DEMAG ACS880- 04 Hardware Manual
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DEMAG ACS880- 04 Hardware Manual

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Hardware Manual
ACS880-DEMAG 04 Drives
(200 to 710 kW, 300 to 700 hp)
010420 enUS
211 323 44
719 IS 922

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  • Page 1 Hardware Manual ACS880-DEMAG 04 Drives (200 to 710 kW, 300 to 700 hp) 010420 enUS 211 323 44 719 IS 922...
  • Page 2 Hersteller / Manufacturer: www.demagcranes.de/dedrive- www.demagcranes.com/en/ pro-880-produktdokumentation dedrive-pro-880-frequency- Demag Cranes & Components GmbH inverter-product-documentation Postfach 67 · 58286 Wetter (Deutschland) Telefon: +49 2335 92-0 Telefax: +49 2335 92-7676 www.demagcranes.com Liste ergänzender Handbücher / List of related manuals Frequenzumrichter-Handbücher und Anleitungen ACS 880...
  • Page 3 Hardware manual ACS880-04 drive modules (200 to 710 kW, 300 to 700 hp) Table of contents 1. Safety instructions 6. Installation instructions 10. Start-up...

  • Page 5: Table Of Contents

    Table of contents 1. Safety instructions Contents of this chapter ..........15 Use of warnings and notes .
  • Page 6 Layout example, door open (standard drive module configuration) ... . . 47 Layout example, door open (option +H391) ....... 48 Layout example, door open (option +0B051) .
  • Page 7 Conduit ............72 Armored cable / shielded power cable .
  • Page 8 Checking the compatibility with IT (ungrounded) systems ..... . . 93 Installation alternatives ..........93 Standard drive module configuration (bookshelf mounting) .
  • Page 9 7. Installation example of the standard drive module configuration Contents of this chapter ..........121 Limitation of liability .
  • Page 10 Warning and fault messages ..........151 12.
  • Page 11 Dimensions, weights and free space requirements ......183 Losses, cooling data and noise ......... . . 184 Terminal and lead-through data for the power cables .
  • Page 12 Frame R11 with options +E208+H370+H391+0J400 ......212 Air baffles for the standard drive module and option +C173 ....213 Air baffles for option +H381 in Rittal TS 8 400 mm wide cabinet installation .
  • Page 13 Connection procedure ..........234 Start-up .

  • 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 and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 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 that install the drive module and do maintenance work on it. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
  • Page 17 Safety instructions 17 • To prevent the drive module from falling, attach its top lifting lugs with chains to the cabinet frame before you push the module into the cabinet and pull it from the cabinet. Work carefully preferably with help from another person as shown below. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back 3AUA0000088632...

  • Page 18: Electrical Safety In Installation, Start-Up And Maintenance

    18 Safety instructions Electrical safety in installation, start-up and maintenance Precautions before electrical work  These warnings are for all personnel that do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 19: Additional Instructions And Notes

    Safety instructions 19 Additional instructions and notes  WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you are not a qualified electrician, do not do installation or maintenance work. •...

  • Page 20: Grounding

    20 Safety instructions Grounding  These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase. •...

  • Page 21: Additional Instructions For Permanent Magnet Motor Drives

    Safety instructions 21 Additional instructions for permanent magnet motor drives Safety in installation, start-up and maintenance  These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death and equipment malfunction can occur.
  • Page 22 22 Safety instructions...

  • Page 23: Introduction To The Manual

    Introduction to the manual 23 Introduction to the manual Contents of this chapter This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.

  • Page 24: Contents Of The Manual

    24 Introduction to the manual Contents of the manual This manual contains the instructions and information for the basic drive module configuration. The chapters of the manual are briefly described below. Safety instructions gives safety instructions for the installation, commissioning, operation and maintenance of the drive module.

  • Page 25: Categorization By Frame Size And Option Code

    Introduction to the manual 25 Step-by-step drawings for a flat installation example in Rittal TS 8 600 mm wide cabinet shows how to install the drive module in a Rittal TS 8 cabinet. Step-by-step drawings for option +H391 installation example in Rittal TS 8 600 mm wide cabinet shows how to install drive module with option +H391 to a Rittal TS 8 cabinet.
  • Page 26 26 Introduction to the manual Task Standard drive modules Installing the drive module into a cabinet (page 123) • Install the additional components into the cabinet: for example, main disconnector, main contactor, main AC Connecting the power cables and installing the fuses, etc..

  • Page 27: Terms And Abbreviations

    Introduction to the manual 27 Task Connect the external control cables to the drive control unit. Connecting the control cables to the terminals of the control unit (page 107) Check the installation. Installation checklist (page 145) Commission the drive. Start-up (page 149) Commission the brake chopper (if used).
  • Page 28 28 Introduction to the manual Term/Abbreviation Explanation FENA-21 Optional high performance Ethernet/IP™, Modbus/TCP and PROFINET IO adapter module, 2-port FEPL-01 Optional Ethernet POWERLINK fieldbus adapter module FIO-01 Optional digital I/O extension module FIO-11 Optional analog I/O extension module ® FLON-01 Optional LonWorks adapter module FPBA-01...

  • Page 29: Operation Principle And Hardware Description

    Operation principle and hardware description 29 Operation principle and hardware description Contents of this chapter This chapter describes the operating principle and construction of the drive module.

  • Page 30: Product Overview

    30 Operation principle and hardware description Product overview The ACS880-04 is a drive module for controlling asynchronous AC induction motors, permanent magnet motors, AC induction servomotors and synchronous reluctance motors (SynRM motors). The main circuit of the drive module is shown below. ACS880-04 UDC+ UDC-...

  • Page 31: Layout

    Operation principle and hardware description 31 Layout Standard drive module configuration with option +E208  The assembled standard drive module configuration with option +E208 is shown below. Drive module Optional common mode filter (+E208) Upper front cover Pedestal Lower front cover External control unit with control panel holder Clear plastic shrouds attached Control panel...
  • Page 32 32 Operation principle and hardware description +H370 Clear plastic shroud to be attached onto the Fiber optic cables drive module input power cabling (a). Lead- through shroud for side cabling (b). Clear plastic shrouds to be attached onto the PE (ground) terminal drive module output power cabling Clear plastic shroud to be attached on top of Main cooling fans...

  • Page 33: Drive Module For Flat Mounting (Option +C173)

    Operation principle and hardware description 33 Drive module for flat mounting (option +C173)  Front view of an assembled drive module for flat mounting is shown below. Option +C173 adds flat mounting brackets to the standard drive module configuration. Option +0H354 removes the pedestal and option +0P919 the installation ramp.

  • Page 34: Drive Module With Full Power Cabling Panels (Option +H381)

    34 Operation principle and hardware description Drive module with full power cabling panels (option +H381)  Accessories Assembled drive module Input power cabling panel Rubber grommet Side guides Input power cabling panel to be attached to the drive cabinet Output power cabling panel Output power cabling panel to be attached to the drive cabinet Top guide plate...

  • Page 35: Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) And Ip20 Shrouds (Option +0B051)

    Operation principle and hardware description 35 Drive module without full-size output cable connection terminals  (option +0H371) and IP20 shrouds (option +0B051) Lifting lugs Fastening bracket Input cable connection busbars (L1/U1, L2/V1, L3/W1) and DC+ and DC- busbars (UDC+, UCD- with option +H356) Circuit board compartment Output cable connection busbars (T1/U2, T2/V2, T3/W2) and brake resistor connection busbars (R+...

  • Page 36: Drive Module Configuration With Power Cable Connection Terminals On The Right-Hand Side Of The Drive Module (Option +H391)

    36 Operation principle and hardware description Drive module configuration with power cable connection terminals  on the right-hand side of the drive module (option +H391) Lifting lugs Fastening bracket Input cable connection busbars (L1/U1, L2/V1, L3/W1) and DC+ and DC- busbars (UDC+, UCD- with option +H356) Circuit board compartment cooling fans Circuit board compartment...

  • Page 37: Control Unit

    Operation principle and hardware description 37 Control unit  See section Standard drive module configuration with option +E208 on page 31. Control panel  ACS-AP-W Assistant control panel DPMP-01 door mounting kit (option +J410) DPMP-02 door mounting kit for surface mounting (option +J413) In the standard drive module configuration, the control panel is located in the control panel holder of the external control unit.

