ABB ACS880-107 Hardware Manual

Inverter units

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ABB INDUSTRIAL DRIVES

ACS880-107 inverter units

Hardware manual

Table of Contents

Summary of Contents for ABB ACS880-107

Page 1 — ABB INDUSTRIAL DRIVES ACS880-107 inverter units Hardware manual...
Page 3 ACS880-107 inverter units Hardware manual Table of contents 3. Electrical installation 6. Start-up 3AUA0000102519 Rev G Original instructions EFFECTIVE: 2023-12-28...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter ............... . Applicability .
Page 6 6 Table of contents Charging switch (frame R8i and multiples only) ........Type designation labels .
Page 7 Table of contents 7 Connecting the emergency stop push buttons (options +Q951, +Q952, +Q963, +Q964, +Q978,+Q979) ..............Connecting the emergency stop push buttons (option +Q951) .
Page 8 8 Table of contents Replacing the roof outlet filters (IP54) ........... Cleaning the heatsink .
Page 9 Table of contents 9 Output terminals (frames R6i…R7i) ............Output terminals (frame R8i) .
Page 10 10 Table of contents Wiring ....................Activation switch .
Page 11: Introduction To The Manual
Introduction to the manual Contents of this chapter This chapter gives basic information on the manual. Applicability This manual is applicable to air-cooled ACS880-107 inverter units. Safety instructions Obey all safety instructions of the drive. • Read the complete safety instructions before you install, commission, use or service the drive.
Page 12: Categorization By Frame Size, Option Code And Item Designation
12 Introduction to the manual Categorization by frame size, option code and item designation Some descriptions, instructions, technical data and dimensional drawings which concern only a certain group of units may be marked with the symbol of the frame size (such as “R2i”, “4×R8i”, etc.). The marking derives from the quantity and basic construction of the inverter modules that form the inverter unit.
Page 13: Related Documents
Supply module(s) under control of one control unit, and related components. Uninterruptible power supply Type of control unit Related documents You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. Manuals for ACS880 multidrives cabinets...
Page 15: Operation Principle And Hardware Description
Contents of this chapter This chapter describes a typical drive system and the hardware of the inverter unit. The information is valid for all ACS880-107 inverter units. Overview diagram of the drive system The diagram that follows shows an example of a multidrive. The supply unit connects the drive to the AC supply network.
Page 16 16 Operation principle and hardware description Incoming unit Supply unit Inverter unit Brake unit (optional) AC supply Main breaker, or main contactor and main switch-disconnector Input (AC) fuses Supply module DC bus Supply and inverter module DC fuses DC switch/disconnector (optional) Inverter modules Brake chopper fuses 3-phase brake chopper module (optional)
Page 17: Inverter Unit Hardware
ACS880-107 inverter units range from 1.5 to 5600 kW in power. ACS880-107 inverter units employ inverter modules from frame size R1i to R8i. Up to approximately 500 kW, inverter units consist of one module only;...
Page 18: Inverter Module Frame Sizes R1I
18 Operation principle and hardware description Inverter module frame sizes R1i…R4i ￭ General The motor (output) cables are connected to either detachable or non-detachable screw terminal blocks at the bottom of the cubicle. The modules have a built-in ZCU drive control unit, which contains the basic I/Os and slots for optional I/O modules.
Page 19: Standard Cabinet Layout
Operation principle and hardware description 19 Frame R4i (Frame R3i has a similar layout) Item Explanation Power unit DC (input) connections (under connector cover) Motor (output) connection (under connector cov- er). This has been wired to a separate terminal block in the lower part of the cubicle. ZCU-14 control unit mounted on top of the power unit Grounding/strain relief rail for control cables...
Page 20: Layout Of Cubicle With Frame R1I
20 Operation principle and hardware description Item Explanation Main DC switch fuse for all units in the cubicle (optional) or main DC fuses DC fuse disconnectors for each individual module Three frame R1i inverter modules Frame R3i inverter module Two frame R4i inverter modules Output connections Cable entries Air outlet compartment with cabinet cooling fan...
Page 21 Operation principle and hardware description 21 Each module has a dedicated DC switch-disconnector. When the switch-disconnector is open, the door to that particular compartment can be opened. It is also allowable to replace the module, its cooling fan, or its DC fuses. The motor (output) connections for each module are located at the lower part of the cubicle;...
Page 22 22 Operation principle and hardware description This illustration shows an example of a 400 mm wide cubicle with three R1i…R4i modules. Compartment (doors closed) Compartment (doors open) Item Explanation Main DC switch-disconnector handle for all units in the cubicle Compartments for inverter mod- ules (with DC switch-disconnector handle) Output connections...
Page 23: Inverter Module Frame Size R5I
Operation principle and hardware description 23 Inverter module frame size R5i ￭ General The motor (output) cables are connected to either detachable or non-detachable screw terminal blocks at the bottom of the cubicle. The modules have a built-in ZCU drive control unit, which contains the basic I/Os and slots for optional I/O modules.
Page 24: Layout Of Cubicle With Frame R5I Modules In Their Own Compartments (Option +C204)
24 Operation principle and hardware description This illustration shows an example of a 500 mm wide cubicle with four R5i modules. Item Explanation Main DC switch for all units in the cubicle (option- al) and main DC fuses DC fuse disconnectors for each individual module R5i inverter modules (with ZCU-12 control units) Output connections Output cable entries...
Page 25 Operation principle and hardware description 25 Each module has a dedicated DC switch-disconnector. When the switch-disconnector is open, the door to that particular compartment can be opened. It is also allowable to replace the module, its cooling fan, or its DC fuses. The motor (output) connections for each module are located at the lower part of the cubicle.
Page 26: Inverter Module Frame Sizes R6I And R7I
26 Operation principle and hardware description Inverter module frame sizes R6i and R7i ￭ The inverter cubicle is equipped with cable entries for the motor cables in the floor of the cubicle. As standard, the output busbars are extended to the lower part of the cubicle for easy access.
Page 27: Motor Cabling
Operation principle and hardware description 27 This illustration shows an example of a cubicle with an R6i/R7i inverter module. Item Explanation Air outlet DC fuses DC switch-disconnector (behind DC fuses and mounting plate) (optional) Charging contactor (R7i only) (optional) Charging resistors (R7i only) (optional) Common mode filters Inverter module Inverter module cooling fan(s)
Page 28: Inverter Module Frame Size R8I And Multiples
28 Operation principle and hardware description Inverter module frame size R8i and multiples ￭ This figure shows the layout of the R8i module. R8i module, front R8i module, back DC busbars Handle LEDs and fiber optic connectors Fan (standard speed-controlled fan shown; a direct-on-line fan is available as option +C188) Quick connector (three phases).
