Page 1 — ABB INDUSTRIAL DRIVES ACS880-07LC drives Hardware manual...
Page 3 ACS880-07LC drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 10. Start-up 3AXD50000569786 Rev C Original instructions EFFECTIVE: 2024-06-28...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ............... . Use of warnings and notes .
Page 6 6 Table of contents CSA Approved (option +C134) ............. . Plinth height (options +C164 and +C179) .
Page 7 Additional requirements for braking applications ....... . . Additional requirements for ABB high-output and IP23 motors ....
Page 8 8 Table of contents Additional grounding requirements – UL (NEC) ........Selecting the control cables .
Page 9: Table Of Contents
Table of contents 9 Motor connection diagram (with option +H366) ........Procedure .
Page 10 10 Table of contents Safe torque off (XSTO, XSTO OUT) ............Safety functions module connection (XFSO) .
Page 11 Table of contents 11 Replacing the fan in the auxiliary control cubicle ........Replacing the cooling fan of a D8T supply module .
Page 12 12 Table of contents Coolant flow rate limits ..............Cooling circuit materials .
Page 13 ACS880-07LC-1660A-7+A004 (12-pulse) ........
Page 14 14 Table of contents Single-channel connection of activation switch (BCU) ....... Multiple drives .
Page 15: Safety Instructions
Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start-up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 16: General Safety In Installation, Start-Up And Maintenance
16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all persons who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 17 Safety instructions 17 • Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors, and brake resistors, can be hot for a period after operation. • Make sure that debris from drilling, cutting and grinding does not go into the drive during installation.
Page 18: Work On The Liquid Cooling System
• If you need to store the drive in temperature below -15 °C (5 °F), drain the cooling circuit, or make sure that it is filled with the coolant specified by ABB. • Drives with the cooling unit: Do not open the cooling unit pump inlet or outlet valves before filling up the coolant circuit.
Page 19: Electrical Safety In Installation, Start-Up And Maintenance
Safety instructions 19 Electrical safety in installation, start-up and maintenance Electrical safety precautions ￭ These electrical safety precautions are for all persons who 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 20: Additional Instructions And Notes
The equipment produces electromagnetic fields that can cause interference in electronic medical devices. This can cause a health hazard. • ABB does not recommend attaching the cabinet by arc welding. If you have to, obey the welding instructions in the drive manuals. Note: •...
Page 21: Printed Circuit Boards
Safety instructions 21 The brake circuit, including the brake chopper (option +D150) and brake resistor (option +D151) are also at a dangerous voltage. After you disconnect the drive from the input power, these remain at a dangerous voltage until the intermediate circuit capacitors discharge. •...
Page 22: General Safety In Operation
22 Safety instructions General safety in operation These instructions are for all persons that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Keep the cabinet doors closed when the drive has electrical power. If the doors the drive cabinet are open, there is a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists.
Page 23: Additional Instructions For Permanent Magnet Motor Drives
Safety instructions 23 Additional instructions for permanent magnet motor drives Safety in installation, start-up, maintenance ￭ These are additional warnings for 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, or damage to the equipment can occur.
Page 25: Introduction To The Manual
Introduction to the manual 25 Introduction to the manual Contents of this chapter This chapter describes the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals. Target audience This manual is intended for people who plan the installation, install, commission, and do maintenance work on the drive, or create instructions for the end user of the drive...
Page 26: Use Of Component Designations
26 Introduction to the manual Use of component designations Some device names in the manual include the component designation in brackets (for example, [Q20]). This will help you to identify the components in the circuit diagrams of the drive. Quick installation, commissioning and operation flowchart Task Guidelines for planning the electrical in- Plan the electrical installation and acquire the accessories...
Page 27: Terms And Abbreviations
Introduction to the manual 27 Terms and abbreviations Term/ Description Abbreviation ACS-AP-W Industrial assistant control panel with Bluetooth interface Type of control unit Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary. The chopper operates when the DC link voltage exceeds a certain maximum limit.
Page 28: Related Manuals
28 Introduction to the manual Related manuals You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. ACS880-07LC related manuals...
Page 29: Operation Principle And Hardware Description
Contents of this chapter This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACS880-07LC is a liquid-cooled cabinet-installed drive for controlling AC induction motors and servomotors, permanent magnet synchronous motors, and synchronous reluctance (SynRM) motors.
Page 30: Overview Circuit Diagram Of The Drive
30 Operation principle and hardware description Overview circuit diagram of the drive ￭ Main circuit breaker [Q1] AC fuses Supply module (including choke and rectifier) Supply module DC fuses Inverter module DC fuses Inverter modules Motor Brake chopper DC fuses Brake chopper module Brake resistors Auxiliary voltage switch [Q21] with fuses (connection for external supply is optional)
Page 31: Overview Diagram Of The Rectifier Bridge
Operation principle and hardware description 31 Overview diagram of the rectifier bridge Diodes. The diodes connect the AC terminals in cyclic sequence to the lower DC busbar (-). Thyristors. The thyristors connect the AC line terminals in cyclic sequence to the upper DC busbar (+).
Page 32 32 Operation principle and hardware description 6-pulse connection 12-pulse connection Supply transformer Switching equipment Diode supply modules...
Page 33: Layout Drawings
Operation principle and hardware description 33 Layout drawings ￭ Cabinet line-up example, doors open (Frame 2×D8T+2×R8i shown) Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. Incoming cubicle (ICU). Contains the power input cable terminals and switchgear. 12-pulse types, as well as large drive types, have two incoming cubicles.
Page 34 34 Operation principle and hardware description Supply module 1 DC fuses Supply module 1 Supply module 2 AC fuses Supply module 2 DC fuses Supply module 2 Supply module cubicle fan Inverter module DC fuses (at the input of each inverter module) Inverter modules Inverter module cooling fan.
Page 35 Operation principle and hardware description 35 Supply module cubicle, cooling circuit Heat exchanger Inlet manifold with stop and drain valves Outlet manifold with stop and drain valves Inlet pipes (cold coolant) from main pipe to modules and heat exchanger Output pipes (hot coolant) to main pipe from modules and heat exchanger Supply modules Draining pipes (inlet draining pipe, and outlet draining pipe)
Page 36: Ka Input Cubicle (Option +F274)
100 kA input cubicle. All other customer cables go into the auxiliary control cubicle or other supply unit cubicles. ABB does not install optional door devices (for example, meters) on the door of the 100 kA cubicle at the factory. No UL version (option +C129) is available.
Page 37: Overview Of Power And Control Connections
Operation principle and hardware description 37 Overview of power and control connections The diagram shows the power connections of the drive and the control interfaces of the inverter control unit (type UCU, wiring diagram designation A41). XPAN SLOT 1...3 XETH1..4 SLOT 4 XFSO V1T/R…...
Page 38: Door Devices
38 Operation principle and hardware description Memory unit Connection for FSO safety functions module Control panel and PC connection Ethernet ports for fieldbus. Terminal blocks on the inverter control unit. These terminals are optionally wired to terminal block X504 in the auxiliary control cabinet of the drive. Fiber optic link to each inverter module.
Page 39: Main Disconnecting Device [Q1]
Operation principle and hardware description 39 ENABLE / RUN Run enable signal switch for the supply unit No Run enable or Start signal Run enable and Start signal on E-STOP RESET Emergency stop reset push button (with emergency stop options only) EARTH FAULT Ground (earth) fault light and reset push button (option +Q954)
Page 40: Control Panel
40 Operation principle and hardware description Note: The voltage is measured on the supply side of the main switch or breaker. • AC current meter (option +G335) on one phase. • AC current meter (option +3G335) on three phases. Control panel ￭...
Page 41: Descriptions Of Options
Operation principle and hardware description 41 Descriptions of options Note: All options are not available for all drive types, are not compatible with some other options, or require additional engineering. Degree of protection ￭ The standard degree of protection is IP42 (UL type 1). IP54 (UL type 12) is available as option +B055.
Page 42: Csa Approved (Option +C134)