  • Page 38: Overview Of Power And Control Connections

    38 Operation principle and hardware description Overview of power and control connections The diagram shows the power connections and control interfaces of the drive module. Slot 1 Slot 2 X205 Slot 3 t° UDC+ UDC- T1/U2 L1/U1 T2/V2 L2/V1 T3/W2 L3/W1 Analog and digital I/O extension modules, feedback interface modules and fieldbus communication modules can be inserted into slots 1, 2 and 3.

  • Page 39: External Control Connection Terminals

    Operation principle and hardware description 39 External control connection terminals  The layout of the external control connection terminals on the drive module control are shown below. Description XPOW External power input XRO1 Analog inputs Analog outputs XRO2 XD2D Drive to drive link XRO1 Relay output RO1 XRO3...

  • Page 40: External Control Unit Connection Cables

    Air Cooling Dedrive Pro 880 IP21 Icc 65 kA UL type 1 Made in Finland by ABB S/N: 1160900001 Demag Cranes & Components GmbH Type designation, see section Type designation key on page 41. Manufacturing address Frame size Cooling method...

  • Page 41: Type Designation Key

    Operation principle and hardware description 41 Degree of protection Ratings, see section Ratings on page 175. Short-circuit withstand strength, see section Electrical power network specification on page 185. Valid markings Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively.
  • Page 42 42 Operation principle and hardware description Code Description H381 Full power cabling panels to be attached to a cabinet. The drive module can be pulled from the cabinet for maintenance without disconnecting the power cables. Degree of protection IP20. (Not to be used with options +0B051, +C173, 0H354 and 0H371.) H391 Power cable connection terminals on the right-hand side of the drive module.
  • Page 43 Operation principle and hardware description 43 Code Description L521 FSE-31 pulse encoder interface module. Requires option +Q972. L525 FAIO-01 analog I/O extension module L526 FDIO-01 digital I/O extension module L536 FPTC-01 thermistor protection module L537 FPTC-02 ATEX-certified thermistor protection module. Requires option +Q971. Control program N7502 Enables setting of synchronous reluctance motor parameters in the drive control program.
  • Page 44 44 Operation principle and hardware description...

  • Page 45: Guidelines For Planning The Cabinet Installation

    Limitation of liability You must always plan and make the installation according to applicable local laws and regulations. Demag does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Installation positions of the drive module You can put the drive module in the bookshelf or flat position or on its back in a cabinet.

  • Page 46: Planning The Layout Of The Cabinet

    46 Guidelines for planning the cabinet installation Planning the layout of the cabinet Plan a spacious layout to ensure easy installation and maintenance. Sufficient cooling air flow, obligatory clearances, cables and cable support structures all require space. Place the control board(s) away from: •...

  • Page 47: Layout Example, Door Open (Standard Drive Module Configuration)

    Guidelines for planning the cabinet installation 47 Layout example, door open (standard drive module configuration)  L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A 1 Supporting frame of the cabinet 8 Motor cable including the protective ground conductor of the drive module Vertical (2a) and horizontal (2b) air baffles 9 Drive module control unit.

  • Page 48: Layout Example, Door Open (Option +H391)

    48 Guidelines for planning the cabinet installation Layout example, door open (option +H391)  L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A 1 Supporting frame of the cabinet 8 Motor cable including the protective ground conductor of the drive module Vertical (2a) and horizontal (2b) air baffles 9 Drive module control unit.

  • Page 49: Layout Example, Door Open (Option +0B051)

    Guidelines for planning the cabinet installation 49 Layout example, door open (option +0B051)  This diagram shows a layout example for drive modules with no IP20 shrouds (option +0B051) or no cabling panels (option +H381 not included). L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2...

  • Page 50: Arranging The Grounding Inside The Cabinet

    Always fasten the drive module from its fastening points to the cabinet. For details, see the module installation instructions. WARNING! Do not fasten the cabinet by electric welding. Demag does not assume any liability for damages caused by electric welding as the welding...

  • Page 51: Planning The Cabinet Placement On A Cable Channel

    Guidelines for planning the cabinet installation 51 Planning the cabinet placement on a cable channel Note the following when you plan to place the cabinet on a cable channel: • The cabinet structure must be sturdy enough. If the whole cabinet base is not supported from below, the cabinet weight will lie on the sections that the floor carries.

  • Page 52: Planning The Cooling

    52 Guidelines for planning the cabinet installation • We recommend 360° high frequency grounding of the motor cable shields at their entries. The grounding can be implemented by a knitted wire mesh screening as shown below. Cable Cable tie Strain relief Bare cable shield Knitted wire mesh Cabinet lead-through plate...
  • Page 53 Guidelines for planning the cabinet installation 53 • Make sure that the air inlets and outlets are large enough to allow sufficient air flow in and out of the cabinet. This is critical for proper cooling of the drive module. Minimum air inlets are four Rittal air filters (SK 3243.200 for a 600 mm wide cabinet) or two ABB air inlet filters (see section Cabinet ventilation...

  • Page 54: Preventing The Recirculation Of Hot Air

    54 Guidelines for planning the cabinet installation Preventing the recirculation of hot air Prevent hot air circulation outside the cabinet by leading the outcoming hot air away from the area where the inlet air to the cabinet is taken. Possible solutions are listed below: •...

  • Page 55: Bookshelf Mounting (Standard Drive Module Configuration)

    Guidelines for planning the cabinet installation 55 Bookshelf mounting (standard drive module configuration)  This diagram shows the air baffle position inside an example cabinet. For dimensions of the baffle, see page 213. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 B – B C –...

  • Page 56: Bookshelf Mounting (Option +0B051)

    56 Guidelines for planning the cabinet installation Bookshelf mounting (option +0B051)  This diagram shows air baffle positions inside an example cabinet. For the descriptions, see the next page. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 C – C A - A B - B D –...

  • Page 57: Bookshelf Mounting (Option +H381)

    Guidelines for planning the cabinet installation 57 1a Air flow to the drive module, max. 40 °C Drive module (104 °F) 1b Air inlet to the drive circuit boards and DC and Disconnector and fuses output busbars 2a Vertical air baffle that separates the cool and Contactor hot areas in the cabinet 2b Vertical air baffle...

  • Page 58: Flat Mounting (Option +C173)

    58 Guidelines for planning the cabinet installation Flat mounting (option +C173)  This diagram shows air baffle positions inside an example cabinet. For dimensions of the baffle, see page 213. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A B – B 1a Air flow to the drive module, max.

  • Page 59: Flat Mounting (Option +C173+0B051)

    Guidelines for planning the cabinet installation 59 Flat mounting (option +C173+0B051)  This diagram shows air baffle positions inside an example cabinet. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A C – C B – B 1a Air flow to the drive module, max. 40 °C Disconnector and fuses (104 °F) 1b Air inlet to the drive circuit boards and DC and...

  • Page 60: Required Free Space

    • height 2000 mm (78.74 in.). Other installation positions Contact your local Demag representative for more information. Drive module on its back  If you install the drive module on its back, make sure that the hot cooling air that flows...

  • Page 61: Planning The Placement Of The Control Panel

    Guidelines for planning the cabinet installation 61 Planning the placement of the control panel Note the following alternatives when you plan the placement of the control panel: • When the control unit is inside the drive module (option +P905), the control panel can be integrated in the drive module (option +J414).
  • Page 62 62 Guidelines for planning the cabinet installation...

  • Page 63: Guidelines For Planning The Electrical Installation

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

  • Page 64: Selecting The Supply Disconnecting Device

    64 Guidelines for planning the electrical installation Selecting the supply disconnecting device Install a hand-operated input disconnecting device between the AC power source and the drive. The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work.

  • Page 65: Protecting The Motor Insulation And Bearings

    Guidelines for planning the electrical installation 65 Protecting the motor insulation and bearings  The drive uses modern IGBT inverter technology. Regardless of frequency, the drive output has pulses of approximately the drive DC bus voltage with a very short rise time. Up to twice bus voltage can be at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals.
  • Page 66 66 Guidelines for planning the electrical installation Motor Nominal AC supply Requirement for type voltage ABB du/dt and common mode filters, insulated N-end Motor motor bearings insulation system 100 kW < P < 350 kW > 350 kW IEC 315 < frame size < frame size >...

