Page 1 — ABB INDUSTRIAL DRIVES ACS880-17 drives (45…400 kW, 60…450 hp) Hardware manual...
Page 3 ACS880-17 drives (45…400 kW, 60…450 hp) Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 9. Start-up 3AXD50000035158 Rev J Original instructions EFFECTIVE: 2024-11-29...
Page 5 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 External control cable connection terminals (other than control unit terminals) . Connection terminals of R8 ............. Connection terminals of R6i+R6i, R7i+R7i and R11 .
Page 7 Requirements tables ............... . . Requirements for ABB motors, P...
Page 8 Additional requirements for the regenerative and low harmonics drives ..Additional requirements for ABB high-output and IP23 motors ....Additional requirements for non-ABB high-output and IP23 motors ..
Page 9 Table of contents 9 Implementing an ATEX-certified motor thermal protection ......Implementing the Prevention of unexpected start-up function ......Implementing the functions provided by the FSO safety functions module .
Page 10 10 Table of contents Frame R8 ..................Frame R11 .
Page 11 Table of contents 11 Recommended maintenance intervals after start-up ....... . . Cabinet .
Page 12 12 Table of contents Memory unit ..................Replacing the memory unit of the motor-side converter control unit (frame R8) .
Page 13 Table of contents 13 R11 input cable terminals ..............R11 motor cable terminals .
Page 14 Single ACS880-17 drive, internal power supply ........
Page 15 Table of contents 15 Further information...
Page 17 Safety instructions 17 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 18 18 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 19 Safety instructions 19 • If you must do work on a drive that is connected to the power supply, obey the local laws and regulations on live electrical work. This includes, but is not limited to, electric shock and arc protection. •...
Page 20 20 Safety instructions • Select the correct personal protective equipment (PPE). • Stop the drive and motor(s). Clearly identify the work location and equipment. Disconnect all possible voltage sources. Make sure that connection is not possible. Lock out and tag out. •...
Page 21 Safety instructions 21 Measuring the voltage ￭ Make sure that the voltage between the drive input power terminals (L1, L2, L3) and the grounding (PE) busbar is close to 0 V. L1, L2, L1, L2, L3...
Page 22 22 Safety instructions R6i+R6i and R7i+R7i L1, L2, L3...
Page 23 Safety instructions Safety instructions 23 • Frame R11: Make sure that the voltage of the drive AC busbars between the drive Frame R11: Make sure that the voltage of the drive AC busbars between the drive module and the LCL filter and the grounding (PE) busbar are close to 0 V. module and the LCL filter and the grounding (PE) busbar are close to 0 V.
Page 24 24 Safety instructions Make sure that the voltage between the drive DC busbars (+ and -) and the grounding (PE) busbar is close to 0 V. DC-, DC+ R6i+R6i and R7i+R7i DC+, DC-...
Page 25 Safety instructions 25 Make sure that the voltage between the drive output terminals (T1/U, T2/V, T3/W) and the grounding (PE) busbar is close to 0 V. For frame R8, you can measure the voltage at the drive module input (a) and output (b) terminals through the holes in the shroud.
Page 26 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 27 Safety instructions 27 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 28 28 Safety instructions 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 29 Introduction to the manual 29 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 30 30 Introduction to the manual Quick installation, commissioning and operation flowchart Task Plan the electrical installation and acquire the ac- Guidelines for planning the electrical installa- cessories needed (cables, fuses, etc.). tion (page 93) Check the ratings, required cooling air flow, input Technical data (page 245) power connection, compatibility of the motor, mo- tor connection, and other technical data.
Page 31 Type of control unit Type of memory unit, attached to the 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. ACS880-17 (45…400 kW, 60…450 hp) manuals...
Page 33 This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACS880-17 is a four-quadrant, air-cooled, cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance (SynRM) motors.
Page 34 34 Operation principle and hardware description Single-line circuit diagram of the drive ￭ Single-line diagram of R8 Auxiliary voltage supply fuses Auxiliary circuit protection switch Switch fuse Line contactor with options +Q951, +Q952, +Q978 Common mode filter (option +E208) d u /d t filter (option +E205) or sine filter (option +E206) Auxiliary voltage transformer supplying 24 V and 230/115 V control voltage for, for example, cabinet fan(s), control devices and I/O extension adapter module.
Page 35 Operation principle and hardware description 35 Single-line diagram of R6i+R6i and R7i+R7i Main switch-disconnector (switch-disconnector and separate fuses) AC fuses Auxiliary voltage supply fuses Auxiliary circuit protection switch Main contactor Charging contactor LCL filter Charging resistor d u /d t filter (option +E205) or sine filter (option +E206) Supply module Inverter module.
Page 36 36 Operation principle and hardware description Single-line diagram of R11 Main switch-disconnector (switch-disconnector and separate fuses) AC fuses Auxiliary voltage supply fuses Auxiliary circuit protection switch Line contactor inside the drive module. Q2 is controlled by the line-side converter control unit. If Start (Running) command is given to the drive, Q2 is closed and the line-side converter starts to modulate.
Page 37 Operation principle and hardware description 37 Line-side converter ￭ The line-side converter rectifies three-phase AC current to direct current for the intermediate DC link of the drive. The line-side converter is also capable of regenerating, that is, feeding braking energy back into the electrical power network. The following diagram shows the simplified main circuit of the line-side converter.
Page 38 The rise of the input current can heat the fuses. If there are brief low line situations when the drive boosts voltage significantly, there is a risk for nuisance fuse blowing of smaller AC line fuses. For more information, refer to ACS880-11, ACS880-31, ACS880-14, ACS880-34, ACS880-17, ACS880-37 drives product note on DC voltage boost (3AXD50000691838 [English]).
Page 39 Operation principle and hardware description 39 Cabinet layout The layout drawings give an example of the cabinets. The contents of the cabinet depends on the ordered options. For example: • In the lower power R8 and R11 cabinets with only a few options the “door fan” is replaced with a shroud (basic cabinet without 24 V auxiliary voltage supply, option +E205 d u /d t filter and option +E208 common mode filter).