42 Operation principle and hardware description CSA Approved (option +C134) ￭ The option includes the following accessories and features: • bottom entry and exit of cables with US cable conduit entry (plain plate without ready-made holes) • all components UL/CSA listed/recognized •...
Page 43: Output For Motor Space Heater (Option +G313)
Operation principle and hardware description 43 • Supplying power for the auxiliary circuits (page 97) • circuit diagrams delivered with drive for the actual wiring. Output for motor space heater (option +G313) ￭ The option contains: • load switch for providing electrical isolation during service •...
Page 44: Additional Wire Markings
44 Operation principle and hardware description • Main circuit terminals: Connector identifier (eg. "U1") marked on terminal, or on insulating material close to the terminal. Input and output main circuit cables are not marked. • Plug-in connectors of wire sets (except those that require special tools to disconnect) are labeled with connector designation (eg.
Page 45: Common Mode Filter Temperature Monitoring (Option +G453)
Operation principle and hardware description 45 Option Additional markings +G342 Single wires connected to components, between modules, or to terminal blocks are (class C1) marked with component identification and pin numbers for both ends. The marking is printed on sleeving or, if necessary, snap-on markers. Plug-in connectors are marked with an identification label (or snap-on markers) placed on the wires near the connector (individual wires are not marked).
Page 46: Roxtec Cable Entry (Option +H394)
￭ The cabinet can be equipped with a multi-cable transit frame for Roxtec cable entry (option +H394). ABB provides only the frames, not the seals or the installation tools. For sealing components and installation instructions, refer to www.roxtec.com. The figure below shows a bottom cable entry frame and and an example of a sealing module for a W600 cabinet.
Page 47: Additional Terminal Block X504 (Option +L504)
Operation principle and hardware description 47 Designed for Cable frame Roxtec frame Description 3AUA5000221237 ABB designed flange and Roxtec frame ACS880LC W400 S 6X2 AISI316 (kit) welded together. ACS880LC W500 3AUA5000118748 S 8X1 AISI316 Roxtec frame with integrated flange. S 8X3 AISI316...
Page 48: L536, +L537
48 Operation principle and hardware description Option +L513 is an ATEX-certified thermal protection function that has the same external connectivity as +L505. In addition, +L513 comes with +Q971 (ATEX-certified safe disconnection function) as standard and is wired at the factory to activate the Safe torque off function of the drive in an overtemperature situation.
Page 49: Starter For Auxiliary Motor Fan (Options +M600
Operation principle and hardware description 49 addition, each monitoring relay has a 0/4…20 mA output that is available on the terminal block. Option +nL514 comes with +Q971 (ATEX-certified safe disconnection function) as standard and is wired at the factory to activate the Safe torque off function of the drive in an overtemperature situation.
Page 50: Type Designation Label
50 Operation principle and hardware description Type designation label The type designation label includes ratings, appropriate markings, a type designation and a serial number, which allow the identification of each unit. A sample label is shown below. Quote the complete type designation and serial number when contacting technical support.
Page 51: Option Codes
Operation principle and hardware description 51 Code Description Size xxxxx Refer to the rating tables Voltage range 525…690 V AC. This is indicated in the type designation label as typical input voltage levels (3~ 525/600/690 V AC) Option codes ￭ Code Description A004...
Page 52 52 Operation principle and hardware description Code Description C240 600 mm wide cubicle for input unit C241 800 mm wide cubicle for input unit C242 2-way valve in a dedicated cubicle C245 1000 mm wide cubicle for input unit D150 Brake choppers D151 Brake resistors...
Page 53 Operation principle and hardware description 53 Code Description G450 External supply voltage for fans G451 Voltage transformer for fans (internal supply) Common mode filter temperature monitoring. See section Common mode filter temperature G453 monitoring (option +G453) (page 45). G454 380 … 400 V / 60 Hz supply voltage for pump motor(s) G455 440 …...
Page 54 54 Operation principle and hardware description Code Description L502 FEN-31 HTL incremental encoder interface module L503 FDCO-01 optical DDCS communication adapter module Additional I/O terminal block. See section Additional terminal block X504 (option L504 +L504) (page 47). Thermal protection with PTC relays (1 or 2 pcs). See section Thermal protection with PTC relays L505 (options +L505, +2L505, +L513, +2L513, +L536, +L537) (page...
Page 55 Operation principle and hardware description 55 Code Description 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 Q954 Earth fault monitoring for IT (ungrounded) systems Q957 Prevention of unexpected start-up with safety relays, by activating the Safe torque off function Q963...
Page 57: Mechanical Installation
Mechanical installation 57 Mechanical installation Contents of this chapter This chapter tells you how to examine the installation site, examine the delivery, and mechanically install the drive. Examining the installation site Examine the installation site. Make sure that: • The installation site is sufficiently ventilated or cooled to remove heat from the drive.
Page 58: Examining The Delivery
58 Mechanical installation • torque wrench • set of wrenches or sockets. Examining the delivery The drive delivery contains: • drive cabinet line-up • optional modules (if ordered) installed onto the control unit(s) at the factory • appropriate drive and optional module manuals •...
Page 59: Moving The Drive In Its Packaging
Mechanical installation 59 Moving the drive in its packaging ￭ Lifting the crate with a forklift WARNING! Obey the local laws and regulations that apply to lifting, such as the requirements for planning the lift, the capacity and condition of the lifting equipment, and personnel training.
Page 60: Lifting The Crate With A Crane
60 Mechanical installation Lifting the crate with a crane WARNING! Obey the local laws and regulations that apply to lifting, such as the requirements for planning the lift, the capacity and condition of the lifting equipment, and personnel training. Lifting point Optimal position for the lifting sling: as close to the traverse board as possible...
Page 61: Moving The Crate With A Forklift
Mechanical installation 61 Mechanical installation 61 Moving the crate with a forklift Moving the crate with a forklift 750 mm (29.5'') Removing the transport package ￭ Remove the transport package as follows: Undo the screws that attach the wooden parts of the transport crate to each other.
Page 62: Moving The Unpacked Drive Cabinet
62 Mechanical installation Removing the transport package  62 Mechanical installation Remove the transport package as follows: 1. Undo the screws that attach the wooden parts of the transport crate together. Moving the unpacked drive cabinet ￭ 2. Remove the wooden parts. Lifting the cabinet with a crane 3.
Page 63: Moving The Cabinet On Its Back
Mechanical installation 63 Lay the cabinet on the rollers and move it carefully until close to its final location. Remove the rollers by lifting the unit with a crane, forklift, pallet truck or jack. Moving the cabinet on its back Support the cabinet from below alongside the cubicle seams.
Page 64: Attaching The Cabinet To The Floor And Wall Or Roof
64 Mechanical installation Attaching the cabinet to the floor and wall or roof General rules ￭ • The drive must be installed in an upright vertical position. • Leave 250 mm (9.85”) of free space above the cabinet for maintenance, and to allow pressure relief operation.
Page 65: Attaching The Cabinet (Non-Marine Units)
Mechanical installation 65 Attaching the cabinet (non-marine units) ￭ Alternative 1 – Clamping Insert the clamps (included) into the twin slots along the front and rear edges of the cabinet frame body and fasten them to the floor with a bolt. The recommended maximum distance between the clamps in the front edge is 800 mm (31.5”).
Page 66: Alternative 2 - Using The Holes Inside The Cabinet
66 Mechanical installation Alternative 2 – Using the holes inside the cabinet Attach the cabinet to the floor through the bottom fastening holes with size M10…M12 (3/8”…1/2”) bolts. The recommended maximum distance between the front edge fastening points is 800 mm (31.5”). If the back fastening holes are not accessible, attach the top of the cabinet to the wall with L-brackets (not included in the delivery) bolted to the lifting eye/bar holes.
Page 67: Attaching The Cabinet (Marine Units)
Mechanical installation 67 Attaching the cabinet (marine units) ￭ See the dimension drawing delivered with the drive for details of the fastening points. Fasten the cabinet to the floor and roof (wall) as follows: Bolt the unit to the floor through the flat bars at the base of the cabinet using M10 or M12 screws.
Page 68: Joining Cabinet Sections Together
68 Mechanical installation Joining cabinet sections together Wide cabinet line-ups are delivered in multiple sections. The sections must be joined together at the installation site. There is a joining cubicle at the end of a section for this purpose. The screws for joining the sections are in a plastic bag inside the cabinet. Attach the first section to the floor.