  • Page 67: Additional Requirements For Explosion-Safe (Ex) Motors

    Guidelines for planning the electrical installation 67 Additional requirements for explosion-safe (EX) motors If you use an explosion-safe (EX) motor, obey the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ Use the selection criteria given for non-ABB motors.

  • Page 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 system du/dt filter, insulated N-end bearing and common mode filter 600 V < U < 690 V Reinforced: Û = 1800 V + N + du/dt + CMF Reinforced: Û...

  • Page 69: Selecting The Power Cables

    Guidelines for planning the electrical installation 69 Selecting the power cables General rules  Select the input power and motor cables according to local regulations: • Select a cable capable of carrying the drive nominal current. See section Ratings (page 175) for the rated currents. •...

  • Page 70: Typical Power Cable Sizes

    70 Guidelines for planning the electrical installation Typical power cable sizes  The table below gives copper and aluminum cable types with concentric copper shield for the drives with nominal current. See also Terminal and lead-through data for the power cables on page 184.

  • Page 71: Alternative Power Cable Types

    Guidelines for planning the electrical installation 71 Alternative power cable types  The recommended and not allowed power cable types to be used with the drive are presented below. Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield.

  • Page 72: Motor Cable Shield

    72 Guidelines for planning the electrical installation Motor cable shield  If the motor cable shield is used as the sole protective earth conductor of the motor, make sure that the conductivity of the shield is sufficient. See subsection General rules on page 69, or IEC 61800-5-1.

  • Page 73: Planning The Braking System

    Guidelines for planning the electrical installation 73 Planning the braking system See chapter Resistor braking. Selecting the control cables Shielding  All control cables must be shielded. Use a double-shielded twisted pair cable for analog signals. We recommend this type of cable for the pulse encoder signals also.

  • Page 74: Separate Control Cable Ducts

    74 Guidelines for planning the electrical installation A diagram of the cable routing is shown below. Control cables min 200 mm (8 in.) 90 ° Input power cable Motor cable Drive min 300 mm (12 in.) Power cable Motor cable, brake cable min 500 mm (20 in.) Control cables Separate control cable ducts...

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

    The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers. There are also limitations pertaining to the short-circuit capacity of the supply network. Your local Demag representative can help you in selecting the breaker type when the supply network characteristics are known.

  • Page 76: Protecting The Motor And Motor Cable In Short-Circuits

    ACS880-04-650A-7 ACS880-04-721A-7 3AXD00000588487 Maximum allowed rated conditional short-circuit current (IEC 61800-5-1) of the electrical power network Demag Contact your local representative WARNING! Due to the inherent operating principle and construction of circuit breakers, independent of the manufacturer, hot ionized gases can escape from the breaker enclosure in case of a short-circuit.

  • Page 77: Protecting The Motor Against Thermal Overload

    Guidelines for planning the electrical installation 77 Protecting the drive and the input power and motor cables against  thermal overload The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. No additional thermal protection devices are needed.

  • Page 78: Implementing The Emergency Stop Function

    78 Guidelines for planning the electrical installation Implementing the Emergency stop function For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed. You can implement the emergency stop function using the Safe torque off function of the drive module (see chapter Safe torque off function on page 219).

  • Page 79: Implementing The Power Loss Ride-Through Function

    Guidelines for planning the electrical installation 79 Implementing the Power loss ride-through function Implement the power loss ride-through function as follows: 1. Check that the power-loss ride-through function of the drive is enabled with parameter 30.31 Undervoltage control in the ACS880 primary control program. 2.

  • Page 80: Using A Contactor Between The Drive And The Motor

    80 Guidelines for planning the electrical installation Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate. See also section Implementing a bypass connection on page 80. When you have selected to use DTC motor control mode and motor ramp stop, open the contactor as follows: 1.

  • Page 81: Example Bypass Connection

    Guidelines for planning the electrical installation 81 Example bypass connection  An example bypass connection is shown below. Drive main switch Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor Drive main contactor on/off control Motor power supply selection (drive or direct-on-line) Start when motor is connected direct-on-line Stop when motor is connected direct-on-line Switching the motor power supply from drive to direct-on-line...

  • Page 82: Switching The Motor Power Supply From Direct-On-Line To Drive

    82 Guidelines for planning the electrical installation Switching the motor power supply from direct-on-line to drive 1. Stop the motor with S42. 2. Switch the motor power supply from direct-on-line to the drive with S40. 3. Close the main contactor of the drive with switch S11 (-> turn to position ST for two seconds and leave to position 1).

  • Page 83: Implementing A Motor Temperature Sensor Connection

    Guidelines for planning the electrical installation 83 Implementing a motor temperature sensor connection WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non-conductive but not connected to the protective earth. To connect a motor temperature sensor and other similar components to the drive, you have four alternatives: 1.

  • Page 84: Example Circuit Diagram

    84 Guidelines for planning the electrical installation Extension module Temperature sensor Temperature sensor type insulation requirement Type Insulation/Isolation Pt100, Pt1000 FPTC- Reinforced insulation between sensor No special requirement connector and other connectors (including drive control unit connector). Note: The inaccuracy of the drive analog inputs for Pt100 sensors is 10 °C (18 °F). If a better accuracy is needed, use the FAIO-01 analog I/O extension module (option +L525).

  • Page 85: Installation Instructions

    Installation instructions 85 Installation instructions Contents of this chapter This chapter contains the general installation instructions for the drive module. The chapter refers to the installation example chapters which contain instructions that depend on the selected drive configuration. Safety WARNING! If you are not a qualified electrician do not do the installation work described in this chapter.

  • Page 86: Moving And Unpacking The Unit

    86 Installation instructions Moving and unpacking the unit WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Move the transport package by pallet truck to the installation site. Unpack the package as follows (see the package drawing on page 87): •...

  • Page 87: Package Drawings

    Installation instructions 87 Package drawings  3AUA0000101742 Transport package contents With standard drive module configuration: Clear plastic shrouds. With option +H381: Input cabling panel parts. See below for the box contents. With standard drive module configuration: Output cable connection terminals. With option +H370 also Input cable connection terminals.
  • Page 88 88 Installation instructions Option +H391: Top and bottom brackets and handle Top bracket Bottom bracket Handle Screw package 3AXD10000407466 Box B1 contents (standard drive module configuration) Paper fill Clear plastic shroud for output cabling Cardboard box cover Cardboard box bottom Support Bands Back clear plastic shroud (lower)
  • Page 89 Installation instructions 89 Box B1 contents with option +H381: Input power cabling panel parts Screw package Paper fill Grounding busbar to be connected to the input power cabling panel and the drive module Cardboard tray Top cardboard cover Rubber grommet Support Bands Input power cabling panel...
  • Page 90 90 Installation instructions Ramp box contents Screw package Telescopic extraction and insertion ramp Cardboard box 3AXD50000010005 Accessories box contents Screw package, includes also spacers for FSO module installation Rubber grommets for control unit cable lead-through holes in the middle front cover of the drive module Bracket for attaching the drive module from top to Rittal cabinet...

  • Page 91: Checking The Delivery

    Installation instructions 91 Flat installation box contents (option +C173) Screw package Paper fill Mounting bars for 600 mm wide Rittal TS 8 cabinet Cardboard box 3AUA0000100915 Checking the delivery Check that all items listed in section Moving and unpacking the unit are present.

  • Page 92: Checking The Insulation Of The Assembly

    92 Installation instructions Checking the insulation of the assembly Drive  Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive. Every drive has been tested for insulation between the main circuit and the chassis at the factory.

  • Page 93: Brake Resistor And Resistor Cable

    Installation instructions 93 Brake resistor and resistor cable  Check the insulation of the brake resistor assembly (if present) as follows: 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work. 2.

  • Page 94: Standard Drive Module Configuration (Bookshelf Mounting)

    94 Installation instructions Standard drive module configuration (bookshelf mounting)  For an installation example on how to install the drive module with clear plastic shrouds into a Rittal TS 8 cabinet, see chapter Installation example of the standard drive module configuration on page 121.