Page 40 40 Operation principle and hardware description Drive module cubicle, door closed Drive module cubicle, door open Drive control panel Operating buttons and door lights Main switch handle Indicators, for example, V-meter and A-meter UL Type V-meter V-meter switch Main fuses for control devices, IP54 fan with option +B055, transformer with option +B055, V- meter (option +G334), starter for auxiliary motor fan (option +M600) Thermistor and PT100 relays (options +L505, +L506) Buffering module and power supply unit...
Page 41 Operation principle and hardware description 41 Swing-out frame open Main contactor Switch fuse (Q1) Internal cabinet fans Auxiliary cooling fan Swing-out frame Terminal block (X504, option +L504) for external control cable connections to the control unit Module cooling fan Input cable connection terminals behind the shroud (bottom entry) PE busbar Cabinet heater (option +G300) Auxiliary voltage transformer (T21) and distribution components...
Page 42 42 Operation principle and hardware description Cabinet layout of R6i+R6i and R7i+R7i ￭ IP22 (UL Type 1) IP54 (UL Type 12) option +B055 IP42 (UL Type 1 Filtered) option +B054...
Page 43 Operation principle and hardware description 43 Drive module cubicle, door closed Drive module cubicle, door open Drive control panel Charging switch (Q3) Indicators, for example, V-meter and A-meter V-meter switch Operating buttons and door lights Main switch-disconnector (Q1) Main fuses for control devices, IP54 fan with option +B055, V-meter (option +G334), starter for auxiliary motor fan (option +M600) Air baffles Thermistor and Pt100 relays (options +L505, +L506)
Page 44 44 Operation principle and hardware description X250 terminal block Buffering module and power supply unit Terminal blocks X18 and X19 Components and connection terminals for options +G300, +G301, +G307, +G313 Swing-out frame open Common mode filter (included by default) Charging switch and fuses (behind the fuse plate) Main AC fuses Line-side converter unit Motor-side converter unit...
Page 45 Operation principle and hardware description 45 Cabinet layout of R11 ￭ IP22 (UL Type 1) IP54 (UL Type 12) option +B055 IP42 (UL Type 1 Filtered) option +B054...
Page 46 46 Operation principle and hardware description Main breaker and power cabling cubicle Drive module cubicle Swing-out frame on the drive module side open Main switch-disconnector (Q1) handle Drive control panel Operating buttons and door lights Indicators, for example, V-meter and A-meter UL Type V-meter V-meter switch Drive module...
Page 47 Operation principle and hardware description 47 Swing-out frame Main fuses for control devices, IP54 fan with option +B055, transformer with option +B055, V- meter (option +G334), starter for auxiliary motor fan (option +M600) Buffering module and power supply unit Terminal blocks X18 and X19 Ground fault monitoring and safety circuit component Optional extension adapters and modules Thermistor and PT100 relays (options +L505, +L506)
Page 48 48 Operation principle and hardware description Swing-out frame Auxiliary voltage transformer (T102) with option +B055 and distribution components Auxiliary voltage transformer (T21) and distribution components Line-side control unit Extraction ramp Auxiliary voltage transformer (T101) with options +B055 and +C128 and distribution components...
Page 49 Operation principle and hardware description 49 Overview of power and control connections This section shows the power connections and control interfaces of the drive. Connection overview – Frame R8 ￭ Drive control unit (ZCU-12). QCON-21 control board controls the line side-converter. Analog and digital I/O extension modules, feedback interface modules and fieldbus communication modules can be inserted into slots 1, 2 and 3.
Page 50 2 (X12) Note: When installed into the slot 3 of a ZCU-14 control unit, the module goes over the edge. ABB recommends to use slot 1 or 2 whenever possible. Memory unit Connector for FSO-xx safety functions module (X12). The module reserves slot 2 when connected.
Page 51 Operation principle and hardware description 51 Connection overview – Frame R11 ￭ Motor-side converter control unit (drive control unit, ZCU-14) Line-side converter control unit (ZCU-12) Analog and digital I/O extension modules, feedback interface modules and fieldbus communication modules can be inserted into slots 1, 2 and 3. See Type designation key (page 66).
Page 52 52 Operation principle and hardware description External control cable connection terminals (other than control unit ￭ terminals) Connection terminals of R8 The layout of external control cable connection terminals at the right-hand side of the drive cabinet is shown below. The composition depends on the options selected. Terminals for X250 Main switch feedback for customer and line contactor...
Page 53 Operation principle and hardware description 53 Connection terminals of R6i+R6i, R7i+R7i and R11 The layout of external control cable connection terminals at the left-hand side of the drive cabinet is shown below. The composition depends on the options selected. Terminals for X250 Line contactor and main switch feedback for customer X506...
Page 54 54 Operation principle and hardware description Door devices Label in English Label in local language Description READY Ready light (option +G327) Run light (option+G328) FAULT Fault light (option +G329) ENABLE / RUN Run enable signal switch for the line-side con- verter with options +Q951, +Q952 and +Q978 Frames R6i+R6i and R7i+R7i: Run enable signal switch for the supply unit by default...
Page 55 Operation principle and hardware description 55 Main disconnecting device (Q1) ￭ The main disconnecting device switches the main supply to the drive on and off. To disconnect the main supply, turn the switch-disconnector (frames R6i+R6i, R7i+R7i and R11) or switch fuse (frame R8) to the 0/OFF position. WARNING! The main disconnecting device does not isolate the input power terminals from the power line.
Page 56 56 Operation principle and hardware description 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 ￭ Definitions According to IEC/EN 60529, the degree of protection is indicated by an IP code where the first numeral means protection against ingress of solid foreign objects, and the second numeral protection against ingress of water.
Page 57 Operation principle and hardware description 57 Marine product certifications may require additional wire markings. Refer to section Wire markings (page 60). Cooling air inlet through bottom of cabinet (option +C128) ￭ See section Air inlet through the bottom of the cabinet (option +C128) (page 87).