Page 69 Mechanical installation 69 Center the Axilock connectors onto the gaps between coolant pipe ends. Tighten the connector screws to the torque indicated on the connector label. Attach the front and rear posts of the joining cubicle to the posts of the other section with 16 screws (8 per post).
Page 70 70 Mechanical installation Connect the PE (ground) busbars using the M10 bolts included. Tighten to 35…40 N·m (25…30 lbf·ft). Side Above Plain washer Spring washer Bolt Remove the shroud covering the DC busbars in the joining cubicle.
Page 71 Mechanical installation 71 10. Connect the DC and AC busbars. Tighten the bolts to 55…70 N·m (40…50 lbf·ft). Units with single DC busbars Units with double DC busbars Accessories kit identification: Single DC busbars: 3AXD50000125876 Double DC busbars: 3AXD50000126361 Triple DC busbars (not shown): 3AXD50000126378 Joint piece Plain washer with electroplated zinc coating and blue chromate passivation Spring washer with mechanically sprayed zinc coating...
Page 72 72 Mechanical installation Units with single AC busbars Units with double AC busbars Accessories kit identification: Single AC busbars: 3AXD50000126392 Double AC busbars: 3AXD50000126408 Triple AC busbars (not shown): 3AXD50000126514 Bolt (M12) Bolt (M12) Joint piece Plain washer with electroplated zinc coating and blue chromate passivation Spring washer with mechanically sprayed zinc coating Nut (M12) WARNING!
Page 73: Miscellaneous
Arc welding ￭ ABB does not recommend attaching the cabinet by arc welding. However, if arc welding is the only option, connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1’6”) of the welding point.
Page 74: Lifting Lugs And Bars
74 Mechanical installation Lifting lugs and bars Certificate of conformity ￭ The certificate is available in ABB Library at www.abb.com/drives/documents (document number 3AXD10001061361). Declarations of conformity ￭ https://search.abb.com/library/Download.aspx?Document- ID=3AXD10000686042&LanguageCode=en&DocumentPartId=&Action=Launch https://search.abb.com/library/Download.aspx?Document- ID=3AXD10001329600&LanguageCode=en&DocumentPartId=&Action=Launch...
Page 75: Guidelines For Planning The Electrical Installation
Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
Page 76: Selecting The Supply Transformer
76 Guidelines for planning the electrical installation Selecting the supply transformer Basic guidelines ￭ Define the apparent power of the transformer. You can use this rule of thumb: (kVA) = 1.32 × sum of the motor shaft power (kW) Define the nominal voltage for the transformer secondary winding according to the nominal input voltage of the drive.
Page 77 Guidelines for planning the electrical installation 77 Medium voltage network Three-winding transformer 12-pulse drive No grounding of transformer secondary windings is permitted No load unbalance between transformer secondary windings is permitted Large 6-pulse drives (possible sources of harmonics) No (or only minimal) voltage distortion in medium voltage network is permitted. a.
Page 78: Selecting The Supply Disconnecting Device
Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.
Page 79: Requirements Tables
Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound ≤...
Page 80: Requirements For Abb Motors, P
82). Motor type Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW IEC 315 ≤ frame size <...
Page 81: Requirements For Non-Abb Motors, P
Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound and ≤...
Page 82: Requirements For Non-Abb Motors, P
82). Motor type Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW IEC 315 ≤ frame size <...
Page 83: Availability Of D U /D T Filter And Common Mode Filter By Drive Type
The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive...
Page 84: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
If motor power is above 350 kW: Consult the motor manufacturer. Nominal AC supply Requirement for voltage Motor insulation system ABB d u /d t and common mode filters, insulated N- end motor bearings 100 kW < P < 100 kW or frame size < 350 kW or <...
Page 85: Additional Note For Sine Filters
Guidelines for planning the electrical installation 85 Inverter/drive without du/dt filter du/dt ------------ - (1/μs) Û l (m) Inverter with du/dt filter Û du/dt ------------ - (1/ s) l (m) Motor cable length Û Relative peak line-to-line voltage (d u /d t )/ U Relative (d u /d t ) value (d u /d t filter in use) Note: Û...
Page 86: General Guidelines
Make sure that the cable can enter the cabinet through the cable entry plate. Refer to the dimension drawings of the drive delivery or technical data in the drive hardware manual. For special cable entry solutions, consult ABB. Make sure that there is sufficient space to install the cable(s) and cable lugs to the terminals.
Page 87: Power Cable Types
Guidelines for planning the electrical installation 87 Power cable types ￭ Preferred power cable types This section shows the preferred cable types. Make sure that the selected cable type also complies with local/state/country electrical codes. Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar-...
Page 88: Not Allowed Power Cable Types
88 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Yes with motors up to 100 kW (135 hp). A potential equalization between the frames of motor and driven equipment is required.
Page 89: Grounding Requirements
Guidelines for planning the electrical installation 89 Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient.
Page 90: Additional Grounding Requirements - Iec
￭ Only use shielded control cables. Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable also for the pulse encoder signals. Use one individually shielded pair for each signal. Do not use common return for different analog signals.
Page 91: Signals In Separate Cables
Relay cable ￭ The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel to drive cable ￭ Use EIA-485, Cat 5e (or better) cable with male RJ-45 connectors. The maximum length of the cable is 100 m (328 ft).
Page 92: The Motor Cable
92 Guidelines for planning the electrical installation The following figure illustrates the cable routing guidelines with an example drive. min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min.
Page 93: Situations And Against Thermal Overload
The drive protects the motor cable and motor in a short-circuit situation when: • the motor cable is sized correctly • the motor cable type complies with the motor cable selection guidelines by ABB • the cable length does not exceed the allowed maximum length specified for the drive •...
Page 94: Protecting The Motor Against Overload Without Thermal Model Or Temperature Sensors
94 Guidelines for planning the electrical installation Protecting the motor against overload without thermal model or ￭ temperature sensors Motor overload protection protects the motor against overload without using motor thermal model or temperature sensors. Motor overload protection is required and specified by multiple standards including the US National Electric Code (NEC) and the common UL/IEC 61800-5-1 standard in conjunction with UL/IEC 60947-4-1.
Page 95: Implementing The Safe Torque Off Function
Guidelines for planning the electrical installation 95 Note: The UCU control unit does not support options +Q978 and +Q979. Option User’s manual Manual code (Eng- code lish) Emergency stop, stop category 0 (using main contactor/breaker and +Q951 3AUA0000119895 Safe torque off) Emergency stop, stop category 1 (using main contactor/breaker and +Q952 3AUA0000119896...
Page 96: Implementing The Functions Provided By The Fso Safety Functions Module
96 Guidelines for planning the electrical installation ATEX-certified Safe motor disconnection function and with ATEX-compliant protection relays for PTC or Pt100 temperature sensors. For more information, see: User's manual Manual code (English) ATEX-certified Safe disconnection function, Ex II (2) GD for ACS880 drives (+Q971) 3AUA0000132231 application guide FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option...
Page 97: Implementing A Bypass Connection
IEC/EN/UL 61800-5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”. Bypass connection is available as a factory-installed option for some cabinet-installed drive types. Consult ABB for more information. WARNING! Never connect the drive output to the electrical power network. The connection may damage the drive.
Page 98: Using A Safety Switch Between The Drive And The Motor
Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.
Page 99: Protecting The Contacts Of Relay Outputs
Guidelines for planning the electrical installation 99 Protecting the contacts of relay outputs Inductive loads (relays, contactors, motors) cause voltage transients when switched off. The relay contacts on the drive control unit are protected with varistors (250 V) against overvoltage peaks. In spite of this, it is highly recommended that inductive loads are equipped with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) to minimize the EMC emission at switch-off.
Page 100: Connecting A Motor Temperature Sensor To The Drive Through An Option Module
100 Guidelines for planning the electrical installation of the drive. See the control cable connection instructions. Make sure that the voltage is not more than the maximum allowed voltage over the sensor. If there is basic insulation between the sensor and the live parts of the motor, or if the insulation type is not known: You can connect the sensor to the drive via an option module.