  • Page 95: Drive Module With Full Cabling Panels (Option +H381)

    Installation instructions 95 Install the metallic shroud with ground bar as shown below. Combi screw M4×8 Torx T20 2 N·m Drive module with full cabling panels (option +H381)  For an installation example of the drive module with full cabling panels (option +H381) into a Rittal cabinet including power cable connection procedure, see chapter Installation example with full cabling panels (option...

  • Page 96: Drive Module Without Pedestal (Option +0H354)

    96 Installation instructions Drive module without pedestal (option +0H354)  The drive module without pedestal can be mounted on a wall or a cabinet with four screws through the fastening holes at the top and bottom of the module. Make sure that the cabinet mounting plate and frame are strong enough to carry the weight of the drive module.

  • Page 97: Alternatives For Grounding The Drive Module

    Installation instructions 97 Alternatives for grounding the drive module  You can ground the drive module from its top back to the cabinet frame with these alternatives: 1. from the grounding hole 2. to a Rittal punched section: with the fastening bracket. Tapping screw M6×12 Torx T30 (Hex) 9 N·m...

  • Page 98: Installing The Bottom Grille For Ip20 Degree Of Protection

    98 Installation instructions Installing the bottom grille for IP20 degree of protection  If IP20 degree of protection is needed from the bottom side, install the bottom grille as shown below. Installing the EMC filter (option +E202) See ARFI-10 EMC filter installation guide (3AFE 68317941 [English). Connecting the power cables WARNING! Obey the safety instructions in chapter Safety...

  • Page 99: Power Cable Connection Diagram

    Installation instructions 99 Power cable connection diagram  (PE) (PE) ACS880-04 UDC- UDC+ INPUT OUTPUT For alternatives, see section Selecting the supply disconnecting device on page In the installing example of this chapter, the disconnecting device is not in the same cubicle with the drive module. If a shielded cable is used (not required but recommended) and the conductivity of the shield is <...

  • Page 100: Power Cable Connection Procedure

    100 Installation instructions External brake resistor (optional, see page 231) Common mode filter (optional, see page 65) du/dt filter (optional, see page 237) EMC filter (option +E202, see page 98) The drive module frame must be connected to the cabinet frame. See section Arranging the grounding inside the cabinet on page...

  • Page 101: Removing The Control Panel Holder From The External Control Unit

    Installation instructions 101 Removing the control panel holder from the external control unit 1. Disconnect the control panel cable from connector X13 on the control unit. 2. Loosen the mounting screws of the control panel holder and take the holder off.

  • Page 102: Fastening The Control Cable Clamp Plate

    102 Installation instructions Fastening the control cable clamp plate Fasten the control cable clamp plate either to the top or base of the control unit with four screws as shown below. Note: If you install the FSO-xx safety functions module above the control unit, fasten the control cable clamp plate on the base of the control unit.

  • Page 103: Connecting The External Control Unit To The Drive Module

    Installation instructions 103 Connecting the external control unit to the drive module WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. Routing the control unit cables into the drive module ...

  • Page 104: Connections To The Control Unit

    104 Installation instructions Connections to the control unit  Connect the fiber optic, power supply and BGDR cables to the external control unit as follows: 1. Thread the cables inside the back frame of the control unit. 2. Connect the cables to the ZBIB board terminals. BPOW ZBIB ZINT/SOIA...

  • Page 105: Mounting The External Control Unit

    Installation instructions 105 Mounting the external control unit The drive control unit can be fastened on a mounting plate through the fastening holes in its back or by using a DIN rail. Mounting the external control unit to wall  1.

  • Page 106: Mounting The External Control Unit Vertically On A Din Rail

    106 Installation instructions Mounting the external control unit vertically on a DIN rail  1. Fasten the latch (A) to the back of the control unit with three screws. 2. Click the control unit to the rail as shown below (B). 3aua0000130997 Mounting the control unit horizontally on a DIN rail ...

  • Page 107: Connecting The Control Cables To The Terminals Of The Control Unit

    Installation instructions 107 Connecting the control cables to the terminals of the control unit 1. Route the cables to the control unit as shown below. 2. Ground the shields of the control cables at the clamp plate. The shields should be continuous as close to the terminals of the control unit as possible.

  • Page 108: Default I/O Connection Diagram

    108 Installation instructions Default I/O connection diagram  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 24 V DC, 2 A +24VI Reference voltage and analog inputs...

  • Page 109: Notes

    Installation instructions 109 Notes: 1) Current [0(4)…20 mA, R = 100 ohm] or voltage [0(2)…10 V, R > 200 kohm] input selected by jumper J1. Change of setting requires reboot of control unit. 2) Current [0(4)…20 mA, R = 100 ohm] or voltage [0(2)…10 V, R >...

  • Page 110: Ai1 And Ai2 As Pt100, Pt1000, Ptc And Kty84 Sensor Inputs (Xai, Xao)

    110 Installation instructions AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) Three Pt100, Pt1000 or PTC sensors or one KTY84 sensor for motor temperature measurement can be connected between an analog input and output as shown below. Do not connect both ends of the cable shields directly to ground.

  • Page 111: Di6 (Xdi:6) As Ptc Sensor Input

    Installation instructions 111 DI6 (XDI:6) as PTC sensor input A PTC sensor can be connected to this input for motor temperature measurement as follows. The sensor resistance must not exceed the threshold resistance of the digital input at the motor normal operating temperature. Do not connect both ends of the cable shield directly to ground.

  • Page 112: Safe Torque Off (Xsto)

    112 Installation instructions The following diagram shows the wiring of the drive-to-drive link. Safe torque off (XSTO) For the drive to start, both connections (OUT1 to IN1 and IN2) must be closed. By default, the terminal block has jumpers to close the circuit. Remove the jumpers before connecting an external Safe torque off circuitry to the drive.

  • Page 113: Connecting The Control Cables To The Internal Control Unit (Option +P905)

    Installation instructions 113 Connecting the control cables to the internal control unit (option  +P905) 1. Ground the outer control cable shields 360 degrees at the cabinet lead-through plate (recommendation). 2. Remove the middle front cover of the drive module (view of standard drive module configuration below).

  • Page 114: Connecting The Control Cables To The Internal Control Unit (Options +P905 And +0B051)

    114 Installation instructions Connecting the control cables to the internal control unit (options  +P905 and +0B051) 1. Remove the middle front cover of the drive module. 2. Fasten the clamp plate to the control unit with two screws from front, see Fastening the control cable clamp plate on page 102.

  • Page 115: Connecting A Control Panel

    Installation instructions 115 Connecting a control panel With external control unit and control panel holder mounted on the drive module (option +J414), put the control panel on the control panel holder. With door mounting kit (option +J410)), connect the control panel to the control unit as follows: 1.

  • Page 116: Controlling Several Drives From One Control Panel Through Panel Bus

    116 Installation instructions Controlling several drives from one control panel through panel bus One control panel (or PC) can be used to control several drives by constructing a panel bus. 1. Connect the panel to one drive using an Ethernet (eg. CAT5E) cable. •...

  • Page 117: Connecting A Pc

    Installation instructions 117 Connecting a PC You need a control panel to connect a PC to the drive module. Connect the control panel to the drive control unit as described in section Connecting a control panel on page 115. WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage.

  • Page 118: Case 1: Fso Safety Functions Module On Slot 2

    118 Installation instructions Case 1: FSO safety functions module on Slot 2 WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start work.

  • Page 119: Case 2: Fso Safety Functions Module Above The Control Unit

    Installation instructions 119 Case 2: FSO safety functions module above the control unit WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start work.

  • Page 120: Installing I/O Extension, Fieldbus Adapter And Pulse Encoder Interface Modules

    120 Installation instructions Installing I/O extension, fieldbus adapter and pulse encoder  interface modules See page for the available slots for each module. WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 121: Installation Example Of The Standard Drive Module Configuration

    Alternative parts that are available from the manufacturer are also given. Limitation of liability Always obey the general rules given in this chapter and local laws and regulations. Demag do not assume any liability whatsoever for any installation which breaches local laws and/or other regulations.

  • Page 122: Required Parts

    122 Installation example of the standard drive module configuration Required parts Drive module standard parts • Drive module • Fastening bracket • Pedestal guide plate • Telescopic extraction and insertion ramp • Fastening screws and insulators in a plastic bag •...