Page 29: Cooling Fans
Operation principle and hardware description 29 Cooling fans The cooling fan unit at the base of the inverter module contains two DC fans. The fans are PWM-controlled according to an internal temperature measurement. The fan carriage can be easily removed for fan replacement, or to allow access to the output cable connections at the back of the cubicle.
Page 30 30 Operation principle and hardware description This illustration shows a cubicle with two R8i inverter modules with shrouding removed. The top compartment of the cubicle is shown with and without optional DC switch-disconnector and charging components. Item Explanation Without DC switch-disconnector Side view Front view Inverter modules...
Page 31: Motor Cabling
Operation principle and hardware description 31 The illustration that follows shows an example of a 300 mm wide control equipment cubicle. Front view Item Explanation Terminal block for auxiliary voltage distribution 24 V DC power supply for control circuits Circuit breakers for control voltages Space for installation of items 2 and 3 for a second inverter unit (On the left-hand side wall) Terminal blocks for...
Page 32: Control Interfaces
1, 2, 3 FSO safety functions module 2 (X12) 1) When installed into slot 3 of a ZCU-14 control unit, the module will extend over the edge. ABB recommends that you use slot 1 or 2 instead whenever possible. Memory unit Connector for FSO safety functions module (X12).
Page 33: Overview Of The Control Connections Of The Bcu Control Unit
Operation principle and hardware description 33 Control panel Overview of the control connections of the BCU control unit ￭ Analog and digital I/O extension modules and Control panel. fieldbus communication modules can be in- serted into slots 1, 2 and 3. Memory unit Fiber optic links to power modules (inverter, supply, brake or converter)
Page 34: Control By Pc Tools
34 Operation principle and hardware description The control panel can be mounted on a platform on the inverter cubicle door. The maximum number of platforms on one door is four, but one control panel can be used to control several units through a panel link. For details on the control panel, see ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels user's manual (3AUA0000085685...
Page 35: Type Designation Labels
Operation principle and hardware description 35 closes the charging switch. After the precharging completes, a green light [H1] on the cabinet door illuminates. The DC switch-disconnector can now be closed, and the charging switch opened. Note: The charging switch must be opened before the inverter unit can be started. Type designation labels Inverter unit type designation label ￭...
Page 36 36 Operation principle and hardware description Examples of the labels are shown below. Type designation. Frame size. Degree of protection; additional UL/CSA specifications. Ratings. The labels show ratings for inverter module (INVERTER), IGBT supply module (LINE CON- VERTER), brake chopper module (BRAKE CHOPPER), regenerative rectifier module (REGENERATIVE RECTIFIER) and DC/DC converter module (DC/DC CONVERTER).
Page 37: Type Designation Key
Operation principle and hardware description 37 Type designation key Type designation key of the inverter unit ￭ The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic drive type. The optional selections are given thereafter, separated by plus signs, eg, +E202.
Page 38 38 Operation principle and hardware description Code Description C180 Seismic design C188 Direct-on-line module cooling fans C204 Modules in their own compartments C205 Marine product certification issued by DNV GL C206 Marine product certification issued by the American Bureau of Shipping (ABS) C207 Marine product certification issued by Lloyd's Register (LR) C209...
Page 39 Operation principle and hardware description 39 Code Description H351 Power cabling entry from top H352 Power cabling exit from bottom H353 Power cabling exit from top H358 Cable gland plates (3 mm steel, undrilled) H359 Common motor terminal cubicle H364 Cable gland plates (3 mm aluminum, undrilled) H365 Cable gland plates (6 mm brass, undrilled)
Page 40 40 Operation principle and hardware description Code Description L505 Thermal protection with PTC relays (1 or 2 pcs) L506 Thermal protection with Pt100 relays (3, 5 or 8 pcs) L508 FDCO-02 optical DDCS communication adapter module L509 RDCO-04 optical DDCS communication module (4×Transmitter/Receiver) L513 ATEX-certified thermal protection with PTC relays (1 or 2 pcs) L514...
Page 41: Type Designation Key Of The Inverter Module
Operation principle and hardware description 41 Code Description P948 Customized extended warranty P966 Special color (other than RAL Classic) P967 High-speed variant Prevention of unexpected start-up with FSO safety functions module, by activating the Safe Q950 torque off function Q951 Emergency stop (category 0) with safety relays, by opening the main breaker/contactor Q952 Emergency stop (category 1) with safety relays, by opening the main breaker/contactor...
Page 42 42 Operation principle and hardware description The subcodes are described below. Code Description Basic codes ACS880 Product series Construction: Inverter, supply, converter or brake module. Size xxxxx Refer to the ratings table in the technical data. Voltage range 513…566 V DC. This is indicated in the type designation label as typical input voltage level (566 V DC).
Page 43: Electrical Installation
Electrical installation 43 Electrical installation Contents of this chapter This chapter describes the electrical installation of the inverter units. The circuit diagrams in this chapter are simplified presentations. Refer to the diagrams delivered with the drive system for details. For more information on cable selection, protections, etc., see ACS880 multidrive cabinets and modules electrical planning instructions (3AUA0000102324 [English]).
Page 44: Electrical Safety Precautions
44 Electrical installation Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. This procedure gives information on how to de-energize the drive and make it safe to do work on it. The procedure does not include all possible drive configurations. Each drive is made to order.
Page 45: General Notes
Electrical installation 45 structures, obey the local laws and regulations applicable to live working (including – but not limited to – electric shock and arc protection). • Before and after you measure the installation, verify the operation of the voltage tester on a known voltage source. •...
Page 46: 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 47: Connecting The Motor Cable - Frame Sizes R1I
Electrical installation 47 Connecting the motor cable – Frame sizes R1i…R5i Connection diagram ￭ Inverter unit 360° grounding at cable entry Use a separate grounding cable if the conductivity of the cable shield is less than 50% of the conductivity of the phase conductor in a cable with no symmetrically constructed grounding conductor.
Page 48 48 Electrical installation Cut the cable to suitable length and strip the ends of the individual conductors. Twist the shield strands of the cable together to form a separate conductor and crimp a ferrule onto it. (With frame R4i, connect the cable shield to the PE busbar using a crimp ring terminal.) Connect the conductors to terminal block/connector X1.