Page 58 58 Operation principle and hardware description Empty cubicles on right (options +C196…C198) ￭ The option adds an empty 400, 600 or 800 mm wide cubicle to the right end of the line-up. The cubicle is equipped with blank power cable entries both at the top and the bottom.
Page 59 Operation principle and hardware description 59 The heater prevents condensation inside the cabinet when the drive is not in operation. The power output of the heating elements increases when the surrounding air temperature is low and decreases when the surrounding air temperature is high. The customer must stop the heating when it is not needed by disconnecting the heater supply voltage.
Page 60 60 Operation principle and hardware description Wire markings ￭ Standard wiring Color The standard color of the wiring is black, with the following exceptions: • PE wiring: Yellow/Green, or yellow/green sleeving • UPS input wiring (option +G307): Orange • Pt100 sensor wiring with ATEX-certified thermal protection (option +nL514): Light blue.
Page 61 Connectivity for wired remote monitoring (option +K496) ￭ This option provides a gateway to connect the drive to ABB Ability™ via a local Ethernet network. Includes NETA-21 remote monitoring tool and FMBT-21 Modbus/TCP adapter module. See the appropriate manual for more information.
Page 62 62 Operation principle and hardware description Code Manual (English) NETA-21 remote monitoring tool user’s manual 3AUA0000096939 NETA-21 remote monitoring tool installation and start-up guide 3AUA0000096881 FMBT-21 Modbus/TCP adapter module user’s manual 3AXD50000158607 FMBT-21 Modbus/TCP adapter module quick installation and start-up guide 3AXD50000158560 InRouter 615-S commissioning guide 3AXD50000837939...
Page 63 Operation principle and hardware description 63 +L536, +L537 An alternative to a thermistor relay option is the FPTC-01 (option +L536) or FPTC-02 (option +L537, also requires option +Q971) thermistor protection module. The module mounts onto the inverter control unit, and has reinforced insulation to keep the control unit PELV-compatible.
Page 64 64 Operation principle and hardware description • firmware manual for parameter settings • ATEX-certified motor thermal protection functions for cabinet-built ACS880 drives (options +L513+Q971 and +L514+Q971) user's manual (3AXD50000014979 [English]) • Pt100 relay alarm and trip limit setting instructions in the start-up instructions •...
Page 65 Operation principle and hardware description 65 Type designation label The type designation label includes an IEC and UL (NEC) rating, appropriate markings, a type designation and a serial number, which allow identification of each unit. A sample label is shown below. Quote the complete type designation and serial number when contacting technical support.
Page 66 66 Operation principle and hardware description Type designation key The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic drive type. The optional selections are given next, separated by plus signs. Codes that start with zero (eg. +0A123) indicate the absence of a specified feature.
Page 67 Operation principle and hardware description 67 Code Description Empty 600 mm wide cubicle on right. See section Empty cubicles on right (options C197 +C196…C198) (page 58). Empty 800 mm wide cubicle on right. See section Empty cubicles on right (options C198 +C196…C198) (page 58).
Page 68 68 Operation principle and hardware description Code Description J425 ACS-AP-I control panel (without Bluetooth) K451 FDNA-01 DeviceNet™ adapter module K454 FPBA-01 PROFIBUS DP® adapter module K457 FCAN-01 CANopen® adapter module K458 FSCA-01 RS-485 (Modbus/RTU) adapter module K462 FCNA-01 ControlNet™ adapter module K469 FECA-01 EtherCAT®...
Page 69 Operation principle and hardware description 69 Code Description M603 Starter for auxiliary motor fan, trip limit 4 … 6.3 A M604 Starter for auxiliary motor fan, trip limit 6.3 … 10 A M605 Starter for auxiliary motor fan, trip limit 10…16 A N5000 Winder control program N5050...
Page 70 70 Operation principle and hardware description Code Description Q986 FSPS-21 PROFIsafe safety functions module Q989 FSCS-21 CIP Safety functions module R700 Printed documents in English R701 Printed documents in German R702 Printed documents in Italian R703 Printed documents in Dutch R704 Printed documents in Danish R705...
Page 71 Mechanical installation 71 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 72 72 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 73 Mechanical installation 73 Moving the drive in its packaging – Frames R6i+R6i, R7i+R7i and R8 ￭ 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 74 74 Mechanical installation Moving the drive in its packaging – Frame R11 ￭ 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 75 Mechanical installation 75 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 76 76 Mechanical installation 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 77 62 Mechanical installation Removing the transport package  Mechanical installation 77 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 78 78 Mechanical installation 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 WARNING! Transportation of the cabinet on its back is only allowed if it is packed for such transportation at the factory.
Page 79 Mechanical installation 79 Installing the IP54 roof (option +B055) If the roof of an IP54 cabinet is delivered in a separate package, install the roof as follows. Frame R8 ￭ Undo the lifting eye screws and remove the lifting eyes. To remove the top front profile of the cabinet, undo the mounting screws.
Page 80 80 Mechanical installation Frames R6i+R6i, R7i+R7i and R11 ￭ Undo the lifting eye screws and remove the lifting eyes. To remove the top front profile of the cabinet, undo the mounting screws. Undo the back mounting screws. Install the roof. Connect the power supply wires to the fan.
Page 81 Mechanical installation 81...
Page 82 82 Mechanical installation Attaching the cabinet to the floor and wall or roof General rules ￭ • Install the drive in an upright vertical position. • Leave 400 mm (15.75”) of free space above the basic roof level of the cabinet for cooling.
Page 83 Mechanical installation 83 WARNING! Do not stand or walk on the cabinet roof. Make sure that nothing presses against the roof, side or back plates or door. Do not store anything on the roof while the drive is in operation. Attaching the cabinet (non-marine units) ￭...
Page 84 84 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 85 Mechanical installation 85 Attaching the cabinet (marine units, option +C121) ￭ 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: Fasten the cabinet to the floor through the flat bars at the base of the back and the front of the cabinet.
Page 86 86 Mechanical installation Dimension drawing for clamp (a), example. 45 [1.77’’] 13.5 [0.53’’] 23.5 [0.93’’] 50 [1.97’’] Ø13 [0.51’’] Ø13 [0.51’’] 30 [1.18’’] 95 [3.74’’]...