  • Page 123: Installing The Drive Module Into A Cabinet

    Installation example of the standard drive module configuration 123 Mount the external control unit. Mounting the external control unit, page Connect the control cables. Connecting the control cables to the terminals of the control unit, page Install the remaining parts, for example, cabinet The component manufacturer’s instructions.
  • Page 124 124 Installation example of the standard drive module configuration Step Task (motor cables) Connect the phase T2/V2 conductors to the T2/V2 connection terminal. Install the T1/U2 connection terminal to the insulators. See the warning in step 4. Connect the phase T1/U2 conductors to the T1/U2 terminal. Remove the plastic sheeting from the output clear plastic shrouds from both sides.

  • Page 125: Installing The Roof And Door (Rittal Parts)

    Installation example of the standard drive module configuration 125 Installing the roof and door (Rittal parts) This drawing shows a layout tested by the manufacturer. Rittal 7967.000 Rittal 3326.200 592 [23.31] 3AUA0000145776 Door Install these gratings as close to each other as possible. Remove the filter mats.

  • Page 126: Installing The Roof And Door (Abb Air Filters And Roof)

    126 Installation example of the standard drive module configuration Installing the roof and door (ABB air filters and roof) This drawing shows a layout tested by the manufacturer. ABB 3AUA0000125202 (IP20) ABB 3AUA0000114971 (IP42) ABB 3AUA0000117003 (IP20) ABB 3AUA0000117008 (IP42) 3AXD50000016652...

  • Page 127: Removing The Protective Covering From The Drive Module Air Outlet

    Installation example of the standard drive module configuration 127 Removing the protective covering from the drive module air outlet  WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature.
  • Page 128 128 Installation example of the standard drive module configuration...

  • Page 129: Installation Example With Full Cabling Panels (Option +H381)

    Installation example with full cabling panels (option +H381) 129 Installation example with full cabling panels (option +H381) Contents of this chapter In this chapter, the drive module is installed in a 400 mm wide Rittal TS 8 cabinet in a bookshelf way.

  • Page 130: Required Parts

    130 Installation example with full cabling panels (option +H381) Required parts The parts are used in this installation example: Drive module standard parts • Drive module • Top guide plate • Fastening bracket • Grounding busbar • Pedestal guide plate •...

  • Page 131: Overall Flowchart Of The Installation Process

    Installation example with full cabling panels (option +H381) 131 Overall flowchart of the installation process Step Task For instructions, see Install the Rittal parts and drive module Installing the mechanical accessories into the mechanical accessories into the cabinet. cabinet on page and appendix Step-by- step drawings for installing full cabling panels...

  • Page 132: Connecting The Power Cables

    132 Installation example with full cabling panels (option +H381) Connecting the power cables Connection diagram  (PE) (PE) ACS880-04 L1/U1 L2/V1 L3/W1 UDC- UDC+ L1/U1 L2/V1 L3/W1 UDC- UDC+ INPUT OUTPUT T1/U2 T2/V2 T3/W2 T1/U2 T2/V2 T3/W2 Motor For alternatives, see section Selecting the supply disconnecting device on page In the installing...

  • Page 133: Power Cable Connection Procedure

    Installation example with full cabling panels (option +H381) 133 External brake resistor (optional, see page 231). Common mode filter (optional, see page 65). du/dt filter (optional, see page 237). The drive module frame must be connected to the cabinet frame. See section Arranging the grounding inside the cabinet on page...
  • Page 134 134 Installation example with full cabling panels (option +H381) An example installation is shown below. WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. L1/U1, L2/V1, L3/W1 102 mm (4 in.) T1/U2, T2/V2, T3/W2 View without cabinet side plate in place.

  • Page 135: Installing The Drive Module Into The Cabinet

    Installation example with full cabling panels (option +H381) 135 Installing the drive module into the cabinet WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work: Open the support legs by pressing each leg a little down and turning it aside (1, 2).
  • Page 136 136 Installation example with full cabling panels (option +H381) 4. Attach the drive module lifting lugs to the cabinet frame with chains. 5. Push the drive module carefully into to the cabinet preferably with the help from another person. 6. Attach the grounding busbar that has been previously attached to the input cabling panel to the drive module.
  • Page 137 Installation example with full cabling panels (option +H381) 137...

  • Page 138: Assembly Drawing Of Installing The Drive Module To The Cabinet (Frame R10)

    138 Installation example with full cabling panels (option +H381) Assembly drawing of installing the drive module to the cabinet (frame R10)

  • Page 139: Assembly Drawing Of Installing The Drive Module To The Cabinet (Frame R11)

    Installation example with full cabling panels (option +H381) 139 Assembly drawing of installing the drive module to the cabinet (frame R11)

  • Page 140: Assembly Drawing Of Installing The Roof And Door

    140 Installation example with full cabling panels (option +H381) Assembly drawing of installing the roof and door This drawing shows a layout tested by the manufacturer. If you use ABB air filters, place them vertically in the positions shown in the drawing on page 126. Rittal 7967.000 Rittal 3326.200 3AUA0000145776...

  • Page 141: Removing The Protective Covering From The Drive Module Air Outlet

    Installation example with full cabling panels (option +H381) 141 Removing the protective covering from the drive module air outlet  WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature.

  • Page 142: Installing The Rubber Grommet

    142 Installation example with full cabling panels (option +H381) Installing the rubber grommet  To get IP20 degree of protection for the drive module, install the input power cables through the rubber grommet. Install the grommet as follows: 1. Cut adequate holes into the grommet for the input power cables. 2.

  • Page 143: Modular Design Of Rittal Ts8 Cabinets

    Installation example with full cabling panels (option +H381) 143 Modular design of Rittal TS8 cabinets  The design of the drive module with optional cabling panels (+H381) is optimized to the Rittal TS 8406.510 cabinet. To make space for the additional components, connect two or more TS8 cabinets together.
  • Page 144 144 Installation example with full cabling panels (option +H381)

  • Page 145: Installation Checklist

    Installation checklist 145 Installation checklist Contents of this chapter This chapter contains a list for checking the mechanical and electrical installation of the drive module. Installation checklist Go through the checklist below together with another person. WARNING! Obey the safety instructions in chapter Safety instructions.
  • Page 146 146 Installation checklist Check that … Drive option modules and other components Type and number of option modules and other equipment is correct. Option modules and other equipment are not damaged. Optional modules and terminals are labelled correctly. The placement of optional modules and other equipment inside the cabinet and on the cabinet door is correct.
  • Page 147 Installation checklist 147 Check that … Installation of the cabinet The drive cabinet has been attached to floor and also from top to the wall or roof. The ambient operating conditions agree with the specifications given in chapter Technical data. The cooling air will flow freely in and out of the drive cabinet, and air recirculation inside the cabinet will not be possible (air baffle plates are on place).
  • Page 148 148 Installation checklist...

  • Page 149: Start-Up

    Start-up 149 Start-up Contents of this chapter This chapter describes the start-up procedure of the drive. Start-up procedure 1. Only qualified electricians are allowed to start-up the drive. 2. Make sure that the installation of the drive module has been checked according to the checklist in chapter Installation checklist, and that the motor and driven equipment are...
  • Page 150 150 Start-up • For drives with resistor braking (option +D151), see also section Start-up on page 234. • For option +N7502, see also ACS880 drives with SynRM motors (option +N7502) supplement (3AUA0000145506 [English]). • For drives with ABB du/dt filter, check that bit 13 of parameter 95.20 HW options word 1 is switched on.

  • Page 151: Fault Tracing

    Fault tracing 151 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs with options +J410 Where Color When the LED is lit Control panel POWER Green Control unit is powered and +15 V is supplied to the control mounting platform panel.
  • Page 152 152 Fault tracing...

  • Page 153: Maintenance

    Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available from Demag. For more information, consult your local Demag Service representative. The maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions.

  • Page 154: Recommended Maintenance Intervals After Start-Up

    154 Maintenance Action Target Spare parts DC circuit capacitors reforming, spare modules and spare capacitors Tightness of terminals Dustiness, corrosion and temperature Heat sink cleaning Recommended maintenance intervals after start-up  Component Years from start-up Cooling Main cooling fan of drive module Circuit board compartment cooling fans of drive module NSIN filter cooling fan Aging...