Page 101 Guidelines for planning the electrical installation 101 Option module Temperature sensor type Temperature sensor in- sulation requirement Type Insulation/Isolation Pt100, Pt1000 FEN-31 Galvanic isolation between sensor Reinforced insulation connector and drive control unit connector. No isolation between sensor connector and other connect- ors.
Page 103: Electrical Installation
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...
Page 104: Measuring The Insulation Resistance Of The Input Power Cable
104 Electrical installation Note: Moisture inside the motor reduces the insulation resistance. If you think that there is moisture in the motor, dry the motor and do the measurement again. U1-PE, V1-PE, W1-PE 1000 V DC, > 100 Mohm Measuring the insulation resistance of the input power cable ￭...
Page 105: Connecting The Control Cables
Electrical installation 105 Connecting the control cables The default I/O connections can be different with some hardware options. See the circuit diagrams delivered with the drive for the actual wiring. For other control programs, see their firmware manuals. Control cable connection procedure ￭...
Page 106 106 Electrical installation 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 107: Routing The Control Cables Inside The Cabinet
Electrical installation 107 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 108: Connecting The Motor Cables (Units Without Common Motor Terminal Cubicle)
108 Electrical installation 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 the motor cables (units without common motor terminal cubicle) On units without a common motor terminal cubicle, the motor cables connect to...
Page 109: Motor Connection Diagram (With Option +H366)
Electrical installation 109 Inverter unit cubicle(s) The recommended cable types are given in the technical data. WARNING! The cabling from all inverter modules to the motor must be physically identical considering cable type, cross-sectional area, and length. Inverter unit cubicle(s) Motor connection diagram (with option +H366) ￭...
Page 110: Procedure
110 Electrical installation 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. In case of three parallel modules, make sure that the load capacity of the bridging is not exceeded.
Page 111: Removing The Shrouds
Electrical installation 111 Removing the shrouds The illustration below shows the parts to be removed. Inner shroud Fan retaining screws Lower front mounting plate Open the door of the incoming cubicle. Remove the shrouding, fans and assembly plates covering the input terminals. Connecting the cables This section describes the power cable connecting procedure for a bottom cable entry with the standard cable entry plate.
Page 112 112 Electrical installation IP54 cabinet: Remove the rear horizontal cable support bracket and the cable entry plate. IP54 cabinet: Remove a sealing grommet from the cable entry plate for each cable. Cut hole into the rubber grommet and move it onto the cable. Put the cables inside the cabinet through the cable entry plate.
Page 113: Installing The Shrouds
Electrical installation 113 WARNING! Do not tighten the clamp on the bare shield (stripped part of the cable). It can damage the cable. For each cable, connect the PE conductor to the PE busbar, and two phase conductors to the phase terminals. Connect the third phase conductor to the PE busbar.
Page 114: Connecting The Cables At The Motor End
114 Electrical installation Reinstall the shrouding, fans and assembly plates removed earlier. Close the cubicle door. Connecting the cables at the motor end At the motor, connect the cables according to instructions from the motor manufacturer. Pay special attention to the phase order. For minimum radio-frequency interference, ground the cable shield 360 degrees at the cable entry of the motor terminal box, or ground the cable by twisting the shield so that the flattened shield is wider than 1/5 of its length.
Page 115: Procedure
Electrical installation 115 Procedure ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. This procedure is valid for the standard bottom cable entry. If the cabinet has a Roxtec cable entry (option +H394), refer to Roxtec's instructions.
Page 116: Installing Shrouds
116 Electrical installation For each cable, attach the conductive sleeve to the bare cable shield with a cable tie. Attach the cable to the support bracket with a clamp. WARNING! Do not tighten the clamp on the bare shield (stripped part of the cable). It can damage the cable.
Page 117: Connecting The Cables At The Motor End
Electrical installation 117 Connecting the cables at the motor end At the motor, connect the cables according to instructions from the motor manufacturer. Pay special attention to the phase order. For minimum radio-frequency interference, ground the cable shield 360 degrees at the cable entry of the motor terminal box, or ground the cable by twisting the shield so that the flattened shield is wider than 1/5 of its length.
Page 118: Connection Diagram, 12-Pulse Units
118 Electrical installation Connection diagram, 12-pulse units ￭ Fuses or other protection means for short-circuit protection of the cable. Grounding of the cable shield at the cable entry (360-degree grounding). Additional information: • See the technical data for the dimensions of the cable entries, and the dimensions and tightening torques of the terminals.
Page 119: Connecting The Cables
Electrical installation 119 Connecting the cables This section describes the power cable connecting procedure for a bottom cable entry with the standard cable entry plate. The standard cable entry plate has conductive sleeves for the 360° grounding of the cable shields. For Rotex cable entry plate (option +H394) and cable gland plate (option +H358), refer to the manufacturer's instructions.
Page 120 120 Electrical installation Put the cables inside the cabinet through the cable entry plate. If there are several cables, use the rear 3 holes first. IP54 cabinet: Attach the sealing grommets to the cable entry plate. Attach also the cable entry plate, and the cable support bracket. For each cable, strip off 3…5 cm (1.2 …...
Page 121: Installing Shrouds
Electrical installation 121 WARNING! Do not tighten the clamp on the bare shield (stripped part of the cable). It can damage the cable. For each cable, connect the PE conductor to the PE busbar, and two phase conductors to the phase terminals. Connect the third phase conductor to the PE busbar.
Page 122: Connecting Input Power Cables - Cable Entry In 100 Ka Input Cubicle (Option +F274)
122 Electrical installation Connecting input power cables - cable entry in 100 kA input cubicle (option +F274) Connection diagram ￭ 100 kA input cubicle Incoming cubicle Note: This diagram shows the installation with shielded single core cables. The shields are grounded at both ends and they operate as the PE conductors of the drive.
Page 123: Connecting The Cables
Electrical installation 123 Connecting the cables This section describes the power cable connecting procedure for a bottom cable entry with the standard cable entry plate. The standard cable entry plate has conductive sleeves for the 360° grounding of the cable shields. For Rotex cable entry plate (option +H394) and cable gland plate (option +H358), refer to the manufacturer's instructions.
Page 124 124 Electrical installation IP54 cabinet: Remove the rear horizontal cable support bracket and the cable entry plate. IP54 cabinet: Remove a sealing grommet from the cable entry plate for each cable. Cut hole into the rubber grommet and move it onto the cable. Put the cables inside the cabinet through the cable entry plate.
Page 125: Replacing Shrouds And Beams In Front Of Input Power Cable Terminals
Electrical installation 125 WARNING! Do not tighten the clamp on the bare shield (stripped part of the cable). It can damage the cable. For each cable, connect the PE conductor to the PE busbar, and two phase conductors to the phase terminals. Connect the third phase conductor to the PE busbar.
Page 126: Connecting An External Brake Resistor Assembly
126 Electrical installation Connecting an external brake resistor assembly See chapter Resistor braking (page 291). For the location of the terminals, refer to the dimension drawings delivered with the unit or the dimension drawing examples in this manual.
Page 127: Use Of Fasteners In Cable Lug Connections
Electrical installation 127 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 128: Connecting A Pc
128 Electrical installation Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit. It can cause damage. A PC (with, for example, the Drive Composer PC tool) can be connected as follows: To connect a control panel to the unit, either •...
Page 129 Electrical installation 129 Repeat the above for each drive. With the panel connected to one unit, link the units using Ethernet cables. Switch on the bus termination on the drive that is farthest from the control panel in the chain. •...
Page 130 130 Electrical installation With FDPI-02 modules and BCU control unit:...
Page 131: Installing Option Modules
Electrical installation 131 Installing option modules Installation of I/O extension and fieldbus adapter modules on UCU ￭ control unit Refer to UCU-22/23/24 control units hardware manual (3AXD50000817726 [English]). Mechanical installation of I/O extension, fieldbus adapter and pulse ￭ encoder interface modules on BCU control unit See hardware description for the available slots for each module.
Page 132: Installation Of An Fso Safety Functions Module Onto Bcu Control Unit