Page 87 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 88 88 Mechanical installation Air inlet area Support the plinth of the cabinet all round. The air duct must be able to supply a sufficient volume of cooling air. See technical data for the minimum air flow values. WARNING! Make sure that the incoming air is sufficiently clean. If not, dust goes into the cabinet.
Page 89 Mechanical installation 89 or moist air is able to flow backward to the drive in any case, even during off-time or while servicing the drive or the ventilation system. Calculating the required static pressure difference The required static pressure difference between the exit air duct and the drive installation room can be calculated as follows: Δ...
Page 90 90 Mechanical installation...
Page 91 Mechanical installation 91 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 ￭ Link to Declaration of conformity according to EU Machinery Directive 2006/42/EU (3AXD10000686042) Link to Declaration of conformity according to UK Supply of Machinery (Safety)
Page 93 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 94 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 95 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 96 98). 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 97 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 98 98). 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 99 The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: •...
Page 100 100 Guidelines for planning the electrical installation 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 or frame size 100 kW < P < 350 kW or <...
Page 101 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 102 102 Guidelines for planning the electrical installation General guidelines ￭ Select the input power and motor cables according to local regulations. • Current: Select a cable capable of carrying the maximum load current and suitable for the prospective short-circuit current provided by the supply network. The method of installation and ambient temperature affect the cable current carrying capacity.
Page 103 Guidelines for planning the electrical installation 103 Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar- mored) cable with three phase conductors and a shield (or ar- mor), and separate PE conduct- or/cable 1) A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the PE use.
Page 104 Symmetrical shielded cable with individual shields for each phase conductor Additional guidelines – North America ￭ ABB recommends the use of metallic conduit for power wiring. ABB also recommends the use of symmetrical shielded VFD cable between drive and motor(s).
Page 105 Guidelines for planning the electrical installation 105 This table shows examples of methods for wiring the drive. Refer to NFPA 70 (NEC) along with state and local codes for the appropriate methods for your application. Wiring method Notes 1) 2) Conduit - Metallic Electrical metallic tubing: Type EMT Prefer symmetrical shielded VFD cable.
Page 106 106 Guidelines for planning the electrical installation 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 107 ￭ 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 108 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 RJ45 connectors. The maximum length of the cable is 100 m (328 ft).
Page 109 Guidelines for planning the electrical installation 109 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 110 110 Guidelines for planning the electrical installation Input power cabling Motor cabling Conduit Continuous motor cable shield/conduit and metal enclosure for ￭ equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...
Page 111 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 112 112 Guidelines for planning the electrical installation WARNING! If the drive is connected to multiple motors, use a separate circuit breaker or fuses for protecting each motor cable and motor against overload. The drive overload protection is tuned for the total motor load. It may not trip due to an overload in one motor circuit only.
Page 113 Guidelines for planning the electrical installation 113 Note: As standard, the drive contains capacitors connected between the main circuit and the frame. These capacitors and long motor cables increase the ground leakage current and may cause nuisance faults in residual current devices. Implementing the emergency stop function You can order the drive with an emergency stop function (option).
Page 114 114 Guidelines for planning the electrical installation User's manual Manual code (English) ATEX-certified motor thermal protection functions for cabinet-built ACS880 drives 3AXD50000014979 (options +L513+Q971 and +L514+Q971) user’s manual Implementing the Prevention of unexpected start-up function You can order the drive with a Prevention of unexpected start-up (POUS) function. The POUS function disables the control voltage of the power semiconductors of the drive (inverter) output stage.
Page 115 Guidelines for planning the electrical installation 115 The Safe torque off function can be controlled with PROFIsafe. When using FSPS-21 PROFIsafe safety functions module, other safety functions are not available. Use of PROFIsafe and PROFINET is also possible by using FPNO-21 and FSO option modules. The settings of the module have default values when delivered from the factory.
Page 116 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...
Page 117 Guidelines for planning the electrical installation 117 Implementing the control of a contactor between drive and motor Implementing the control of the output contactor depends on the motor control mode and stopping method selected. When you select the DTC motor control mode and the motor ramp stop mode, use this operation sequence to open the contactor: Give a stop command to the drive.
Page 118 118 Guidelines for planning the electrical installation 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode Implementing a motor temperature sensor connection WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: •...
Page 119 Guidelines for planning the electrical installation 119 Connecting a motor temperature sensor to the drive through an ￭ option module This table shows: • option module types that you can use for the motor temperature sensor connection • insulation or isolation level that each option module forms between its temperature sensor connector and other connectors •...
Page 121 Electrical installation 121 Electrical installation Contents of this chapter This chapter contains instructions on the wiring of the drive. Warnings 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 122 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 123 Electrical installation 123 Ground-to-phase varistor – Frames R8 and R11 ￭ A standard drive with the ground-to-phase varistor connected can be installed to a symmetrically grounded TN-S system. WARNING! Do not install the drive with the ground-to-phase varistor connected to a system that the varistor is not suitable for.
Page 124 124 Electrical installation Setting the voltage range of auxiliary voltage transformers Set the voltage tap in the auxiliary voltage transformer according to the power network voltage. Transformer T21 is included as standard. In frame R8, additional transformer T101 comes with options +B055 and +C128. In frame R11, additional transformer T102 comes with options +B055 and +C128.
Page 125 Electrical installation 125 Frames R6i+R6i and R7i+R7i ￭ The voltage settings of transformer T21 are made at terminal blocks T21_X1/X2. T21 tap settings (400…500 V) T21_X1 T21_X2 500 V 230 V 480 V 460 V 440 V 415 V 400 V 380 V...
Page 126 126 Electrical installation T21 tap settings (690 V) T21_X1 T21_X2 690 V 230 V 660 V 600 V 575 V 540 V 525 V...
Page 127 Electrical installation 127 Connecting the power cables Connection diagram ￭ Connection diagram of frame R8 Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conduct- ivity of the shield does not meet the requirements for the PE conductor. See General guidelines (page 102).