Page 49: Connecting The Motor Cable - Frame Sizes R6I And R7I
Electrical installation 49 Connecting the motor cable – Frame sizes R6i and R7i Connection diagram ￭ Inverter unit 360° grounding at cable entry Use a separate grounding cable if the conductivity of the cable shield is less than 50% of the conductivity of the phase conductor in a cable with no symmetrically constructed grounding conductor.
Page 50 50 Electrical installation Run the cable into the cubicle through the cable cable entries provided. In case a grounding cable gland is available, remove the outer jacket of the cable where it passes through the cable gland (a). Cut the cable to suitable length and strip the ends of the individual conductors. Twist the shield strands together to form a separate conductor and wrap it with tape.
Page 51 Electrical installation 51 b > 1/5 · a...
Page 52: Motor Terminal Cubicle Or Sine Output Filter
52 Electrical installation Connecting the motor cables – Frame size R8i and multiples without common motor terminal cubicle or sine output filter On units without a common motor terminal cubicle or a sine output filter, the motor cables connect to busbars located behind the inverter module(s). The location and dimensions of the busbars are shown in the dimension drawings delivered with the drive and in the example drawings in this manual.
Page 53: Procedure
Electrical installation 53 the modules, which allows more cabling options. For example, it is possible to use a number of cables that could not otherwise be evenly distributed between the inverter modules. Bridging busbars Inverter unit cubicle(s) The recommended cable types are given in the technical data. WARNING! The bridging can carry the nominal output of one inverter module.
Page 54: Removing The Fan Carriage Of An Inverter Module
54 Electrical installation Removing the fan carriage of an inverter module Refer to the drawings below. WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
Page 55 Electrical installation 113 Electrical installation 55...
Page 56: Connecting The Motor Cables
56 Electrical installation Connecting the motor cables Refer to the drawings below. WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
Page 57 Electrical installation 57 360° grounding detail...
Page 58: Installing The Fan Carriage Of An Inverter Module
58 Electrical installation Installing the fan carriage of an inverter module If the inverter module was removed completely instead of only the fan carriage, proceed to section Installing an inverter module (page 131). The installation of the fan carriage is the removal procedure in reverse. See section Removing the fan carriage of an inverter module (page 54).
Page 59: Terminal Cubicle
Electrical installation 59 Connecting the motor cables – Frame size R8i and multiples with common motor terminal cubicle Output busbars ￭ If the drive is equipped with option +H359, the motor cables connect to a common motor terminal cubicle. Similarly, if the drive is equipped with option +E206 (sine output filter), the motor cables connect to the output busbars in the sine filter cubicle.
Page 60 60 Electrical installation Grommet Cut the cables to suitable length. Strip the cables and conductors. Twist the cable screens into bundles and connect the bundles to the PE busbar in the cubicle. Connect any separate ground conductors/cables to the PE busbar in the cubicle. Refer to section Use of fasteners in cable lug connections (page 61).
Page 61: Use Of Fasteners In Cable Lug Connections
Electrical installation 61 Use of fasteners in cable lug connections ￭ Use the bolts, nuts and washers delivered with the drive. Install all the fasteners in the correct order. See the figure below. Tighten the cable lug to the torque specified for the connection.
Page 62: Installing Optional Modules On The Control Unit
62 Electrical installation Installing optional modules on the control unit Installing an FSO safety functions module (frame sizes R1i…R7i) ￭ If you need to install multiple optional modules on the control unit, install the FSO module first. WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]).
Page 63: Installing An Fso Safety Functions Module (Frame Sizes R8I And Multiples)
Electrical installation 63 View of ZCU-14 Installing an FSO safety functions module (frame sizes R8i and ￭ multiples) WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
Page 64 64 Electrical installation Attach the FSO module onto slot 3 of the BCU control unit [A41] with four screws. Torque the FSO module electronics grounding screw to 0.8 N·m (7.1 lbf·in). Note: The screw tightens the connections and grounds the module. It is essential for fulfilling the EMC requirements and for proper operation of the module.
Page 65: Installation Of I/O Extension, Fieldbus Adapter And Pulse Encoder Interface Modules
Electrical installation 65 Installation of I/O extension, fieldbus adapter and pulse encoder ￭ interface modules WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Pay attention to the free space required by the cabling or terminals coming to the option modules.
Page 66: Connecting The Control Cables
66 Electrical installation Connecting the control cables See the control unit chapter for the default I/O connections. Note that the default I/O connections can be affected by some options. See the circuit diagrams delivered with the drive for the actual wiring. Control cable connection procedure ￭...
Page 67 Electrical installation 67 If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the peeled part. Be careful not to cut the conductors or the grounding wire. • Turn the conductive side of the shield inside out over the insulation. •...
Page 68: Routing The Control Cables Inside The Cabinet
68 Electrical installation Routing the control cables inside the cabinet Use the existing trunking in the cabinet where possible. Use sleeving if cables are laid against sharp edges. When running cables to or from a swing-out frame, leave enough slack at the hinge to allow the frame to open fully. Connecting control cabling Connect the conductors to the appropriate terminals.
Page 69: Connecting A 230/115 V Ac Auxiliary Voltage Supply (Ups, Option +G307)
Electrical installation 69 The drawing below represents the grounding of the control cabling when connecting to a terminal block inside the cabinet. The grounding is done in the same way when connecting directly to a component such as the control unit. Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) Wire the external control voltage to terminal block X307 as shown below.
Page 70: Connecting The Emergency Stop Push Buttons (Option +Q951)
70 Electrical installation Connecting the emergency stop push buttons (option +Q951) Connect external emergency stop push buttons (if any) according to the circuit diagrams delivered with the drive. Wiring the starter for auxiliary motor fan (options +M6xx) Connect the power supply wires for the auxiliary motor fan to terminal blocks X601…X605 according to the circuit diagrams delivered with the drive.
Page 71: Wiring The Pt100 Relays (Option +Nl514)
Electrical installation 71 X506 1 × Pt100 Sensor 1 Sensor 2 … … … Sensor 8 Internal wiring for overheat indication Overtemperature = contact open. Sensors 1 to 3 Sensors 4 and 5 Sensors 6 to 8 Wiring the Pt100 relays (option +nL514) External wiring of three Pt100 sensor modules is shown below.
Page 72: Connecting A Pc
104 Electrical installation Powering the heating and lighting equipment (options +G300, +G301 and +G313) 72 Electrical installation See the circuit diagrams delivered with drive. Connect the external power supply wires for the cabinet heater and lighting to terminal Connect the external power supply wires for the cabinet heater and lighting to terminal block X300 at the back of the mounting plate.