  • Page 155: Heatsink

    Maintenance 155 Heatsink The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. Cleaning the interior of the heatsink  WARNING! Obey the safety instructions in chapter Safety instructions.

  • Page 156: Fans

    See the firmware manual for the actual signal which indicates the running time of the cooling fan. For resetting the running time signal after a fan replacement, please contact ABB. Replacement fans are available. Do not use other than Demag specified spare parts. Replacing the circuit board compartment cooling fan ...

  • Page 157: Replacing The Main Cooling Fans

    Maintenance 157 Replacing the main cooling fans  WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 158: Replacing The Standard Drive Module

    158 Maintenance Replacing the standard drive module Note: The replacement module must be of the same type as the original module: same type code and same option codes. WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
  • Page 159 Maintenance 159...

  • Page 160: Replacing The Drive Module With Option +H381

    160 Maintenance Replacing the drive module with option +H381 Note: The replacement module must be of the same type as the original module: same type code and same option codes. WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 161 Maintenance 161 8. Disconnect the power supply cable and the fiber optic cables from the external control unit and coil them on the top of the drive module. For drive modules with an internal control unit (option +P905): Detach the control unit from the drive module by undoing the fastening screws below the optional modules and turn the control unit and the cables aside.

  • Page 162: Capacitors

    It is not possible to predict a capacitor failure. The capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact Demag Service if a capacitor failure is suspected. Replacements are available. Do not use other than Demag specified spare parts.

  • Page 163: Replacing The Control Unit Battery

    Maintenance 163 Replacing the control unit battery Stop the drive and do the steps in section Precautions before electrical work on page before you start the work. To replace the control unit battery: 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 164: Replacing The Memory Unit

    164 Maintenance Replacing the memory unit When a drive module is replaced, the parameter settings can be retained by transferring the memory unit from the defective drive module to the new module. The memory unit is located in the control unit, see page 38. WARNING! Do not remove or insert the memory unit when the drive module is powered.

  • Page 165: Ordering Information

    This chapter lists some installation accessories which are not available. All other parts must be sourced from a third party by the system integrator. For more information, contact your local Demag representative. • See the installation examples for Rittal cabinet tested by the manufacturer in section...

  • Page 166: Brake Resistors

    166 Ordering information The control panel can be mounted on the cabinet door with the help of a door mounting kit. Type Description Ordering code Illustration Control panel with ACS-AP-W 75131646 Bluetooth can be delivered ACS-AP-I Control panel with optionally on request Door mounting kit DPMP-02: see page 37.
  • Page 167 Ordering information 167 Enclosure width / Kit code Ordering code Illustration Degree of protection 400 mm / IP42 A-4-X-024 3AUA0000117007 Instruction code: 3AUA0000116873 400 mm / IP54 A-4-X-027 3AXD50000009184 Instruction code: 3AXD50000009989 600 mm / IP20 A-6-X-022 3AUA0000117003 Instruction code: 3AUA0000116880...
  • Page 168 168 Ordering information Enclosure width / Kit code Ordering code Illustration Degree of protection 600 mm / IP42 A-6-X-025 3AUA0000117008 Instruction code: 3AUA0000116874 600 mm / IP54 A-6-X-028 3AXD50000009185 Instruction code: 3AXD50000009990 800 mm / IP20 A-8-X-023 3AUA0000117005 Instruction code: 3AUA0000116887 800 mm / IP42 A-8-X-026 3AUA0000117009...

  • Page 169: Air Outlet Kits

    Ordering information 169 Enclosure width / Kit code Ordering code Illustration Degree of protection 800 mm / IP54 A-8-X-029 3AXD50000009186 Instruction code: 3AXD50000010001 Air outlet kits  Note: The fan is to be ordered separately. Enclosure width / Kit code Ordering code Illustration Degree of protection...
  • Page 170 170 Ordering information Enclosure width / Kit code Ordering code Illustration Degree of protection 600 mm / IP42 A-6-X-061 3AUA00001149789 Instruction code: 3AUA0000115152 Note: Fan to be ordered separately 400 mm / IP54 (IEC) A-4-X-064 3AXD50000009187 800 mm / IP54 (IEC) Instruction code: 3AXD50000010284 Note: Fan to be ordered separately...

  • Page 171: Cooling Fans

    Ordering information 171 Enclosure width / Kit code Ordering code Illustration Degree of protection 600 mm / IP54 A-6-X-065 3AXD50000009189 (IEC) Instruction code: 3AXD50000010004 Note: Fan to be ordered separately 600 mm / IP54 A-6-X-066 3AXD50000010327 (UL) Instruction code: 3AXD50000010004 Note: Fan to be ordered separately Cooling fans One or two cooling fans are to be installed inside the air outlet compartment to ensure...

  • Page 172: Emc Filter Arfi-10

    172 Ordering information Enclosure width / Component Ordering code Degree of protection Name Data 800 mm / IP54 RB4C-355/170 3AXD50000006934 Capacitor MSB MKP 6/603/E1679 3AXD50000006959 Connector SPB2,5/7 (2.5 mm2, 12AWG) 3AXD50000000723 Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 3AXD50000000724 400 mm, 600 mm / IP20, R2E225-RA92-17 (230 V) 3AXD50000000514 IP42...

  • Page 173: Fso Accessories Kit

    Ordering information 173 FSO accessories kit Kit code Ordering code Illustration A-X-X-279 3AXD50000025495 Instruction code: 3AXD50000025583 Retrofit accessory kits Option Ordering code code Common mode filter kit E208 3AXD50000026145 Full size cable connection terminals for input power cables H370 3AXD50000019542 Full size cable connection terminals for output power cables 3AXD50000019544 For frame R10: Full power cabling panels to be attached to a cabinet...
  • Page 174 174 Ordering information...

  • Page 175: Technical Data

    Technical data 175 Technical data Contents of this chapter This chapter contains the technical specifications of the drive, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Marine type-approved drives (option +C132) See ACS880-01 /04+C132 marine type-approved drives supplement (3AXD50000010521 [English]) for the ratings, marine-specific data and reference to valid marine type approvals.
  • Page 176 176 Technical data IEC RATINGS Drive type Frame Input Output ratings size current Nominal use Light-duty use Heavy-duty use ACS880-04- max_ start 460A-5 503A-5 583A-5 635A-5 715A-5 1100 820A-5 1020 1100 880A-5 1100 1100 697** = 690 V 330A-7 370A-7 430A-7 360*** 470A-7...

  • Page 177: When Is Derating Needed

    The power ratings apply to most IEC 34 motors at the nominal voltage of the drive. We recommend to select the drive, motor and gear combination for the required motion profile with the Caldrive dimensioning tool available from Demag. When is derating needed ...

  • Page 178: Altitude Derating

    178 Technical data 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 179 Technical data 179 With other than recommended sine filters (see section Sine filters (on request only) page 238) and Ex motors of other manufacturers, contact Demag. Drive Output ratings for special settings module Ex motor (ABB Ex motor) ABB sine filter...

  • Page 180: High Speed Mode

    Contact Demag 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 181: Fuses (Iec)

    Technical data 181 Continuous rms output current allowing 10% overload for 1 minute every 5 minutes Typical motor power for light-overload use. Continuous rms output current allowing 50% overload for 1 minute every 5 minutes Continuous rms output current allowing 40% overload for 1 minute every 5 minutes Fuses (IEC) aR fuses for protection against short-circuit in the input power cable or drive are listed below.

  • Page 182: Fuses (Ul)

    182 Technical data Fuses (UL) UL fuses for branch circuit protection per NEC are listed below. Check that the operating time of the fuse is below 0.1 seconds. The operating time depends on the fuse type, supply network impedance and the cross-sectional area, material and length of the supply cable.

  • Page 183: Dimensions, Weights And Free Space Requirements

    Technical data 183 Dimensions, weights and free space requirements Standard drive module configuration Frame Height Width Depth Weight* size 1541 60.67 14.82 19.92 1741 68.54 14.82 19.92 Optional selection +0B051+0H371 (without shrouds and full-size output power cable connection terminals) Frame Height Width Depth...