Page 128 128 Electrical installation Connection diagram of frame R11 Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conduct- ivity of the shield does not meet the requirements for the PE conductor. See General guidelines (page 102) 360°...
Page 129 Electrical installation 129 Connection diagram of frame R6i+R6i and R7i+R7i ACS880-17 (PE) (PE) Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conduct- ivity of the shield does not meet the requirements for the PE conductor. See...
Page 130 130 Electrical installation Layout of power cable connection terminals and cable entries ￭ The layout of power cable connection terminals and cable entries of the standard drive are shown below. Note: You have to remove the “door fan” to gain access to the cable terminals and entries (see page 183).
Page 131 Electrical installation 131 Frames R6i+R6i and R7i+R7i Strain relief Power cable entries. Conductive sleeve under the grommet. Control cable entry with EMI conductive cush- ions. PE terminal...
Page 132 132 Electrical installation Frame R11 Strain relief Power cable entries. Conductive sleeve under the grommet. Control cable entry with EMI conductive cush- ions. PE terminal Input power cable terminals L1, L2 and L3 Motor cable terminals U2, V2, W2...
Page 133 Electrical installation 133 Layout of power cable connection terminals (option +C129) This figure shows the layout of the power cable connection terminals of frame R8. Power cable entries Strain relief Ground bar Input cable power connection terminals L1, L2 and L3 Motor cable connection terminals U2, V2, W2 This figure shows the layout of the power cable connection terminals of frames R6i+R6i and R7i+R7i.
Page 134 134 Electrical installation This figure shows the layout of the power cable connection terminals of frame R11. Strain relief PE terminal Motor cable connection terminals U2, V2, W2 Input cable power connection terminals L1, L2 and L3 External resistor cable connection terminals and cable entries External brake resistor cables are connected directly to the brake chopper (option +D150) terminals in the brake chopper cubicle.
Page 135 Electrical installation 135 For R6i+R6i and R7i+R7i top entry of cables: • Remove the steel shroud in front of fuses. • Unplug the connectors at the top mounting plate, loosen the four screws and lift off the top mounting plate. •...
Page 136 136 Electrical installation WARNING! Apply grease to stripped aluminum conductors before you attach them to non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions. Aluminum-aluminum contact can cause oxidation in the contact surfaces. If fire insulation is used, make an opening in the mineral wool sheet according to the diameter of the cable.
Page 137 Electrical installation 137 Attach the conductive sleeves to the cable shields with cable ties. Tie up the unused conductive sleeves with cable ties. 10. Connect the twisted shields of the motor cables to the ground bar and the phase conductors to the U2, V2 and W2 terminals. 11.
Page 138 138 Electrical installation Connection procedure (North America) ￭ WARNING! Apply grease to stripped aluminum conductors before you attach them to non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions. Aluminum-aluminum contact can cause oxidation in the contact surfaces. Do the steps in section Electrical safety precautions (page 19) before you start the work.
Page 139 Electrical installation 139 For R11 top entry of cables: • Marine drives (option +C121): Undo the three M6 screws on the left side of the swing-out frame. • Undo the two screws and open the swing-out frame or remove the shroud if there is no swing-out frame.
Page 140 140 Electrical installation Grounding the motor cable shield at the motor end ￭ For minimum radio-frequency interference, ground the cable shield 360° at the cable entry of the motor terminal box. Connecting the control cables See chapter Control unit (page 157) for the default I/O connections of the drive control unit (with the ACS880 primary control program).
Page 141 Electrical installation 141 Frame R8 Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work. Open the cabinet door. If there is a mounting plate above the fan, loosen the four screws and pull out the plate.
Page 142 142 Electrical installation Drives with swing-out frame: Open the swing-out frame (a). Marine drives (option +C121): To open the swing-out frame, undo the three M6 screws on the left side of the swing-out frame. Drives without swing-out frame: Remove the shroud (b).
Page 143 Electrical installation 143 Route the cables to the control unit (a) and additional terminal block X504 (option +L504) and to options +QXXX, +MXXX, +L505 and +L506 as shown below. Bottom entry Top entry X504 +QXXX +MXXX +L505 +L506...
Page 144 144 Electrical installation Frame R11 Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work. Open the cabinet door. If there is a mounting plate/two plates above the "door fan", loosen the four screws of the plate and pull out the plate/s.
Page 145 Electrical installation 145 Bottom entry: Route the cables to the control unit (a), additional terminal block X504 (option +L504) as shown below. X504...
Page 146 146 Electrical installation Top entry: Route the control cables to the control unit (a) and additional terminal block X504 (option +L504) as shown below (standard cabinet and option +B054 with blue color; option +B055 with green). +B055 X504...
Page 147 Electrical installation 147 Frames R6i+R6i and R7i+R7i Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work. Open the cabinet door. Open the swing-out frame. Bottom entry: If there is a mounting plate under the swing-out frame, loosen the four screws and pull out the plate.
Page 148 148 Electrical installation Route the cables to the control unit (a) and additional terminal block X504 (option +L504) as shown below. Bottom entry Top entry X504 X506 X504 X506 Connecting the external control cables to the drive control unit ￭ See chapter Control unit (page 157) for the default I/O connections of the drive control...
Page 149 Electrical installation 149 Note: At the other end of the cable, leave the shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg. 3.3 nF / 630 V. The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points.
Page 150 150 Electrical installation Installing option modules Installing option modules ￭ 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 ESD wristband when you handle printed circuit boards.
Page 151 Electrical installation 151 If you must remove the option module after it is installed into the drive, use a suitable tool (for example, small pliers) to carefully pull out the lock. Installation of an FSO safety functions module beside the ZCU-12 ￭...
Page 152 152 Electrical installation Installing an FSO safety functions module onto ZCU control unit ￭ 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 153 Electrical installation 153 Connect the STO cable to FSO module connector X111 and to control unit connector XSTO. Connect the power supply wires to the FSO module terminal X112. Connect any user-defined signal cables to the FSO module according to the application requirements.