Page 73: Panel Bus (Control Of Several Units From One Control Panel)
Electrical installation 73 To connect a control panel to the unit, either • insert the control panel into the panel holder or platform, or • use an Ethernet (eg, Cat 5e) networking cable. Remove the USB connector cover on the front of the control panel. Connect an USB cable (Type A to Type Mini-B) between the USB connector on the control panel (3a) and a free USB port on the PC (3b).
Page 74 74 Electrical installation Make sure that bus termination is off on all other drives. On the control panel, switch on the panel bus functionality (Options - Select drive - Panel bus). The drive to be controlled can now be selected from the list under Options - Select drive.
Page 75 Electrical installation 75 With FDPI-02 modules:...
Page 77: Control Units Of The Drive
Control units of the drive 77 Control units of the drive Contents of this chapter This chapter • describes the connections of the control unit(s) used in the drive, • contains the specifications of the inputs and outputs of the control unit(s). General The inverter unit uses one of these control units: •...
Page 78: Layout
78 Control units of the drive ZCU-12 layout Description Analog inputs Analog outputs X202 Digital inputs X208 X210 XDIO Digital input/outputs XD24 Digital input interlock (DIIL) and +24 V X205 output XD2D Drive-to-drive link XPOW External power input XRO1 Relay output RO1 X203 XRO2 Relay output RO2...
Page 79: Layout
Control units of the drive 79 ZCU-14 layout Description XPOW External power input Analog inputs XRO1 Analog outputs XD2D Drive-to-drive link XRO2 XRO1 Relay output RO1 XRO2 Relay output RO2 XRO3 Relay output RO3 XRO3 XD24 Digital input interlock (DIIL) and +24 V output XPOW XDIO...
Page 80: Default I/O Diagram Of The Inverter Control Unit (Zcu)
80 Control units of the drive Default I/O diagram of the inverter control unit (ZCU) Connection Term Description XPOW External power input +24VI +24VI 24 V DC, 2 A min. (without optional modules) XAI Reference voltage and analog inputs 10 V DC, R +VREF 1…10 kohm +VREF...
Page 81 Control units of the drive 81 Connection Term Description XRO1, XRO2, XRO3 Relay outputs Ready run 250 V AC / 30 V DC Running 250 V AC / 30 V DC Fault Fault (-1) 250 V AC / 30 V DC +24VD DIOGND XD24 Auxiliary voltage output, digital interlock...
Page 82 82 Control units of the drive Connection Term Description X205 Memory unit connection 1) Current [0(4)…20 mA, R = 100 ohm] or voltage [0(2)…10 V, R > 200 kohm] input selected by jumper. Change of setting requires reboot of control unit. 2) See section The XD2D connector (page 89) 3) See section...
Page 83: Bcu Layout
Control units of the drive 83 BCU layout Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface, field-...
Page 84 84 Control units of the drive Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XD24 +24 V output (for digital inputs) XDIO XETH Ethernet port – Not in use XPOW External power input XRO1...
Page 85: Default I/O Diagram Of The Inverter Control Unit (Bcu)
Control units of the drive 85 Default I/O diagram of the inverter control unit (BCU) The table below describes the use of the connections in the inverter unit. Under normal circumstances, the factory-made wiring should not be changed. The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …...
Page 86 86 Control units of the drive Terminal Description Stop (0) / Start (1) Forward (0) / Reverse (1) Reset Acceleration & deceleration select Constant speed 1 select (1 = on) Not in use by default. DIIL Run enable XDIO Digital input/outputs DIO1 Output: Ready DIO2...
Page 87 Control units of the drive 87 Terminal Description X205 Memory unit connection 1) 0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use. 1 = Acceleration/deceleration ramps defined by parameters 23.14/23.15 in use. 2) Constant speed 1 is defined by parameter 22.26. 3) The DIIL input is configured to stop the unit when the input signal is removed.
Page 88 88 Control units of the drive The diagram below shows the default I/O connections on the inverter control unit (A41). XRO1…XRO3 XSTO SGND DIIL XD24 +24VD +24VD AI1+ AI1- AI2+ AI2- AGND AGND Fault If necessary, you can connect a safety device (for example, a safety relay) to the XSTO terminal. Refer to chapter The Safe torque off function.
Page 89: Additional Information On The Connections
Use a shielded twisted-pair cable for data, and another pair or a wire for signal ground (nominal impedance 100…165 ohm, for example Belden 9842). For the best immunity, ABB recommends high quality cable. Keep the cable as short as possible. Avoid unnecessary loops and parallel runs near power cables such as motor cables.
Page 90: Safe Torque Off (Xsto, Xsto Out)
90 Control units of the drive The diagram that follows shows the wiring of the drive-to-drive link. The diagram is applicable to ZCU-12 control units. The diagram that follows shows the wiring of the drive-to-drive link. The diagram is applicable to these control units: •...
Page 91: Sdhc Memory Card Slot
The BCU control unit has an on-board data logger that collects real-time data from the power modules to help fault tracing and analysis. The data is stored onto the SDHC memory card inserted into the SD CARD slot and can be analyzed by ABB service personnel.
Page 92: Connector Data
92 Control units of the drive Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) Maximum tightening torque 0.45 N·m (4 lbf·in[BCU]) 24 V (±10%) DC, 2 A (BCU) 24 V (±10%) DC, 2 A (ZCU) External power input.
Page 93 Control units of the drive 93 Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) (XAI:4 … XAI:7). Maximum tightening torque 0.45 N·m (4 lbf·in[BCU]) Current/voltage input mode selection Current input: -20…20 mA, R = 100 ohm by jumpers (ZCU) or switches (BCU) Voltage input: -10…10 V, R...
Page 94 94 Control units of the drive Control panel connection (X13) Connector: RJ-45 Cable length < 100 m (328 ft) Ethernet connection (XETH [BCU]) Connector: RJ-45 This connection is not supported by the firmware SDHC memory card slot (SD CARD Memory card type: SDHC [BCU]) Maximum memory size: 4 GB Battery...
Page 95: Bcu Ground Isolation Diagram
Control units of the drive 95 BCU ground isolation diagram ￭ XPOW +24VI +24VI +VREF -VREF AGND AI1+ AI1- AI2+ AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO SGND XSTO OUT...