  • Page 184: Losses, Cooling Data And Noise

    184 Technical data Losses, cooling data and noise Drive type Frame size Air flow Heat dissipation Noise /min dB(A) = 400 V ACS880-04-505A-3 1200 5602 ACS880-04-585A-3 1200 6409 ACS880-04-650A-3 1200 8122 ACS880-04-725A-3 1200 8764 ACS880-04-820A-3 1200 9862 ACS880-04-880A-3 1420 10578 = 500 V ACS880-04-460A-5 1200...

  • Page 185: Mode Filter (+E208)

    It is possible to use the maximum cable size (4 × [3 × 240] mm2 or 4 ×[(3 × 500 AWG]) only with special cable lugs and additional insulation. For more information, contact your local Demag representative. Terminal data for the control cables See page 108.

  • Page 186: Dc Connection Data

    186 Technical data DC connection data Drive type Capacitance (mF) = 400 V ACS880-04-505A-3 ACS880-04-585A-3 ACS880-04-650A-3 ACS880-04-725A-3 ACS880-04-820A-3 1033 ACS880-04-880A-3 1120 = 500 V ACS880-04-460A-5 ACS880-04-503A-5 ACS880-04-583A-5 ACS880-04-635A-5 ACS880-04-715A-5 ACS880-04-820A-5 1033 ACS880-04-880A-5 1120 = 690 V ACS880-04-330A-7 ACS880-04-370A-7 ACS880-04-430A-7 ACS880-04-470A-7 ACS880-04-522A-7 ACS880-04-590A-7 ACS880-04-650A-7...

  • Page 187: Control Unit Connection Data (Zcu-14)

    Technical data 187 Control unit connection data (ZCU-14) Power supply 24 V (±10%) DC, 2 A (XPOW) External power supply in. With some drive module sizes, not used as the control unit is supplied from the drive module. Connector pitch 5 mm, wire size 2.5 mm Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3)
  • Page 188 188 Technical data Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm (XD2D) Physical layer: RS-485 Termination by jumper Safe torque off connection Connector pitch 5 mm (0.2 in), wire size 2.5 mm2 (14 AWG) (XSTO) Input voltage range: -3…30 V DC Logic levels: “0”...

  • Page 189: Control Panel Type

    Technical data 189 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 XSTO OUT1 Ground * Ground selector (J6) settings (ZCU-14)

  • Page 190: Efficiency

    190 Technical data Efficiency Approximately 98% at nominal power level Protection classes Degree of protection IP20, requires installation of bottom grille for standard drive module (IEC/EN 60529) configuration and option +H0354, see page 98. With option +0B051: IP00. Enclosure type (UL 508C) UL Open Type Overvoltage category (IEC 60664-1)

  • Page 191: Materials

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

  • Page 192: Ce Marking

    192 Technical data EN 61800-3:2004 +A1:2012 Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific test methods UL 508C (3rd edition) UL Standard for Safety, Power Conversion Equipment, third edition CSA-C22.2 No. 0-10 General Requirements - Canadian Electrical Code, Part II CSA C22.2 No.

  • Page 193: Category C2

    Technical data 193 Note: A professional is a person or organization having necessary skills in installing and/or starting up power drive systems, including their EMC aspects. Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment.

  • Page 194: Ul Marking

    Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local Demag representative. 3. The motor and control cables are selected as specified in the hardware manual. 4. The drive is installed according to the instructions given in the hardware manual.

  • Page 195: Csa Marking

    Technical data 195 installation in the United States, also obey any other applicable local codes. For installation in Canada, also obey any applicable provincial codes. Note: Circuit breakers must not be used without fuses in the USA. See page suitable circuit breakers. •...

  • Page 196: Cybersecurity Disclaimer

    196 Technical data (iii) has been used in a manner contrary to the manufacturer's instructions; or (iv) has failed as a result of ordinary wear and tear. Cybersecurity disclaimer  This product is designed to be connected to and to communicate information and data via a network interface.

  • Page 197: Dimension Drawings

    Dimension drawings 197 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules with optional parts for Rittal TS 8 cabinet assembly.

  • Page 198: R10 - Standard Configuration

    198 Dimension drawings R10 – Standard configuration...

  • Page 199: R10 With Options +E208+H370+J414+P905

    Dimension drawings 199 R10 with options +E208+H370+J414+P905...

  • Page 200: R10 With Options +0B051+C173+E208+H356+0H354+0H371

    200 Dimension drawings R10 with options +0B051+C173+E208+H356+0H354+0H371...

  • Page 201: R10 With Options +0B051+E208+H356+0H371

    Dimension drawings 201 R10 with options +0B051+E208+H356+0H371...

  • Page 202: R10 With Options +E208+H356+H381+J414+P905

    202 Dimension drawings R10 with options +E208+H356+H381+J414+P905...

  • Page 203: R10 - Cabling Panels (+H381) Installed Into A Rittal Ts 8 Cabinet

    Dimension drawings 203 R10 – Cabling panels (+H381) installed into a Rittal TS 8 cabinet...

  • Page 204: Frame R10 With Options +E208+H370+H391+0J400

    204 Dimension drawings Frame R10 with options +E208+H370+H391+0J400...

  • Page 205: R11 - Standard Configuration

    Dimension drawings 205 R11 – Standard configuration...

  • Page 206: R11 With Options +E208+H370+J414+P905

    206 Dimension drawings R11 with options +E208+H370+J414+P905...

  • Page 207: R11 With Options +0B051+E208+H356+0H371

    Dimension drawings 207 R11 with options +0B051+E208+H356+0H371...

  • Page 208: R11 With Options +E208+H356+H381+J414+P905

    208 Dimension drawings R11 with options +E208+H356+H381+J414+P905...

  • Page 209: R11 With Options +0B051+C173+E208+H356+0H354+0H371

    Dimension drawings 209 R11 with options +0B051+C173+E208+H356+0H354+0H371...

  • Page 210: Frame R11 - Cabling Panels (+H381) Installed Into A Rittal Ts 8 Cabinet

    210 Dimension drawings Frame R11 – Cabling panels (+H381) installed into a Rittal TS 8 cabinet...

  • Page 211: Bottom Plate For Option +H381 In Rittal Ts 8 400 Mm Wide Cabinet Installation

    Dimension drawings 211 Bottom plate for option +H381 in Rittal TS 8 400 mm wide cabinet installation Note: The bottom plate has to be provided by the customer. Put nut PEM-S-M8-2 or equal (2 pcs) Cable lead-through area 3AUA0000082240...

  • Page 212: Frame R11 With Options +E208+H370+H391+0J400

    212 Dimension drawings Frame R11 with options +E208+H370+H391+0J400...

  • Page 213: Air Baffles For The Standard Drive Module And Option +C173

    Dimension drawings 213 Air baffles for the standard drive module and option +C173 This drawing shows the dimensions of the hole in the air baffle around the standard drive module and flat mounting option +C173. The drawing also shows the correct vertical location area of the air baffle as measured from the top grill.

  • Page 214: Air Baffles For Option +H381 In Rittal Ts 8 400 Mm Wide Cabinet Installation

    214 Dimension drawings Air baffles for option +H381 in Rittal TS 8 400 mm wide cabinet installation Note: These air baffles have to be provided by the customer.

  • Page 215: External Control Unit

    Dimension drawings 215 External control unit 3axd50000011687...
  • Page 216 216 Dimension drawings...

  • Page 217: Example Circuit Diagram 217

    Example circuit diagram 217 Example circuit diagram Contents of this chapter This chapter shows an example circuit diagram for a cabinet-installed drive module.

  • Page 218: Example Circuit Diagram

    218 Example circuit diagram Example circuit diagram This diagram is an example for the main wiring of a drive cabinet. Note that the diagram includes components which are not included in a basic delivery (* plus code options, ** other options, *** to be acquired by the customer).

  • Page 219: Safe Torque Off Function

    Safe torque off function 219 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 The Safe torque off function can be used, for example, to construct safety or supervision circuits that stop the drive in case of danger (such as an emergency stop circuit).

  • Page 220: Compliance With The European Machinery Directive

    220 Safe torque off function Standard Name IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 1: General requirements IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 2: Requirements for electrical/electronic/programmable electronic safety-related systems IEC 61511-1:2016 Functional safety –...