Page 154 154 Electrical installation Installation of an FSO safety functions module beside the ZCU-14 ￭ control unit for frames R6i+R6i and R7i+R7i Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work. Attach the mounting plate to the cabinet with two screws and tighten to 5 N·m (3.7 lbf·ft).
Page 155 Electrical installation 155 Installation of an FSO safety functions module beside the ZCU-14 ￭ control unit for frame R11 Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work. Loosely attach the FSO module to the mounting plate with four screws. Torque the FSO module electronics grounding screw to 1.2 N·m (10.6 lbf·in).
Page 156 156 Electrical installation Installing the FSCS-21 safety functions module ￭ To install safety functions module FSCS-21 onto the drive control unit, refer to FSCS-21 CIP Safety™ functions module user's manual (3AXD50001065478 [English]).
Page 157 Control unit 157 Control unit Contents of this chapter This chapter • gives information on the connections of the control unit, and • has the specifications of the inputs and outputs of the control unit. General The drive utilizes ZCU-1x control units. Frame R8 contains the ZCU-12 control unit.
Page 158 158 Control unit 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 XRO3...
Page 159 Control unit 159 ZCU-14 layout Description XPOW External power input Analog inputs Analog outputs XRO1 XD2D Drive-to-drive link XRO1 Relay output RO1 XRO2 XRO2 Relay output RO2 XRO3 Relay output RO3 XRO3 XD24 Digital input interlock (DIIL) and +24 V output XDIO Digital input/outputs...
Page 160 160 Control unit Default I/O diagram of the drive 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 161 Control unit 161 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 DIIL Run enable...
Page 162 162 Control unit 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) Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and DIO2. 3) Determines whether DICOM is separated from DIOGND (ie.
Page 163 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 164 164 Control unit 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 165 Control unit 165 Connector data The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (22…12 AWG). Connector pitch is 5 mm. The maximum tightening torque for screw terminals is 0.5 N·m (5 lbf·in). Power supply (XPOW) 24 V DC (±10%), 2 A External power input.
Page 166 166 Control unit XD2D connector Physical layer: RS-485 Transmission rate: 8 Mbit/s Cable type: Shielded twisted-pair cable with a twisted pair for data and a wire or another pair for signal ground (nominal impedance 100 … 165 ohm, for example Belden 9842) Maximum length of link: 50 m (164 ft) Termination by jumper RS-485 connection (X485)
Page 167 Control unit 167 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 XSTO OUT1 * Ground selector (J6) settings...
Page 169 Installation checklist 169 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 170 170 Installation checklist Make sure that … The ambient operating conditions meet the drive ambient conditions specification and enclosure rating (IP code). The supply voltage matches the nominal input voltage of the drive. Refer the type designation label. The insulation resistance of the input power cable, motor cable and motor is measured according to local regulations and the manuals of the drive.
Page 171 Start-up 171 Start-up Contents of this chapter This chapter describes the start-up procedure of the drive. 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. The manufacturing date is on the type designation label. For information on reforming the capacitors, refer to Capacitor reforming instructions (3BFE64059629...
Page 172 172 Start-up Action Safety WARNING! Obey the safety instructions during the start-up procedure. See chapter Safety instruc- tions (page 17). Checks/Settings with no voltage connected Ensure that the disconnector of the supply transformer is locked to the off (0) position, ie. no voltage is, and cannot be connected to the drive inadvertently.
Page 173 Start-up 173 Action Setting up the line-side converter parameters The line-side converter control program parameters are set at the factory. Normally, there is no need to change them at the start-up. For more information on the line-side converter control parameters, see ACS880 primary control program firmware manual (3AUA0000085967 [English]) ACS880 IGBT supply control program...
Page 175 Fault tracing 175 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs Where Color When the LED is lit Control panel POWER Green Control unit is powered and +15 V is supplied to the control mounting plat- panel form...
Page 177 Contents of this chapter This chapter contains preventive maintenance instructions. 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). Description of symbols ￭...
Page 178 DC circuit capacitors reforming for spare modules and spare capacitors Inspections by user IP22 and IP42 air inlet and outlet meshes on the cabinet doors Tightness of terminals Dustiness, corrosion and temperature Cleaning of heatsinks Other ABB-SACE air circuit breaker maintenance 4FPS10000239703, 4FPS10000292961...
Page 179 • 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 180 180 Maintenance 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 181 Maintenance 181 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 19) before you start the work.
Page 182 182 Maintenance Replacing the inlet door filters (IP54) ￭ Stop the drive and do the steps in section Electrical safety precautions (page 19) 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 183 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. Replacing the cabinet “door fan”...
Page 184 184 Maintenance Loosen the four mounting screws of the fan mounting plate. Lift the mounting plate upwards. Unplug the fan supply wires. Lift the fan mounting plate off. Undo the four mounting screws of the fan and remove the fan from the mounting plate.
Page 185 Maintenance 185 Replacing the internal cabinet cooling fans (frame R8) ￭ 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 19) before you start the work.
Page 186 186 Maintenance...
Page 187 Maintenance 187 Replacing the internal cabinet cooling fans (frames R6i+R6i and ￭ R7i+R7i) 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 188 188 Maintenance Replacing the drive module main fan (frame R8) ￭ 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 19) before you start the work.
Page 189 Maintenance 189 To open the module section swing-out frame, undo the M10 bolts from top and bottom (4 pcs). See Replacing the drive and LCL filter modules (frame R11) (page 208). Disconnect the power supply wires of the fans from the connectors FAN1:PWR1 and FAN2:PWR2.
Page 190 190 Maintenance 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 191 Maintenance 191 Replacing the LCL filter module fan (frame R11) ￭ 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 19) before you start the work.
Page 192 192 Maintenance Replacing the BLCL filter module fan (frames R6i+R6i and R7i+R7i) ￭ 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 193 Maintenance 193 Replacing the auxiliary cooling fan of the drive module (frame R8) ￭ 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 19) before you start the work.
Page 194 194 Maintenance Replacing the auxiliary cooling fans of the drive module (frame R11) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Fan in the front panel: Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work.