Page 96: Zcu Ground Isolation Diagram
96 Control units of the drive ZCU ground isolation diagram ￭ XPOW +24VI +VREF -VREF AGND AI1+ AI1- Common mode voltage between AI2+ channels ±30 V AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2...
Page 97: Installation Checklist
Installation checklist 97 Installation checklist Contents of this chapter This chapter contains a checklist for 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 98 98 Installation checklist Make sure that … If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground-to-phase varistor) See the electrical installation instructions in the supply unit manual. There is an adequately sized protective earth (ground) conductor(s) between the drive and the switchboard, the conductor is connected to correct terminal, and the terminal is tightened to the correct torque.
Page 99: Start-Up
Start-up 99 Start-up Contents of this chapter This chapter describes the hardware commissioning of the inverter unit. For information on setting up the control program, refer to the appropriate firmware manual. For information on commissioning the supply unit, refer to its hardware manual.
Page 100 ABB recommends to set the operating temperatures of the relay, typically for example, as follows: • 120…140 °C when only tripping is in use •...
Page 101 Start-up 101 Action With inverter units consisting of frame R8i modules, check the setting of parameter 95.09 Switch fuse controller. Drives with a sine output filter (option +E206): Make sure that bit 1 of parameter 95.15 Special HW settings is activated. Drives with an fieldbus adapter module (optional): Set the fieldbus parameters.
Page 103: Maintenance
Contents of this chapter This chapter contains preventive maintenance instructions. Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. For ABB Service offering, refer to www.abb.com/drivesservices or consult your local ABB Service representative (www.abb.com/searchchannels).
Page 104: Maintenance Timers And Counters
• 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. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.
Page 105: Cabinet
Maintenance 105 set to monitor any parameter. This feature is especially useful as a service reminder. For more information, see the firmware manual. Cabinet Cleaning the interior of the cabinet ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 106: Cleaning The Door Air Inlets (Ip22 And Ip42)
106 Maintenance Cleaning the door air inlets (IP22 and IP42) ￭ Check the dustiness of the air inlet meshes. If the dust cannot be removed by vacuum cleaning from outside through the grating holes with a small nozzle, proceed as follows: Stop the drive and do the steps in section Electrical safety precautions (page 44) before you start the work.
Page 107: Replacing The Inlet Door Filters (Ip54)
Maintenance 107 Replacing the inlet door filters (IP54) ￭ Stop the drive and do the steps in section Electrical safety precautions (page 44) before you start the work. Remove the fasteners at the top of the grating. Lift the grating and pull it away from the door. Remove the air filter mat.
Page 108: Cooling Fans
See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB-specified spare parts.
Page 109: Module Cooling Fans
Maintenance 109 Module cooling fans ￭ Replacing the R1i and R2i module cooling fan WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
Page 110: Replacing The R3I And R4I Module Cooling Fan
110 Maintenance Replacing the R3i and R4i module cooling fan WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
Page 111: Replacing The R5I Module Main Cooling Fan (Without Option +C204)
Maintenance 111 Replacing the R5i module main cooling fan (without option +C204) WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
Page 112: Replacing The R5I Module Main Cooling Fan (With Option +C204)
112 Maintenance Install the new fan assembly and insert the module in reverse order to the above. Make sure that the fan blows upwards. Replacing the R5i module main cooling fan (with option +C204) WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]).
Page 113: Replacing The R5I Module Auxiliary Cooling Fan
Maintenance 113 Replacing the R5i module auxiliary cooling fan Frame R5i modules have an auxiliary fan located at the top front of the module. WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
Page 114 114 Maintenance WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, 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 115: Replacing R8I Module Cooling Fan (Speed-Controlled Version)
If the connectors are not compatible, replace the connector at the end of the fan kit cable. Use the connector in the old fan kit, or order a suitable connector from ABB. Stop the drive and do the steps in section Electrical safety precautions (page 44) before you start the work.
Page 116: Replacing R8I Module Cooling Fan (Direct-On-Line Version)
If the connectors are not compatible, replace the connector at the end of the fan kit cable. Use the connector in the old fan kit, or order a suitable connector from ABB. Refer to Connector replacement guide for ACS880-x04 R8i/D8T, BLCL-2X, BL-2X and BLHF DOL fan (3AXD50001059903 [English]).
Page 117 Maintenance 117 Remove the screws holding the front cover plate. Lift the cover plate somewhat to release it. Remove the bracket. Disconnect the wiring of the fan unit. Remove the screws of the fan unit. Pull out the fan unit. Disconnect the fan wire from the fan unit.
Page 118: Replacing The Circuit Board Compartment Fan
118 Maintenance Replacing the circuit board compartment fan Frame R8i modules are equipped with a fan blowing air through the circuit board compartment. The fan is accessible from the front of the module. WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]).
Page 119: Cabinet Cooling Fans
Maintenance 119 Put the fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder. Install and tighten the four nuts removed earlier. 10. Connect the fan cable. 11. Align and push the fan holder into the module. 12.
Page 120 120 Maintenance WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. Stop the drive and do the steps in section Electrical safety precautions (page 44) before you start the work. Remove the front mesh (1 screw at either side). Remove the 3 screws holding the lower edge of the front grating.
Page 121: Replacing The Control Cubicle Fan (Frame R8I And Multiples)
Maintenance 121 Replacing the control cubicle fan (Frame R8i and multiples) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Stop the drive and do the steps in section Electrical safety precautions (page 44) before you start the work.
Page 122: Replacing R5I Inverter Module (Without Option +C204)
122 Maintenance Stop the drive and do the steps in section Electrical safety precautions (page 44) before you start the work. Switch off the DC switch-disconnector of the compartment and open the door. You can remove the door entirely for better access. Remove the fuses from the DC switch-disconnector of the compartment.
Page 123: Replacing R5I Inverter Module (With Option +C204, Modules In Their Own Compartments)
Maintenance 123 Replacing R5i inverter module (with option +C204, modules in their ￭ own compartments) WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
Page 124: Replacing R6I And R7I Inverter Modules
If you are not a qualified electrical professional, do not do installation or maintenance work. Note: A lifting device is available from ABB. See Converter module lifting device for drive cabinets hardware manual (3AXD50000210268 [English]). Stop the drive and do the steps in section Electrical safety precautions (page 44) before you start the work.
Page 125 Maintenance 125...
Page 126: Replacing R8I Inverter Modules
126 Maintenance Replacing R8i inverter modules ￭ Removing an inverter module Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. See Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). WARNING! Obey the safety instructions given in...