132 Electrical installation Connect the wiring to the module. Obey the instructions given in the documentation of the module. 10. If you need to remove the option module after it has been installed into the drive, use a suitable tool (e.g. small pliers) to carefully pull out the lock. Installation of an FSO safety functions module onto BCU control unit ￭...
Page 133: Wiring Of Option Modules
Electrical installation 133 Connect the FSO module data cable between FSO connector X110 and BCU connector X12. To complete the installation, refer to the instructions in the applicable FSO module user's manual. Wiring of option modules ￭ See the applicable optional module manual for specific installation and wiring instructions.
Page 135: Control Unit (Ucu)
The data is stored on a memory card which can be analyzed by ABB service personnel. Layout The figures below show an example UCU-24 control unit.
Page 136 136 Control unit (UCU) Description I/O terminals SLOT 1 I/O extension, encoder interface or fieldbus SLOT 2 adapter module connection. For F-type modules with USCA-02 adapter. SLOT 3 SLOT 4 RDCO-0x DDCS communication option module connection UMU-01 memory unit connection. Data logger microSDHC memory card for inverter module communication is inside the memory unit.
Page 137 Control unit (UCU) 137 Description Analog input Analog output XCAN Not in use XCAN TERM CAN bus termination switch Digital input XDIO Digital input/output XD2D Drive-to-drive link XD24 +24 V output (for digital input) XETH1 Ethernet ports for fieldbus, internal switch XETH2 XETH3 Ethernet ports for tool communication, internal...
Page 138 138 Control unit (UCU) Description XFSO Not in use Humidity and temperature measurements XFSO...
Page 139: Default I/O Diagram Of The Supply Control Unit
Control unit (UCU) 139 Default I/O diagram of the supply control unit This table describes the use of the connections in the diode supply unit. Terminal Description XD2D Drive-to-drive link Not supported BGND SHIELD XD2D.TERM Drive-to-drive link termination switch X485 RS485 connection CIO-01 module connection.
Page 140 140 Control unit (UCU) Terminal Description Norm. closed XRO4: Not supported COM4 Common 250 V AC / 30 V DC, 2 A Norm. open XSTO Safe torque off input connection SGND XSTO: STO1 and STO2 are connected to OUT at the factory. To enable start and operation, STO1 and STO2 must be connected to OUT.
Page 141: Default I/O Diagram Of The Inverter Control Unit
Control unit (UCU) 141 Terminal Description Analog outputs Zero (no signal indicated) 0…20 mA, R < 500 ohm AGND 0…20 mA, R Zero (not signal indicated) < 500 ohm AGND XPOW External power input +24VI 19…32 V DC, 1.5…2.9 A (depends on the load and supply voltage) External power input +24VI Two supplies can be connected to the control unit for redundancy.
Page 142 142 Control unit (UCU) Terminal Description CIO-01 module connection BGND SHIELD X485 BIAS X485 bias selection switch X485 TERM X485 termination switch XCAN CAN bus CANH CANL Not supported CGND SHIELD Control cable shield XCAN TERM CANopen termination switch XRO1 Relay output 1 Norm.
Page 143 Control unit (UCU) 143 Terminal Description Digital inputs 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. DIIL is connected to XD24:5 at the factory. XDIO Digital input/outputs DIO1...
Page 144 144 Control unit (UCU) Terminal Description XETH1 Ethernet ports for fieldbus. Support depends on the control program. Refer to the firmware manual. XETH2 XETH3 Ethernet ports for tool communication. Support depends on the control program. Refer to the firmware manual. XETH4 XPAN Control panel connection...
Page 145 Control unit (UCU) 145 This is an I/O connection example for the inverter control unit. XRO1…XRO4 COM1 COM2 COM3 COM4 XSTO SGND STO1 STO2 DIIL XD24 +24VD +24VD AI1+ AI1- AI2+ AI2- AGND AGND Fault Connected at the factory. If necessary, you can connect a safety device (eg, a safety relay) to the XSTO terminal.
Page 146: Additional Information On The Connections
146 Control unit (UCU) Additional information on the connections Connecting motor temperature sensors to the drive ￭ Refer to the electrical planning instructions. Power supply for the control unit (XPOW) ￭ Power to the control unit is supplied internally through terminal block XPOW. Refer to the control unit connector data for the current and voltage ratings of the power supply.
Page 147: Safe Torque Off (Xsto, Xsto Out)
The data is stored onto the microSDHC memory card inserted into the UMU-01 memory unit and can be analyzed by ABB service personnel. Connector data The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …...
Page 148 148 Control unit (UCU) Digital inputs DI1…DI6 24 V logic levels: “0” < 5 V, “1” > 15 V (XDI:1…XDI:6) : 2.0 kohm Input type: NPN/PNP (DI1…DI5), PNP (DI6) Hardware filtering: 0.04 ms, digital filtering up to 8 ms : 15 mA (DI1…DI5), 5 mA (DI6) Start interlock input DIIL (XDI:7) 24 V logic levels: "0"...
Page 149 Control unit (UCU) 149 Safe torque off connection (XSTO) Input voltage range: -3…30 V DC Logic levels: "0" < 5 V, "1" > 17 V. Note: Both circuits must be closed to enable start and operation (STO1 and STO2 must be connected to OUT). This applies to all control units (including drive, inverter, supply, brake, DC/DC converter etc.
Page 150: Ground Isolation Diagram
150 Control unit (UCU) Ground isolation diagram ￭ XPOW XD2D X485 XCAN XETH1 XETH2 XETH3 XETH4 XPAN XRO1-XRO4 COM1 … COM4 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO XSTO OUT Power supply ground *The maximum common mode voltage between each AI input and AGND is ±30 V. **Ground selector (DICOM=DIOGND) settings DICOM=DIOGND: ON All digital inputs share a common ground (DICOM connected to DIOGND).
Page 151: Control Unit (Bcu)
Control unit (BCU) 151 Control unit (BCU) 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 drive utilizes BCU-02 control units. The BCU-02 consists of a BCON-12 control board (and a BIOC-01 I/O connector board and power supply board) built in a metal housing.
Page 152: Layout
152 Control unit (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 153 Control unit (BCU) 153 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 154: Default I/O Diagram Of The Supply Control Unit
154 Control unit (BCU) Default I/O diagram of the supply control unit This table describes the use of the connections in the diode supply unit. Terminal Description XD2D Drive-to-drive link Not supported BGND Shield D2D.TERM Drive-to-drive link termination switch X485 RS485 connection CIO-01 module connection.
Page 155 Control unit (BCU) 155 Terminal Description XDIO Digital input/outputs DIO1 Not in use by default DIO2 Not in use by default DIOGND Digital input/output ground DIOGND Digital input/output ground XD24 Auxiliary voltage output +24VD +24 V DC 200 mA DICOM Digital input ground +24VD +24 V DC 200 mA...
Page 156: Default I/O Diagram Of The Inverter Control Unit
156 Control unit (BCU) Default I/O diagram of the inverter control unit This diagram shows the default control connections of the inverter control unit. The ACS880 primary control program is in use. Under normal circumstances, the factory-made wiring should not be changed. Terminal Description XD2D...
Page 157 Control unit (BCU) 157 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. DIIL is connected to XD24:5 at the factory. XDIO Digital input/outputs DIO1...
Page 158 158 Control unit (BCU) 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 159 Control unit (BCU) 159 This is an I/O connection example for the inverter control unit. XRO1…XRO3 XSTO SGND DIIL XD24 +24VD +24VD AI1+ AI1- AI2+ AI2- AGND AGND Fault Connected at the factory. If necessary, you can connect a safety device (for example, a safety relay) to the XSTO terminal.
Page 160: 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 161: Safe Torque Off (Xsto, Xsto Out)
The 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 162 162 Control unit (BCU) Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A (XRO1…XRO3) Protected by varistors +24 V output (XD24:5 and XD24:7) Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus the power taken by DIO1 and DIO2.
Page 163 Control unit (BCU) 163 Safe torque off connection (XSTO) Input voltage range: -3…30 V DC Logic levels: "0" < 5 V, "1" > 17 V. Note: Both circuits must be closed to enable start and operation (IN1 and IN2 must be connected to OUT). This applies to all control units (including drive, inverter, supply, brake, DC/DC converter etc.
Page 164: Bcu Ground Isolation Diagram
164 Control unit (BCU) 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 SGND SGND...
Page 165: Installation Checklist
Installation checklist 165 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 166 166 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) the electrical installation instructions. Appropriate DC fuses are installed.
Page 167: Start-Up
Start-up 167 Start-up Contents of this chapter This chapter contains the start-up and switch-off procedures of the drive. Start-up procedure The tasks which are needed in certain cases only are marked with underlining, and option codes are given in brackets. Default device designations (if any) are given in brackets after the name, for example “main switch-disconnector [Q1]”.
Page 168 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 169 Start-up 169 Action Check the voltage range setting in parameter 195.01 Supply voltage. For more information on setting up the supply control program, refer to the applicable firmware manual (ACS880 diode supply control program firmware manual (3AUA0000103295 [English]) ACS880 diode supply control program (YDILX) firmware manual (3AXD50001096489 [English])).
Page 170: Switching Off The Drive