Page 195 Maintenance 195 Drives with option +C121: Remove the marine supports. See Replacing the drive and LCL filter modules (frame R11) (page 208). To open the swing-out frame, undo the M10 bolts from top and bottom (4 pcs). The fan locates in the bottom part of drive module circuit board compartment. Undo the mounting screw of the fan cassette.
Page 196 196 Maintenance Frame R8: Replacing the IP54 (UL Type 12) roof fan ￭ 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 19) before you start the work.
Page 197 Maintenance 197 Frame R11 with options +B055 and +C128: Replacing the roof fan ￭ 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 19) before you start the work.
Page 198 198 Maintenance Frames R6i+R6i and R7i+R7i and frame R11 with option +B055: ￭ Replacing the roof fan 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 19) before you start the work.
Page 199 • torque wrench with an extension bar • lifting chains. A lifting device is available from ABB with order code 3AXD50000047447. Replacing the drive module (frame R8) ￭ WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 200 200 Maintenance...
Page 201 Maintenance 201 Disconnect the control panel cable from the module and the control wire terminals on the right side of the cabinet. To remove the mounting plate above the “door fan”, loosen the mounting screws and lift the plate up or remove the shroud and four fixing brackets if there is no mounting plate.
Page 202 202 Maintenance 10. Loosen the four M5 screws and remove the plastic shroud. 11. For drives with bottom entry: Undo the four M6 combi screws and remove the plastic shroud. 12. For drives with bottom entry or exit: Remove the connection terminal subassembly: Undo the screws or nuts: •...
Page 203 Maintenance 203 16. For drives with brake chopper (option +D150): Undo the two M10 nuts and bend the two power cables down so that they do not disturb the module replacement. Bottom exit from module Bottom exit with +E208 or +E205...
Page 204 204 Maintenance Top exit...
Page 205 Maintenance 205 17. Undo the four M6 combi screws and remove the plastic air guide. 18. Loosen the four M6 combi screws, unplug the connector, lift the fan up a bit and remove the fan plate. 19. For easier removal of the module, undo the four M6 combi screws, disconnect the wires of the thermal switch and remove the plastic air guide.
Page 206 206 Maintenance 22. Undo the four M8 Serpress® nuts. 23. Undo the two M6 self-tapping screws in the bottom left side of the cabinet and remove the module slide extension rails.
Page 207 Maintenance 207 24. Install the extension rails at the end of the sliding bars. 25. Slide the drive module towards the end of the sliding bars. 26. Secure the drive module with chains from the lifting eyes. 27. Lift the module out of the cabinet with a lifting device. 28.
Page 208 208 Maintenance Replacing the drive and LCL filter modules (frame R11) Required tools ￭ • installation ramp • set of screw drivers • torque wrench with an extension bar • lifting chains. Safety ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 209 Maintenance 209 • Use the support legs when applicable. To open the support legs, push each leg down and turn it out (1, 2). • Use chains to support the module whenever possible. • Do not tilt the module. It is heavy and its center of gravity is high. •...
Page 210 210 Maintenance Replacing the drive module (frame R11) ￭ Replacing the drive module requires preferably two persons. Stop the drive (if running) and do the steps in section Electrical safety precautions (page 19) before you start the work. Open the cabinet doors. For drives with option +C121: Undo the two module attaching screws (3a).
Page 211 Maintenance 211 3a: Combi screw M10 3b, 3c, 3d and 3e: M6...
Page 212 212 Maintenance To open the module section swing-out frame, undo the M10 bolts from top and bottom (4 pcs).
Page 213 Maintenance 213 Loosen the two M6 screws of the air baffle and push it to the left. (Not for drives with option +C128.) Remove the air baffle. Remove the air baffle. (Not for drives with option +C121.) Remove the air baffle: (8a) in IP22/IP42 drives, (8b) in IP54 drives. Disconnect all cables from line-side converter control unit (from terminal X2, INU STO connector and the fiber optic cables from the V8, V13, V2 and V7 connectors).
Page 214 214 Maintenance...
Page 215 Maintenance 215 The connections between the line-side converter control unit and drive are shown below. The drive control unit remains in its place when you remove the drive module.
Page 216 216 Maintenance 10. Loosen the M4 screws, lift the plastic shroud of the DC busbars up and remove 11. Disconnect the input power cabling busbars from the drive module busbar terminals. For drives with option +D150: disconnect the DC busbars also. 12.
Page 217 Maintenance 217 13. To disconnect the drive module from the LCL filter module: • (13a) Remove the shroud. • (13b) Remove the bolts that connect the power busbars. • (13c) Remove the attaching bolt. • (13d) Remove the shroud. • (13e) Remove the bolts.
Page 218 218 Maintenance 14. To open the support legs 90 degrees, press each leg a little down and turn it aside. 15. To remove the lower support bracket of the drive module, undo the two screws. 16. Adjust the extraction ramp to the correct height and attach it to the cabinet base with the two mounting screws of the support bracket that was removed.
Page 219 Maintenance 219 18. To remove the shroud on the X1 connector(s), undo the two mounting screws. 19. For drives with charging contactor (Q3): Undo the screws of the X1 connectors and remove the charging contactor wires. 20. Unplug the connector and auxiliary contact wires of the charging circuit contactor. 21.
Page 220 220 Maintenance...
Page 221 Maintenance 221 Replacing the LCL filter module (frame R11) ￭ If LCL filter module is also to be replaced: To open the support legs 90 degrees, press each leg a little down and turning it aside. To remove the lower support bracket of the LCL filter module, undo the two screws. Adjust the extraction ramp to the correct height and attach it to the cabinet base with the two mounting screws of the lower support bracket that was removed.
Page 222 222 Maintenance Attach the lifting lugs of the module to be removed to the cabinet lifting lug with chains. Pull the LCL filter module carefully out of the cabinet preferably with help from another person. Install new module in reverse order.
Page 223 Maintenance 223 Replacing the converter modules and BLCL filter module (frames R6i+R6i and R7i+R7i) Replacing the converter modules (frames R6i and R7i) ￭ 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 224 224 Maintenance Remove the two screws holding the module at the bottom. Remove the three screws to disconnect the AC busbars.