Page 127 Maintenance 127 WARNING! Use extreme caution when maneuvering the inverter module. It is heavy and has a high center of gravity. Ignoring the following instructions can cause physical injury, or damage to the equipment. • Use the required personal protection equipment: safety shoes with metal toe cap, protective gloves, etc.
Page 128 128 Maintenance Note: The illustrations represent a frame 2×R8i inverter cubicle with option +F286 (DC switch-disconnector). On units without +F286, the DC busbars are oriented differently, but the procedure is otherwise the same. Do the steps in section Electrical safety precautions (page 44) before you start the work.
Page 129 Electrical installation 109 Maintenance 129...
Page 130 130 Maintenance 110 Electrical installation...
Page 131: Installing An Inverter Module
Electrical installation 111 Maintenance 131 Installing an inverter module WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, 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 132 132 Maintenance compatible, replace the connector in the new module. Use the connector from the old module, or order suitable connector from ABB. Refer to Connector replacement guide, auxiliary power supply for ACS880-104 R8i, ACS880-304 D8T and D7T (3AXD50001060015 [English])
Page 133: Activating The Reduced Run Function Of The Inverter Unit
Maintenance 133 10. Connect the wiring and fiber optic cables to the terminals on the front of the module. 11. Repeat the procedure for the other inverter modules. 12. Reinstall the shroud near the top of the cubicle. Activating the reduced run function of the inverter unit A “reduced run”...
Page 134 134 Maintenance • Fasten the front edge of the baffle to the module mounting holes using the module mounting screws (2 × M8). Tighten to 9 N·m (6.6 lbf·ft). • Fasten the left/right sides of the baffle using M4 screws wherever possible. (This depends on the location of the module in the cubicle.) Tighten to 1…2 N·m (0.7 …...
Page 135: Replacing Dc Fuses (Frame R8I And Multiples)
Maintenance 135 • DC busbar assembly to upper insulators (2 × M8): 9 N·m (6.6 lbf·ft) • DC busbar assembly to lower insulators (2 × M10): 18 N·m (13.3 lbf·ft) • Fuses to DC busbars: 50 N·m (37 lbf·ft) (Bussmann), 46 N·m (34 lbf·ft) (Mersen/Ferraz-Shawmut) •...
Page 136: Capacitors
136 Maintenance Loosen the mounting screws of the top busbar (c) so that you can adjust the gap for the fuse block. Without DC switch With DC switch (+F286) Slide out the fuse block. Move the screws, nuts and washers from the blown fuse to the new fuse. Make sure to keep the washers in the original order.
Page 137: Reforming The Capacitors
Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information. Control units Replacing the memory unit (ZCU or BCU control unit) ￭...
Page 138: Replacing The Zcu-14 Control Unit Battery
138 Maintenance Stop the drive and do the steps in section Electrical safety precautions (page 44) before you start the work. Make sure that the control unit is not powered. Remove the fastening screw and pull the memory unit out. Install a memory unit in reverse order.
Page 139: Replacing The Bcu Control Unit Battery
Maintenance 139 Replacing the BCU control unit battery ￭ WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, 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 140: Control Panel
140 Maintenance Control panel ￭ Refer to ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels user’s manual (3AUA0000085685 [English]).
Page 141: Technical Data
Technical data 141 Technical data Contents of this chapter This chapter contains the technical specifications of the inverter unit, for example, the ratings, technical specifications and requirements, and provisions for fulfilling the requirements for CE and other markings. Ratings Output ratings Inverter Input Light-overload...
Page 142 142 Technical data Output ratings Inverter Input Light-overload unit ratings No-overload use Heavy-duty use Frame type size ACS880- 107- … 0094A-3 0100A-3 0140A-3 0170A-3 0210A-3 0250A-3 0300A-3 0350A-3 0470A-3 0640A-3 0760A-3 0900A-3 1013 1080 1250A-3 2×R8i 1406 1630 1250 1200 1480A-3 2×R8i 1665...
Page 143 Technical data 143 Output ratings Inverter Input Light-overload unit ratings No-overload use Heavy-duty use Frame type size ACS880- 107- … 0200A-5 0240A-5 0300A-5 0340A-5 0440A-5 0590A-5 0740A-5 0810A-5 1060 1150A-5 2×R8i 1294 1500 1150 1104 1450A-5 2×R8i 1631 1890 1450 1000 1256 1392...
Page 144: Definitions
Nominal rms input current Nominal output current (available continuously with no over-loading) Typical motor power in no-overload use The horsepower ratings are typical NEMA motor sizes at 460 V (ACS880-107-xxxxA-5) and 575 V (ACS880-107-xxxxA-7) respectively. Apparent power in no-overload use...
Page 145: Derating
Technical data 145 Derating Surrounding air temperature derating ￭ In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1 percentage point for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k) : 1.00 0.90...
Page 146: Inverter Modules Used, Dc Fuses, And Dc Capacitances
146 Technical data 4000 m 13123 ft 0.80 3500 m 11429 ft 0.85 3000 m 0.90 9842 ft 0.95 2500 m 8202 ft 1.00 2000 m 6562 ft 1500 m 4921 ft 1000 m 3300 ft +20 °C +25 °C +30 °C +35 °C +40 °C...
Page 147 Technical data 147 Module type and Unit type Module DC fuse type and quantity quantity capacitance ACS880- ACS880- Type μF 107-… 104-… 0061A-3 0061A-3 Mersen 6.921 CP URQ 27x60/125 1570 0078A-3 0078A-3 Mersen 6.921 CP URQ 27x60/160 2355 0094A-3 0094A-3 Mersen 6.921 CP URQ 27x60/200 2355 0100A-3...
Page 148 148 Technical data Module type and Unit type Module DC fuse type and quantity quantity capacitance ACS880- ACS880- Type μF 107-… 104-… 0110A-5 Eaton Bussmann 170M4409 4500 0110A-5 Eaton Bussmann 170M4389 4500 0110A-5 +C129+V992 0110A-5 Eaton Bussmann 170M4389 4500 +C134+V992 0140A-5 Eaton Bussmann 170M4410 4500...
Page 149 Technical data 149 Module type and Unit type Module DC fuse type and quantity quantity capacitance ACS880- ACS880- Type μF 107-… 104-… 3110A-5 0810A-5 Eaton Bussmann 170M6417 72000 3860A-5 0810A-5 Eaton Bussmann 170M6417 90000 4610A-5 0810A-5 Eaton Bussmann 170M6417 108000 = 690 V 007A3-7 007A3-7...
