Drive Filter Total 11A0-5 B84143V0011R229* 10.2 014A-5 B84143V0016R229* 021A-5 B84143V0025R229* 14.7 027A-5 B84143V0033R229* 18.8 034A-5 B84143V0050R229* 23.7 040A-5 B84143V0050R229* 26.0 052A-5 B84143V0066R229* 33.2 1157 065A-5 B84143V0066R229* 39.2...

  • Page 299: Definitions

    Filters 299 ACS880-01-… Sine filter type I cont. P cont. Heat dissipation Noise Drive Filter Total 142A-7 B84143V0130S230** 84.7 3300 3930 174A-7 B84143V0207S230** 103.7 3900 4830 210A-7 B84143V0207S230** 121.3 4200 5130 271A-7 B84143V0207S230** 156.4 4800 5730 3AXD00000588487 * minimum switching frequency 3.0 kHz ** minimum switching frequency 2.4 kHz...
  • Page 301 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 302 3AUA0000078093P © Copyright 2020 ABB. All rights reserved. Specifications subject to change without notice.

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