170 Start-up Action Drives with the Safely-limited speed with the encoder interface (option +Q965): Test and validate the operation of the Safely-limited speed circuit. See the delivery specific circuit diagrams and wiring, start-up and operating instructions of the option. Drives with a motor thermal protection function (options +L513, +L514, +L536, +L537): Test and validate the operation of the motor thermal protection function.
Page 171: Fault Tracing
Fault tracing 171 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. Control unit LEDs (UCU-22…24) Indication Green Battery voltage of the real-time clock is sufficient (higher than 2.5 V). Battery voltage is below 2.5 V, the battery is missing or the control unit is not powered.
Page 172: Control Unit Leds (Bcu-X2)
172 Fault tracing Control unit LEDs (BCU-x2) Color Indication BATT OK Green Battery voltage of the real-time clock is OK (higher than 2.8 V). When the LED is not lit, • battery voltage is below 2.8 V, • the battery is missing, or •...
Page 173: Maintenance
Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is 35 mm (1.4 in). Maintenance intervals The tables show the maintenance tasks that can be done by the end user. For the ABB Service offering, contact your local ABB Service representative (new.abb.com/contact-centers).
Page 174 174 Maintenance Action Description Performance of on/off-site work (commissioning, tests, measurements or other work) Replacement...
Page 175: Recommended Maintenance Intervals After Start-Up
Tightness of terminals Dustiness, corrosion and temperature Cooling liquid pipe connections Coolant antifreeze concentration Other ABB-SACE Air circuit breaker maintenance ABB Contactors maintenance Recommended every 2nd year actions by the user Inspection of coolant quality Inspection of expansion tank air pressure...
Page 176 • The maintenance and component replacement intervals are based on the assumption that the equipment operates 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 177: Cabinet
Maintenance 177 Cabinet Cleaning the interior of the cabinet ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. WARNING! Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding wristband.
Page 178: Replacing The Fan In The Incoming Cubicle
178 Maintenance Replacement fans are available from ABB. Do not use other than ABB-specified spare parts. Replacing the fan in the incoming cubicle ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
Page 179: Replacing The Cooling Fan Of A D8T Supply Module
Maintenance 179 Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work. Open the door of the auxiliary control cubicle. Disconnect the fan wiring. Remove the CIO module. Remove the fastening screws of the fan collar and slide the fan with the collar out. Detach the fan from the collar and replace the fan.
Page 180: Replacing The Cooling Fan Of An R8I Inverter Module
180 Maintenance Replacing the cooling fan of an R8i inverter module ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
Page 181: Replacing The Cooling Fan In The 100 Ka Input Cubicle
Maintenance 181 Pull the fan outwards to separate it from the heat exchanger housing. Install new fan in reverse order. Align the guide pins (b) at the rear of the fan cowling with the slots (c) in the module bottom guide, then install the retaining screws (a).
Page 182 182 Maintenance Remove all screws on the cover plate. Pull the cover plate out. Disconnect the fan wiring. Remove the 4 screws that attach the fan assembly to the frame. Pull the fan assembly out.
Page 183: Replacing The Common Motor Terminal Cubicle Fan
Maintenance 183 Disassemble the fan assembly as follows: • Remove the 3 screws and 6 nuts that attach the front casing to the rear casing. • Remove the 4 screws that attach the fan to the front casing. Replace the fan. Assemble and install the fan assembly in reverse order.
Page 184: Replacing The Brake Chopper And Resistor Cubicle Fans (Options +D150 And +D151)
184 Maintenance Replacing the brake chopper and resistor cubicle fans (options +D150 ￭ and +D151) See chapter Resistor braking (page 291).
Page 185: Supply And Inverter Modules
Maintenance 185 Supply and inverter modules Assembling the service platform ￭ The service platform is included in the cabinet delivery. It can be used when installing or servicing liquid-cooled R8i modules. Fasten the triangular supports to the cabinet frame (5 × M6 screws for each support).
Page 186: Replacing The D8T Supply Module
The module is heavy. Reserve two persons, hoist and a suitable platform for the replacement procedure. Keep the module fastened to the hoist to prevent the module from falling. For information on a lifting device available from ABB, refer to...
Page 187 Remove the lifting chains. Reinstall the DC busbars and fuses above the module. Connect the plug connector and fiber optic connectors. g. Reconnect the coolant pipes to the module (ABB pipe connector max. torque 20 N·m (14.8 lbf·ft)). Fill up the cooling system.
Page 188 188 Maintenance...
Page 189 Maintenance 189...
Page 190: Replacing An Inverter Module
190 Maintenance Replacing an inverter module ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. WARNING! Make sure that the replacement module has exactly the same type code as the old module.
Page 191: Assembling The Service Platform
The module is heavy. Reserve two persons, hoist and a suitable platform for the replacement procedure. Keep the module fastened to the hoist to prevent the module from falling. For information on a lifting device available from ABB, refer to...
Page 192: Removing The Module
(page 185). Install the converter module lifting device by ABB, or make sure that you have another winch in use. For information on a lifting device available from ABB, refer Converter module lifting device for drive cabinets hardware manual (3AXD50000210268 [English]).
Page 193 Maintenance 193 Remove the L-shaped DC busbars at the top of the module. Make note of the orientation of the screws as well as the order of the washers. Close the inlet valve (a) and outlet valve (located on the right-hand side of the cubicle).
Page 194 194 Maintenance After the module has drained, disconnect the piping from the module. 10. Remove the module retaining screws at the top and the bottom of the module.
Page 195: Installing The Module
Assembling the service platform (page 185). Install the converter module lifting device by ABB, or make sure that you have another winch in use. For information on a lifting device available from ABB, refer Converter module lifting device for drive cabinets hardware manual (3AXD50000210268 [English]).
Page 196: Capacitors
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. Reforming the capacitors ￭ The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more.
Page 197: Fuses
Maintenance 197 Fuses Replacing the AC fuses ￭ This procedure is valid for the IEC design of the supply unit. The UL design (option +C129) with the UL recognized fuses is similar except for one difference: Two parallel fuses form a single fuse block. It is not possible to dismantle this block. WARNING! Obey the safety instructions of the drive.
Page 198: Replacing The Supply Module Dc Fuses
198 Maintenance • IEC design of the supply unit: Bussmann fuses: 50 N·m (37 lbf·ft), Mersen (Ferraz-Shawmut): 46 N·m (34 lbf·ft). Fuses by other manufacturer: Refer to the fuse manufacturer’s instructions. • UL design of the supply unit (option +129) with the UL recognized fuses: 40 N·m (30 lbf·ft).
Page 199 Maintenance 199 WARNING! Be very careful when you loosen or remove screws and bolts inside the cabinet. Do not drop screws, washers or nuts inside the cabinet or module. They can cause severe damage at the power up: a short circuit or an arc blast. Stop the motors connected to the drive.
Page 200: Replacing The Inverter Module Dc Fuses
200 Maintenance Replacing the inverter module DC fuses ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. WARNING! Use the required personal protective equipment.
Page 201 Maintenance 201 Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work. Open the door of the module cubicle. Remove the shrouding in front of the fuses (upper part of the cabinet). Check the condition of the fuses.
Page 202: Replacing Ac Fuses - 100 Ka Input Cubicle (Option +F274)
202 Maintenance Replacing AC fuses - 100 kA input cubicle (option +F274) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
Page 203: Ucu Control Unit
Maintenance 203 UCU control unit UCU control unit types ￭ Different variants of the UCU control units are used in ACS880 drives: UCU-22…26. These have a different number of converter module connections but are otherwise identical. The UCU types are interchangeable as long as the number of connections is sufficient.
Page 204: Replacing The Ucu Control Unit Battery
204 Maintenance Replacing the UCU control unit battery ￭ When the BAT LED is on, the real-time clock battery voltage is high enough. If the LED is off, replace the battery. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 205: Bcu Control Unit
Maintenance 205 Take the memory unit out from the cabinet before you remove the microSDHC card from it. The card is small and can fall into the cabinet. Open the memory card cover in the memory unit. Push the card to remove it. Install a new card in reverse order.
Page 206: Replacing The Bcu Control Unit Battery
206 Maintenance Replacing the BCU control unit battery ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. Replace the real-time clock battery if the BATT OK LED is off when the control unit is powered.
Page 207 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.