Page 150: Noise And Cooling Characteristics
150 Technical data Module type and Unit type Module DC fuse type and quantity quantity capacitance ACS880- ACS880- Type μF 107-… 104-… 5700A-7 0600A-7 Eaton Bussmann 170M6549 90000 1) These DC fuses are used for the protection of individual modules. The cubicle also contains larger main DC fuses that are common to all modules.
Page 151 Technical data 151 Air flow Heat dissipation Sine fil- Inverter unit Noise Sine filter type Inverter level Total Inverter unit Total (option (option ACS880- unit +E206) 107-… +E206) dB(A) /h (cfm) /h (cfm) /h (cfm) 2210A-3 **76 **3900 (2295) 4000 (2350) 7900 (4650) 2610A-3 **76...
Page 152 152 Technical data Air flow Heat dissipation Sine fil- Inverter unit Noise Sine filter type Inverter level Total Inverter unit Total (option (option ACS880- unit +E206) 107-… +E206) dB(A) /h (cfm) /h (cfm) /h (cfm) 3860A-5 **77 **6500 (3825) 8000 (4710) 14500 (8535) 4610A-5 **78...
Page 153: Sine Output Filter Data
Technical data 153 *Contact your local ABB representative for availability and technical data of sine filters. **Maximum value with direct-on-line cooling fan. Sine output filter data Sine output filters are available as option +E206. The table below shows the types and technical data of the filters and filter cubicles used.
Page 154: Input Power (Dc) Connection
Voltage (U2) 3-phase symmetrical, Umax at field weakening point ACS880-107-xxxxx-3: 0…400 V AC. The maximum value (400 V) is a typical drive input voltage level shown on the type designation label of the supply unit corresponding to 380…415 V AC.
Page 155: Typical Power Cable Sizes
Note: Longer cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and charac- teristics. Contact ABB for more information. A sine filter (optional) at the drive output also causes a voltage decrease.
Page 156: Terminal And Cable Entry Data For The Power Cables
156 Technical data Conductor cross-sec- PVC insulation XLPE insulation Typical dimensions of copper tion (copper) cable Conductor temperat- Conductor temperat- ure 70° ure 90° AWG / Time Time Size ø [mm] Lmax Lmax kcmil const. (s) const. (s) 2046 1551 3 ×...
Page 157: Output Terminals (Frames R6I
Technical data 157 Output terminals (frames R6i…R7i) ￭ Screw size: M12 or ½″. Tightening torque: 70 N·m (52 lbf·ft) Busbar material: Tin-plated copper...
Page 158: Output Terminals (Frame R8I)
158 Technical data Output terminals (frame R8i) ￭ Screw size: M12 or ½″. Tightening torque: 70 N·m (52 lbf·ft) Busbar material: Tin-plated copper Connection capability (frame R8i) ￭ The maximum number of motor cables depends on the cable size, cable material, number of inverter modules and on the inverter unit cubicle width.
Page 159: Control Connections
Technical data 159 Maximum number of 3-phase motor cables (copper) for each inverter module, n×R8i with cable exit from bottom Cable cross section Copper compression cable Connection method lugs (DIN 46235) * Requires additional engineering. Standard cable entry plate not suitable. Maximum number of 3-phase motor cables (aluminum) for each inverter module, n×R8i with cable exit from bottom Cable cross section...
Page 160: Energy Efficiency Data (Ecodesign)
Installation site altitude 0…2000 m (0…6562 ft) above sea level. For alti- tudes over 2000 m, con- tact ABB. Output derated above 1000 m (3281 ft). Air temperature 0 … +40 °C -40 … +70 °C -40 …...
Page 161: Cooling
Technical data 161 Operation Storage Transportation installed for stationary in the protective pack- in the protective pack- Contamination IEC/EN 60721-3-3:2002 IEC 60721-3-1:1997 IEC 60721-3-2:1997 Chemical gases: Class Chemical gases: Class Chemical gases: Class Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2 (3S1 with IP20).
Page 162: Packaging Of Options
Substances of Concern In articles as such or in complex objects (Products) established under the Waste Framework Directive (2008/98/EC). For further information, contact your local ABB distributor or consult European Chemicals Agency's SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located.
Page 163: Markings
Technical data 163 Markings Refer to ACS880 multidrive cabinets and modules electrical planning instructions (3AUA0000102324 [English]). Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Electrical connections ￭ Size Torque Strength class 0.5 N·m (4.4 lbf·in) 4.6...8.8 1 N·m (9 lbf·in)
Page 164: Disclaimers
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 theft of...
Page 165: Dimensions And Weights
Dimensions and weights 165 Dimensions and weights Contents of this chapter This chapter contains information on the dimensions and weights of ACS880-107 inverter cubicles. Frames R1i…R7i Frames R1i…R5i ￭ Because of the modularity of the design, the width of the cubicle varies between 400…1000 mm according to the number and size of the modules.
Page 166: Frames R6I And R7I
166 Dimensions and weights Cubicle width Estimated max. weight Frame size R5 with option +C204 Frames R6i and R7i ￭ Each frame R6i and R7i inverter unit is housed in a 400 mm wide cubicle such as the one pictured below. The approximate weight of the cubicle is 250 kg (550 lbs). For details, refer to the dimension drawings delivered with the unit.
Page 167: Dimension Drawing - 400 Mm Wide Cubicle
Dimensions and weights 167 Dimension drawing – 400 mm wide cubicle ￭ R1i…R4i (400 mm) R6i, R7i...
Page 168: Frame R8I And Multiples
168 Dimensions and weights Frame R8i and multiples The standard cubicle widths are 400 mm (frame R8i), 600 mm (2×R8i) and 800 mm (3×R8i). The approximate weights of the cubicles are 320, 510 and 660 kg (705, 1125 and 1455 lbs) respectively. Larger inverter units are combinations of these cubicles. As standard, the control equipment is located in a separate 300 mm wide cubicle (DCU).
Page 169: Dimension Drawing - R8I (Without +C128 Or +H353), Bottom Cable Exit
Dimensions and weights 169 Dimension drawing – R8i (without +C128 or +H353), bottom cable exit ￭...
Page 170: Dimension Drawing - R8I (Without +C128 Or +H353), Top Cable Exit
170 Dimensions and weights Dimension drawing – R8i (without +C128 or +H353), top cable exit ￭...
Page 171: Dimension Drawing - 2×R8I (Without +C128 Or +H353), Bottom Cable Exit
Dimensions and weights 171 Dimension drawing – 2×R8i (without +C128 or +H353), bottom cable ￭ exit...