  • Page 221: Grounding Of Protective Shields

    Safe torque off function 221 Maximum cable lengths: • 300 m (984 ft) between activation switch [K] and drive control unit • 60 m (200 ft) between multiple drives • 60 m (200 ft) between external power supply and first drive. Note that the voltage at the INx terminals of each control unit must be at least 17 V DC to be interpreted as “1”.

  • Page 222: Single-Channel Connection

    222 Safe torque off function Single-channel connection Inverter unit Control unit OUT1 +24 V SGND Notes: • 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 223: Multiple Drives (Internal Power Supply)

    Safe torque off function 223 Multiple drives (internal power supply)  ACS880-04 Control unit XSTO OUT1 +24 V SGND ACS880-04 Control unit XSTO OUT1 SGND ACS880-04 Control unit XSTO OUT1 SGND...

  • Page 224: Multiple Drives (External Power Supply)

    224 Safe torque off function Multiple drives (external power supply)  24 V DC ACS880-04 – Control unit XSTO OUT1 +24 V SGND ACS880-04 Control unit XSTO OUT1 SGND ACS880-04 Control unit XSTO OUT1 SGND...

  • Page 225: Operation Principle

    Safe torque off function 225 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. STO inputs on the drive control unit de-energize. 3. The control unit cuts off the control voltage from the drive IGBTs. 4.
  • Page 226 226 Safe torque off function Action Close the disconnector and switch the power on. 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. Ensure that the drive operates as follows: •...

  • Page 227: Use

    Safe torque off function 227 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. STO inputs on the drive control unit de-energize, and the drive control unit cuts off the control voltage from the drive IGBTs. 3.

  • Page 228: Maintenance

    228 Safe torque off function Notes: • If a running drive is stopped by using the Safe torque off function, the drive will cut off the motor supply voltage and the motor will coast to a stop. If this causes danger or is not otherwise acceptable, stop the drive and machinery using the appropriate stop mode before activating the Safe torque off function.

  • Page 229: Safety Data

    Any failures of the Safe torque off function must be reported to the manufacturer. Please contact your Demag representative. Safety data Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used.
  • Page 230 230 Safe torque off function Abbr. Reference Description IEC 61508 Failure in time: 1E-9 hours IEC 61508 Hardware fault tolerance MTTF EN ISO 13849-1 Mean time to dangerous failure: (The total number of life units) / (the number of dangerous, undetected failures) during a particular measurement interval under stated conditions IEC 61508 Average probability of failure on demand...

  • Page 231: Resistor Braking

    Resistor braking 231 Resistor braking Contents of this chapter This chapter describes how to select, protect and wire brake choppers and resistors. You can find the technical data of the brake resistors in the manual „Technical data Drives Accessories“. Operation principle and hardware description The dive can be equipped with optional built-in brake chopper (+D150).

  • Page 232: Selecting A Custom Resistor

    232 Resistor braking 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. Selecting a custom resistor  If you use a resistor other than the default resistor, make sure that: 1.

  • Page 233: Minimizing Electromagnetic Interference

    Resistor braking 233 Minimizing electromagnetic interference Obey these rules in order to minimize electromagnetic interference caused by the rapid current changes in the resistor cables: • Shield the braking power line completely, either by using shielded cable or a metallic enclosure.

  • Page 234: Protecting The Resistor Cable Against Short-Circuits

    234 Resistor braking A thermal switch (standard in some 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. +24VD Θ...

  • Page 235: Technical Data

    Resistor braking 235 WARNING! If the drive is equipped with a brake chopper but the chopper is not enabled by the parameter setting, the internal thermal protection of the drive against resistor overheating is not in use. In this case, the brake resistor must be disconnected.
  • Page 236 236 Resistor braking...

  • Page 237: Du/Dt And Sine Filters

    du/dt and sine filters 237 du/dt and sine filters Contents of this chapter This chapter describes how to select du/dt and sine filters for the drive. du/dt filters When is a du/dt filter needed?  See section Examining the compatibility of the motor and drive, page 64.

  • Page 238: Selection Table

    238 du/dt and sine filters Selection table  du/dt filter types for the drive modules are given below. Drive module du/dt filter type Drive module du/dt filter type Drive module du/dt filter type type type type ACS880-04- ACS880-04- ACS880-04- = 400 V = 500 V = 690 V 505A-3...

  • Page 239: Derating

    239 Derating  See section Deratings for special settings in the drive control program on page 180. Description, installation and technical data of the sine filters  See Sine filters hardware manual (3AXD50000016814 [English]). For more information, contact Demag.
  • Page 240 240 du/dt and sine filters...
  • Page 241 Step-by-step drawings for an installation example of standard drive configuration with option +E208 in Rittal TS 8 600 mm wide cabinet 241 Step-by-step drawings for an installation example of standard drive configuration with option +E208 in Rittal TS 8 600 mm wide cabinet Tapping screw M6×12 Torx Combi screw M8×30 (Hex) Tapping screw M6×12 Torx...
  • Page 242 242 Step-by-step drawings for an installation example of standard drive configuration with option +E208 in Rittal TS 8 600 mm wide cabinet Combi screw M12×25 Hex 70 N·m Combi screw M8×16 Hex Hex nut M12 70 N·m Combi screw M6×12 Torx T25 20 N·m Combi screw M12×25 Hex Washer M12 or equal...
  • Page 243 Step-by-step drawings for an installation example of standard drive configuration with option +E208 in Rittal TS 8 600 mm wide cabinet 243 Hex nut M12 70 N·m Washer M12 or equal Hex screw M12×35 full thread 70 N·m Washer M12 or equal Combi screw M4×10 Torx T20 2 N·m Combi screw M6×20...
  • Page 244 244 Step-by-step drawings for an installation example of standard drive configuration with option +E208 in Rittal TS 8 600 mm wide cabinet...

  • Page 245: Step-By-Step Drawings For Installing Full Cabling Panels (Option +H381) In A Rittal Ts 8 400 Mm Wide Cabinet

    Step-by-step drawings for installing full cabling panels (option +H381) in a Rittal TS 8 400 mm wide cabinet 245 Step-by-step drawings for installing full cabling panels (option +H381) in a Rittal TS 8 400 mm wide cabinet Rittal 8406.510 Rittal 8612.160 (5 pcs) Rittal 8612.140 (3 pcs) Tapping screw M6×12 (3 pcs) 8 N·m...
  • Page 246 246 Step-by-step drawings for installing full cabling panels (option +H381) in a Rittal TS 8 400 mm wide cabinet ABB parts Output cabling panel Side guide (2 pcs) Input cabling panel Telescopic extraction and insertion ramp Tapping screw M6×12 Torx T30 (Hex) (4 pcs) Combi screw M4×8 Torx T20 (4 pcs)

  • Page 247: Step-By-Step Drawings For A Flat Installation Example In Rittal Ts 8 600 Mm Wide Cabinet 247

    Step-by-step drawings for a flat installation example in Rittal TS 8 600 mm wide cabinet 247 Step-by-step drawings for a flat installation example in Rittal TS 8 600 mm wide cabinet Rittal 8606.500 Rittal 8612.160 Combi screw M10×25 Hex 40 N·m Tapping screw M6×12 Torx T30 (Hex) 9 N·m Tapping screw M6×12 Torx T30 (Hex) 9 N·m Combi screw M10×25 Hex 40 N·m...
  • Page 248 248 Step-by-step drawings for a flat installation example in Rittal TS 8 600 mm wide cabinet...
  • Page 249 Step-by-step drawings for option +H391 installation example in Rittal TS 8 600 mm wide cabinet 249 Step-by-step drawings for option +H391 installation example in Rittal TS 8 600 mm wide cabinet Hex nut M10 40 N·m Rittal 8606.500 Rittal 8612.160 M8×20 Hex 20 N·m Combi screw M4×8...
  • Page 250 250 Step-by-step drawings for option +H391 installation example in Rittal TS 8 600 mm wide cabinet...
  • Page 252 PO Box 67 · 58286 Wetter (Germany) Phone +49 (0)2335 92-0 +49 (0)2335 92-7676 www.demagcranes.com Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter (Germany) Subject to change. Not liable for errors or omissions.

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