Page 209: Internal Cooling Circuit
Each cubicle has an inlet and an outlet manifold, fitted with a stop valve and a drain valve. The stop valves can be closed to isolate all modules in the cubicle from the main cooling circuit. In cabinet line-ups built by ABB, valves are color-coded: • Blue – Open during operation •...
Page 210 210 Internal cooling circuit Supply modules. The drawing shows the configuration of a diode supply unit with two modules, ie. there is a common air-to-liquid exchanger in the cubicle. With an IGBT supply unit, each module has a dedicated air-to-liquid exchanger as shown for item 2. Inverter modules To/From cooling unit Air-to-liquid heat exchanger...
Page 211: Connection To A Cooling Unit
Internal cooling circuit 211 Connection to a cooling unit Connection to an ACS880-1007LC cooling unit ￭ Refer to ACS880-1007LC cooling unit user’s manual (3AXD50000129607 [English]). Connection to a custom cooling unit ￭ General requirements Equip the system with an expansion tank to damp pressure rise due to volume changes when the temperature varies.
Page 212: Filling Up And Bleeding The Internal Cooling Circuit
212 Internal cooling circuit Filling up and bleeding the internal cooling circuit Both the drive and coolant must be at room temperature before filling up the cooling circuit. WARNING! Make sure that the maximum permissible operating pressure is not exceeded. When necessary regulate the pressure to appropriate level by draining excess coolant out of the system.
Page 213: Draining The Internal Cooling Circuit
Internal cooling circuit 213 Close the bleed valve at the cooling unit. 10. Continue to fill in coolant until a base pressure of approximately 250 kPa is achieved. 11. Open the bleed valve of the pump to let out any air. 12.
Page 214: Technical Data For The Internal Cooling Circuit
Coolant type Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% mixture, available from Clariant distributors and ABB Service representatives. Do not dilute the coolant. It is ready to use. Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F).
Page 215 Internal cooling circuit 215 be derated by 6 percentage points per 1 °C (1.8 °F) temperature increase, as shown by curve (c). • If there are no components with a maximum operating temperature of 55 °C (131 °F) installed in the same space as the drive modules, drive output current must be derated by 2 percentage points per 1 °C (1.8 °F) temperature increase, as shown by curve (b).
Page 216: Pressure Limits
216 Internal cooling circuit Maximum temperature rise: Depends on heat losses and mass flow. Typically 10 °C (18 °F) with nominal losses and flow. Pressure limits ￭ Note: The pressure limits for ACS880-1007 cooling units manufactured before week 24 of 2020 are given in ACS880-1007LC user's manual, revision C. Base pressure: 250 kPa (recommended);...
Page 217: Technical Data
Technical data 217 Technical data Contents of this chapter This chapter contains the technical specifications of the drive, for example, the ratings, fuse data, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Ratings The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table.
Page 218 218 Technical data Output ratings Input rating No-overload use Light-overload use Heavy-duty use ACS880- 07LC-… 1470A-7 1345 1470 2205 1400 1500 1757 1411 1200 1500 1100 1000 1000 1660A-7 1519 1660 2490 1600 1750 1984 1594 1400 1750 1242 1200 1250 1940A-7 1775...
Page 219: Definitions
Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.
Page 220: Supply Voltage Derating
220 Technical data Supply voltage derating Allowed AC supply voltage range for the drive is 400 V … 690 V. With an IGBT supply, AC supply voltage derating is not needed. With diode supply unit and electrical power network voltage less than 600 V AC, the rated output current of the drive or inverter must be derated with 1% for every 10 V.
Page 221 Technical data 221 Supply module(s) used Inverter modules used ACS880- Frame size Type Type 07LC-… ACS880-304LC-… ACS880-104LC-… 1470A-7 2×D8T + 2×R8i 0780A-7+A018 0750A-7+E205 1660A-7 2×D8T + 2×R8i 0780A-7+A018 0850A-7+E205 1940A-7 2×D8T + 3×R8i 1060A-7+A018 0670A-5+E205 2180A-7 2×D8T + 3×R8i 1060A-7+A018 0750A-7+E205 2470A-7 3×D8T + 3×R8i...
Page 222: Fuses
222 Technical data Fuses Internal AC fuses ￭ The drive has AC fuses at the input of each supply module. Notes: • Fuses with higher current rating than the recommended ones must not be used. • Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.
Page 223 Technical data 223 AC fuses at supply module input (IEC) ACS880- 07LC-… (per Manufacturer Type (total) phase) 2470A-7+A004 2880A-7+A004 1250 Bussmann 170M6416 3260A-7+A004 3580A-7+A004 Bussmann 170M6413 4050A-7+A004 4840A-7+A004 5650A-7+A004 Bussmann 170M6413 6460A-7+A004 AC fuses at supply module input (UL) ACS880- 07LC-…...
Page 224 224 Technical data AC fuses at supply module input (UL) ACS880- 07LC-… (per Manufacturer Type (total) phase) 2470A-7+A004 2880A-7+A004 1250 Bussmann 170M6416 3260A-7+A004 3580A-7+A004 1800 Bussmann 170M6904 4050A-7+A004 4840A-7+A004 5650A-7+A004 1800 Bussmann 170M6904 6460A-7+A004...
Page 225: Dc Fuses
Technical data 225 DC fuses ￭ The drive has DC fuses at the output of each supply module and at the input of each inverter module. Notes: • Fuses with higher current rating than the recommended ones must not be used. •...
Page 226 226 Technical data DC fuses at supply module output (IEC) ACS880- 07LC-… (per Manufacturer Type (total) phase) 2470A-7+A004 2880A-7+A004 1250 Bussmann 170M6546 3260A-7+A004 3580A-7+A004 1100 1000 Bussmann 170M6549 4050A-7+A004 4840A-7+A004 5650A-7+A004 1100 1000 Bussmann 170M6549 6460A-7+A004 DC fuses at supply module output (UL) ACS880- 07LC-…...
Page 227 Technical data 227 DC fuses at supply module output (UL) ACS880- 07LC-… (per Manufacturer Type (total) phase) 2470A-7+A004 2880A-7+A004 1600 Bussmann 170M6792 3260A-7+A004 3580A-7+A004 2200 1250 Bussmann 170M6827 4050A-7+A004 4840A-7+A004 5650A-7+A004 2200 1250 Bussmann 170M6827 6460A-7+A004 DC fuses at inverter module input (IEC/UL) ACS880- 07LC-…...
Page 228: Brake Chopper Dc Fuses
228 Technical data DC fuses at inverter module input (IEC/UL) ACS880- 07LC-… Manufacturer Type 1470A-7+A004 1400 1100 Bussmann 170M6501 1660A-7+A004 1940A-7+A004 1250 1100 Bussmann 170M6500 2180A-7+A004 1400 1100 Bussmann 170M6501 2470A-7+A004 2880A-7+A004 1400 1100 Bussmann 170M6501 3260A-7+A004 3580A-7+A004 1400 1100 Bussmann 170M6501 4050A-7+A004...
Page 229 6460A-7+A004 52.0 13.75 67.1 1) The values are not calculated according to the ecodesign standard IEC 61800-9-2. Energy efficiency data according to IEC 61800-9-2 is available from https://ecodesign.drivesmotors.abb.com and from ACS880-07LC drives energy efficiency data (EU ecodesign) supplement (3AXD50000788279 [English]).
Page 230: Typical Power Cable Sizes
230 Technical data Typical power cable sizes The tables below give the current carrying capacity ( I ) and typical size for copper Lmax and aluminum cables with PVC or XLPE insulation. A correction factor K = 0.70 is used. Time const.
Page 231: Terminal And Cable Entry Data For The Power Cables
Technical data 231 Terminal and cable entry data for the power cables The locations and sizes of the cable entries are shown in the dimension drawings delivered with the drive, and the dimension drawing examples in this manual. Busbar terminal material: Tin-plated copper. Connection capability ￭...
Page 232: Terminal Data For The Supply And Inverter Control Units
232 Technical data Maximum number of 3-phase motor cables (aluminum) for each inverter module, n×R8i with cable exit from bottom Aluminum compression cable lugs (DIN 46329) Cable cross 1×R8i 1×R8i 2×R8i 3×R8i section Connection method (300 mm (400 mm (500 mm (700 mm cubicle) cubicle)
Page 233: Electrical Power Network Specification
, 3-phase symmetrical, U at the field weakening point Frequency ( f 0…500 Hz • For higher operational output frequencies, please contact your local ABB representative. • Operation outside the range of 12…150 Hz requires derating. See the de- rating information.
Page 234: Relay Contact Data For Control Of External Main Contactor/Breaker
234 Technical data Relay contact data for control of external main contactor/breaker If the drive cabinet is not equipped with a main contactor/breaker, it must have an external main contactor/breaker. It is the customer's responsibility to acquire and install it. The customer must also connect the external contactor/breaker control circuit of the drive to the control circuit of the external breaker.
Page 235: Efficiency
The efficiency is not calculated according to the ecodesign standard IEC 61800-9-2. Energy efficiency data (ecodesign) Energy efficiency data according to IEC-61800-9-2 is available from https://ecodesign.drivesmotors.abb.com and from ACS880-07LC drives energy efficiency data (EU ecodesign) supplement (3AXD50000788279 [English]). Protection classes Degrees of protection...
Page 236: Ambient Conditions
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 … +45 °C -40 … +70 °C -40 …...
Page 237: Storage Conditions
Storage conditions The table below specifies the storage conditions for the drive. Store the drive in its package. ABB recommends seaworthy package (option +P912) if the drive is in long-term storage. The storage conditions must also comply with the environmental...
Page 238: Materials
European Chemicals Agency's SCIP database. SCIP is the database for information on 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...
Page 239: Applicable Standards
SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located. Contact your local ABB distributor for further information on environmental aspects. End of life treatment must follow international and national regulations.
Page 240: Emc Compliance (Iec/En 61800-3)
Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of Conformity is available from https://library.abb.com. RCM mark Product complies with Australian and New Zealand requirements specific to EMC, telecom- munications and electrical safety.
Page 241: Category C3
Technical data 241 Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes. Second environment includes establishments connected to a network not supplying domestic premises.
Page 242: Ul And Csa Checklist
242 Technical data Medium voltage network Equipment Neighboring network Supply transformer Point of measurement Static screen Low voltage Drive Equipment (victim) An EMC plan for preventing disturbances is drawn up for the installation. A template is available in Technical guide No. 3 EMC compliant installation and configuration for a power drive system (3AFE61348280 [English]).
Page 243 The fuses are listed elsewhere in this chapter. • The drive provides motor overload protection. The protection is not enabled when the drive leaves the ABB factory. For enabling the protection, see the firmware manual. • The drive overvoltage category according to IEC 60664-1 is III, except for auxiliary power connections (fan, control, heating, lighting, cooling unit pump etc) which are of category II.
Page 244: Tightening Torques
244 Technical data 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) 4.6...8.8 4 N·m (35 lbf·in) 9 N·m (6.6 lbf·ft) 22 N·m (16 lbf·ft) 42 N·m (31 lbf·ft)
Page 245: Cyber Security Disclaimer
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 data or information.
Page 247: Dimensions
The table is followed by selected dimension drawing examples. The dimensions are in millimeters (for inches, divide by 25.4). The data given is preliminary. ABB reserves the right to modify the design at any time without notice. Consult ABB for up-to-date, drive-specific information.
Page 248 248 Dimensions Height Width Weight ACS880-07LC-… 2180A-7 2002 2100 1930 4250 2470A-7 2002 2500 2230 4920 2880A-7 2002 2800 2490 5490 3260A-7 2002 2800 2490 5490 3580A-7 2002 3600 3410 7520 4050A-7 2002 3600 3410 7520 4840A-7 2002 4500 4210...
Page 249: Dimension Drawing Examples
Dimensions 249 Dimension drawing examples ￭ ACS880-07LC-0850A-7...
Page 250: Acs880-07Lc-1660A-7 (6-Pulse)
250 Dimensions ACS880-07LC-1660A-7 (6-pulse)
Page 251: Acs880-07Lc-1660A-7+A004 (12-Pulse)
Dimensions 251 ACS880-07LC-1660A-7+A004 (12-pulse)
Page 252: Acs880-07Lc-3260A-7
252 Dimensions ACS880-07LC-3260A-7...
Page 253: Cabinet Height And Depth
Dimensions 253 Cabinet height and depth Side view, bottom cable exit Side view, marine construction (option +C121), bottom cable exit...
Page 254 254 Dimensions Side view, top cable exit with common motor Side view, top cable exit without common motor terminal cubicle terminal cubicle...
Page 255: Location And Size Of Input Terminals
Dimensions 255 Location and size of input terminals 600 mm, with main breaker, single-busbar, bottom cable entry ￭...
Page 256: 600 Mm, With Main Breaker, Double-Busbar, Bottom Cable Entry
256 Dimensions 600 mm, with main breaker, double-busbar, bottom cable entry ￭...
Page 257: 600 Mm, With Main Breaker, Double-Busbar, Top Cable Entry
Dimensions 257 600 mm, with main breaker, double-busbar, top cable entry ￭...
Page 258: Ka Input Cubicle (Option +F274)
258 Dimensions 100 kA input cubicle (option +F274) ￭...
Page 259: Location And Size Of Output Terminals
Dimensions 259 Location and size of output terminals Units without common motor terminal cubicle ￭ Inverter module cubicle with one R8i module, bottom cable exit...
Page 260: Inverter Module Cubicle With Two R8I Modules, Bottom Cable Exit
260 Dimensions Inverter module cubicle with two R8i modules, bottom cable exit...
Page 261: Inverter Module Cubicle With Three R8I Modules, Bottom Cable Exit
Dimensions 261 Inverter module cubicle with three R8i modules, bottom cable exit...
Page 262: Brake Chopper Cubicle
262 Dimensions Brake chopper cubicle...
Page 263: Units With Common Motor Terminal Cubicle (+H359)
Dimensions 263 Units with common motor terminal cubicle (+H359) ￭ Cubicle width 300 mm, bottom cable exit...
Page 264: Cubicle Width 300 Mm, Top Cable Exit
264 Dimensions Cubicle width 300 mm, top cable exit...
Page 265: Cubicle Width 400 Mm, Bottom Cable Exit
Dimensions 265 Cubicle width 400 mm, bottom cable exit...
Page 266: Cubicle Width 400 Mm, Top Cable Exit
266 Dimensions Cubicle width 400 mm, top cable exit...
Page 267: Cubicle Width 600 Mm, Bottom Cable Exit
Dimensions 267 Cubicle width 600 mm, bottom cable exit...
Page 268: Cubicle Width 600 Mm, Top Cable Exit
268 Dimensions Cubicle width 600 mm, top cable exit...
Page 269: The Safe Torque Off Function
The Safe torque off function 269 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description WARNING! In case of parallel-connected drives or dual-winding motors, the STO must be activated on each drive to remove the torque from the motor.
Page 270: Chinery (Safety) Regulations
270 The Safe torque off function Standard Name 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 Electrical equipment for measurement, control and laboratory use – EMC requirements –...
Page 271: 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 272: Dual-Channel Connection With Internal Power Supply (Ucu)
272 The Safe torque off function Dual-channel connection with internal power supply (UCU) ￭ XSTO +24 V SGND STO1 STO2 XSTO OUT STO IN (X52) OUT1 24VDC CH1 SGND GND CH1 OUT2 24VDC CH2 SGND GND CH2 STO IN (X52) STO OUT (X51) 24VDC CH1 24VDC CH1...
Page 273: Dual-Channel Connection With Internal Power Supply (Bcu)
The Safe torque off function 273 Dual-channel connection with internal power supply (BCU) ￭ 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...
Page 274: Single-Channel Connection Of Activation Switch (Ucu)
274 The Safe torque off function Single-channel connection of activation switch (UCU) ￭ XSTO +24 V SGND STO1 STO2 Note: • Both STO inputs (STO1, STO2) 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 275: Multiple Drives
The Safe torque off function 275 Multiple drives ￭ Internal power supply (example, drives with UCU) XSTO +24 V SGND STO1 STO2 XSTO SGND STO1 STO2 XSTO SGND STO1 STO2 Drive Control unit Activation switch...
Page 276: Internal Power Supply (Example, Drives With Bcu)
276 The Safe torque off function Internal power supply (example, drives with BCU) XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch...
Page 277: External Power Supply (Example, Drives With Ucu)
The Safe torque off function 277 External power supply (example, drives with UCU) 24 V DC XSTO +24 V SGND STO1 STO2 XSTO SGND STO1 STO2 XSTO SGND STO1 STO2 Drive Control unit Activation switch...
Page 278: External Power Supply (Example, Drives With Bcu)
278 The Safe torque off function External power supply (example, drives with BCU) 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch...
Page 279: Operation Principle
The Safe torque off function 279 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 280: Start-Up Including Validation Test
280 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 281 The Safe torque off function 281 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 282: Use
282 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 283 The Safe torque off function 283 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 284: 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 280). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...
Page 285: Perfect Proof Test Procedure
The Safe torque off function 285 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 286: 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 287: Safety Data
The Safe torque off function 287 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 288 288 The Safe torque off function...
Page 289: Terms And Abbreviations
The Safe torque off function 289 • The STO is a type B safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) • The STO does not activate when requested • A fault exclusion on the failure mode “short circuit on printed circuit board”...
Page 290: Tüv Certificate
290 The Safe torque off function Term or Reference Description abbreviation IEC 61508-6 Proof test interval. T is a parameter used to define the probabilistic failure rate (PFH or PFD) for the safety function or subsystem. Performing a proof test at a maximum interval of T is required to keep the SIL capability valid.
Page 291: Resistor Braking
Resistor braking 291 Resistor braking The brake units available for the drive are: • Single-phase, on/off-controlled brake chopper indicated by option codes +D150 (chopper) and +D151 (resistors) • Three-phase ACS880-607LC 3-phase dynamic brake units with control of current and power by modulation. For more information, refer to •...
Page 293: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/contact-centers.

This manual is also suitable for:

Acs880-07lc-0850a-7 Acs880-07lc-1660a-7 Acs880-07lc-1660a-7+a004 Acs880-07lc-3260a-7

ABB ACS880-07LC Hardware Manual

Safety Instructions

Introduction to the Manual

Operation Principle and Hardware Description

Mechanical Installation

Guidelines for Planning the Electrical Installation

Electrical Installation

Control Unit (UCU)

Control Unit (BCU)

Installation Checklist

Start-Up

Fault Tracing

Maintenance

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Summary of Contents for ABB ACS880-07LC