Page 172: Dimension Drawing - 2×R8I (Without +C128 Or +H353), Top Cable Exit
172 Dimensions and weights Dimension drawing – 2×R8i (without +C128 or +H353), top cable exit ￭...
Page 173: Dimension Drawing - 3×R8I (Without +C128 Or +H353), Bottom Cable Exit
Dimensions and weights 173 Dimension drawing – 3×R8i (without +C128 or +H353), bottom cable ￭ exit...
Page 174: Dimension Drawing - 3×R8I (Without +C128 Or +H353), Top Cable Exit
174 Dimensions and weights Dimension drawing – 3×R8i (without +C128 or +H353), top cable exit ￭...
Page 175: Dimension Drawing - Drive Control Unit (Dcu) (300 Mm)
Dimensions and weights 175 Dimension drawing – drive control unit (DCU) (300 mm) ￭...
Page 176: Location And Size Of Output Terminals
176 Dimensions and weights Location and size of output terminals ￭ Units without common motor terminal cubicle Inverter module cubicle with one R8i module, bottom cable exit...
Page 177 Dimensions and weights 177 Inverter module cubicle with one R8i module, top cable exit...
Page 178 178 Dimensions and weights Inverter module cubicle with two R8i modules, bottom cable exit...
Page 179 Dimensions and weights 179 Inverter module cubicle with two R8i modules, top cable exit...
Page 180 180 Dimensions and weights Inverter module cubicle with three R8i modules, bottom cable exit...
Page 181 Dimensions and weights 181 Inverter module cubicle with three R8i modules, top cable exit...
Page 182 182 Dimensions and weights Sine filter cubicle, 1000 mm, bottom cable exit...
Page 183 Dimensions and weights 183 Sine filter cubicle, 1000 mm, top cable exit...
Page 184: Units With Common Motor Terminal Cubicle (+H359)
184 Dimensions and weights Units with common motor terminal cubicle (+H359) Cubicle width 300 mm, bottom cable exit...
Page 185 Dimensions and weights 185 Cubicle width 300 mm, top cable exit...
Page 186 186 Dimensions and weights Cubicle width 400 mm, bottom cable exit...
Page 187 Dimensions and weights 187 Cubicle width 400 mm, top cable exit...
Page 188 188 Dimensions and weights Cubicle width 600 mm, bottom cable exit...
Page 189 Dimensions and weights 189 Cubicle width 600 mm, top cable exit...
Page 191: The Safe Torque Off Function
The Safe torque off function 191 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. Note: In this chapter, the term 'drive' refers to one inverter unit of the drive system. Description WARNING! In case of parallel-connected drives or dual-winding motors, the STO must be...
Page 192: Chinery (Safety) Regulations
192 The Safe torque off function The Safe torque off function complies with these standards: Standard Name IEC 60204-1:2021 Safety of machinery – Electrical equipment of machines – Part 1: General requirements EN 60204-1:2018 IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards – Immunity requirements for equipment intended to perform functions in a safety-related system (functional safety) in industrial locations IEC 61326-3-1:2017...
Page 193: Wiring
For more information, see the module documentation. Cable types and lengths ￭ • ABB recommends double-shielded twisted-pair cable. • Maximum cable lengths: • 300 m (1000 ft) between activation switch [K] and drive control unit •...
Page 194: Dual-Channel Connection With Internal Power Supply
194 The Safe torque off function Dual-channel connection with internal power supply ￭ Frames R1i…R7i +24 V SGND Inverter unit Control unit Activation switch * OUT1 in frame R5i...
Page 195: Frame R8I And Multiples
The Safe torque off function 195 Frame R8i and multiples XSTO +24 V SGND XSTO OUT STO IN (X52) 24VDC CH1 SGND GND CH1 24VDC CH2 SGND GND CH2 STO IN (X52) STO OUT (X51) 24VDC CH1 24VDC CH1 GND CH1 GND CH1 24VDC CH2 24VDC CH2...
Page 196: Single-Channel Connection Of Activation Switch
196 The Safe torque off function Single-channel connection of activation switch ￭ +24 V SGND Note: • Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL classi- fication is given. • Pay special attention to avoiding any potential failure modes for the wiring. For example, use shielded cable.
Page 197: Multiple Inverter Units
The Safe torque off function 197 Multiple inverter units ￭ Internal power supply XSTO +24 V SGND XSTO SGND XSTO SGND Inverter unit Control unit Activation switch * OUT1 in inverters with ZCU-12 control units.
Page 198: External Power Supply
198 The Safe torque off function External power supply 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Inverter unit Control unit Activation switch * OUT1 in inverters with ZCU-12 control units.
Page 199: Operation Principle
The Safe torque off function 199 Operation principle The Safe torque off activates (the activation switch is opened, or safety relay contacts open). The STO inputs of the drive control unit de-energize. The control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).
Page 200: Start-Up Including Validation Test
200 The Safe torque off function Start-up including validation 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 a validation test. The test must be performed at initial start-up of the safety function after any changes related to the safety function (circuit boards, wiring, components, settings, replacement of inverter module, etc.)
Page 201 The Safe torque off function 201 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 202: Use
202 The Safe torque off function Open the activation switch, or activate the safety functionality that is wired to the STO connection. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).
Page 203 The Safe torque off function 203 danger or is not otherwise acceptable, stop the drive and machinery using the appropriate stop mode before activating the Safe torque off function. • The Safe torque off function overrides all other functions of the drive. •...
Page 204: Maintenance
If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 200). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...
Page 205: Perfect Proof Test Procedure
The Safe torque off function 205 Perfect proof test procedure ￭ Action WARNING! Obey the safety instructions. If you ignore them, injury or death, or damage to the equip- ment can occur. Test the operation of the STO function. If the motor is running, it will stop during the test. •...
Page 206: 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 207: Safety Data
The Safe torque off function 207 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and applies only if both STO channels are used.
Page 208 208 The Safe torque off function...
Page 209: Terms And Abbreviations
The Safe torque off function 209 • The STO is a type A (frames R1i…R7i) or type B (frame R8i and multiples) safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) •...
Page 210: Tüv Certificate
IEC 61508-6 Dangerous failure rate (per hour) of the diagnostics function of Diag_d λ IEC 61508-6 Safe failure rate (per hour) of the diagnostics function of STO Diag_s TÜV certificate ￭ The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
Page 211 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/contact-centers.

ABB ACS880-107 Hardware Manual

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