Page 225 Maintenance 225 Remove the two screws holding the module at the top. Remove the two screws to disconnect the DC busbars.
Page 226 226 Maintenance 10. Pull the module out until the lifting eyes at each side of the module are accessible. 11. Attach a hoist to the lifting eyes and pull the module out. Install a new module in reverse order.
Page 227 Maintenance 227 Replacing the BLCL filter module (frames R6i+R6i and R7i+R7i) ￭ 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 228 228 Maintenance Remove the two screws and pull out the filter module fan. Remove the two M8 screws on the back of the module. Remove the two screws that attach the bottom of the module to the base of the cabinet.
Page 229 Maintenance 229 12. Pull the module carefully out of the cabinet along the ramp. While you pull the handle, keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. 13.
Page 230 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 231 Maintenance 231...
Page 232 232 Maintenance Replacing fuses (frame R11) ￭ 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. Stop the drive (if running) and do the steps in section Electrical safety precautions (page 19)
Page 233 Maintenance 233...
Page 234 234 Maintenance Replacing fuses (frames R6i+R6i and R7i+R7i) ￭ 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. Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work.
Page 235 Maintenance 235 Control panel Replacing the battery and cleaning ￭ ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels user's manual (3AUA0000085685 [English]).
Page 236 ￭ The ZCU-12 control unit in R11 frames produced after week 13 2022 does not have a battery in it. For earlier revisions of the control unit, contact ABB service for instructions on how to replace the control unit battery.
Page 237 Maintenance 237 Replacing the ZCU-14 control unit battery ￭ 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 238 238 Maintenance Memory unit ￭ One memory unit is located on the drive control unit (motor-side converter control unit), another on the line-side converter control unit. If you replace a control unit, you can retain the existing parameter settings by transferring the memory unit from the defective control unit to the new control unit.
Page 239 Maintenance 239 Replacing the memory unit of the motor-side converter control unit (frame R8) 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 240 240 Maintenance Replacing the memory unit of the motor-side and line-side converter control unit (frames R6i+R6i and R7i+R7i) 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 241 14. Press Loc/Rem key to turn the panel to remote control mode (external motor control is possible). If the value is 999, the software has not identified the Drive rating ID. Contact ABB. If you do not have a parameter backup file, contact ABB for instructions on how to...
Page 242 242 Maintenance Replacing the memory unit of the motor-side converter control unit (frame R11) Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work. Open the cabinet doors. The control unit is located on the module-side swing-out frame.
Page 243 Maintenance 243 Replacing the memory unit of the line-side converter control unit (frame R11) 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 244 244 Maintenance have a shorter lifespan than 20 years, depending on their usage. These components must be replaced before the end of their lifetime. Contact your local ABB service representative for more information.
Page 245 Technical data 245 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. Marine type-approved drives (option +C132) Refer to ACS880 +C132 marine type-approved cabinet-built drives supplement (3AXD50000039629 [English])
Page 246 The rise in input current can heat the input cable and fuses. To avoid heating, select an input cable and fuses according to the increased input current caused by the DC voltage boost. For more information, refer to ACS880-11, ACS880- 31, ACS880-14, ACS880-34, ACS880-17, ACS880-37 drives product note on voltage boost (3AXD50000691838 [English]).
Page 247 The rise in input current can heat the input cable and fuses. To avoid heating, select an input cable and fuses according to the increased input current caused by the DC voltage boost. For more information, refer to ACS880-11, ACS880- 31, ACS880-14, ACS880-34, ACS880-17, ACS880-37 drives product note on voltage boost (3AXD50000691838 [English]). Definitions ￭...
Page 248 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 249 Ex motor, sine filter, low noise The ratings in these cases are given in the table below: • drive is used with an ABB motor for explosive atmospheres (Ex) and EX motor in parameter 95.15 Special HW settings is enabled •...
Page 250 250 Technical data Note: If Ex motors are used together with sine filters, EX motor in parameter 95.15 Special HW settings is disabled and ABB Sine filter in parameter 95.15 Special HW settings is enabled. Obey the instructions of the motor manufacturer.
Page 251 High speed mode Selection High speed mode of parameter 95.15 Special HW settings improves control performance at high output frequencies. ABB recommends it to be selected with output frequency of 120 Hz and above. This table gives the drive module ratings for 120 Hz output frequency and the maximum output frequency for the drive ratings when High speed mode in parameter 95.15...
Page 252 120 Hz output frequency (no derating) Maximum output frequency 500 Hz Drive type Light- Heavy- Light- Heavy- Nominal use Nominal use duty use duty use duty use duty use ACS880-17-… 0293A-3 0363A-3 0442A-3 0505A-3 0585A-3 0650A-3 = 500 V 0101A-5 0124A-5 0156A-5 0180A-5 0190A-5...
Page 253 0.875 Example 1: P for ACS880-17-650A-3 is 355 kW. The input voltage ( U ) is 350 V. -> U / U = 350 V / 400 V = 0.875. -> P / P = 0.975 -> The derated power P = 0.975 × 355 kW = 346 kW.
Page 254 0.96 Example 1: P for ACS880-17-430A-7 is 400 kW. The input voltage ( U ) is 660 V. -> U / U 660 V / 690 V = 0.96 -> P / P = 0.96 -> The derated power P = 0.96 × 400 kW = 384 kW.
Page 255 Technical data 255 Fuses (IEC) The drive is equipped with aR fuses listed below as standard. Input cur- Ultrarapid (aR) fuses (one fuse per phase) Drive type rent ACS880-17-… Manufacturer Type Size = 400 V 0105A-3 8250 Bussmann 170M3814D 0145A-3...
Page 256 256 Technical data Input cur- Ultrarapid (aR) fuses (one fuse per phase) Drive type rent ACS880-17-… Manufacturer Type Size = 400 V 0105A-3 0145A-3 0169A-3 0206A-3 0220A-3 0290A-3 160000 Mersen SC32AR69V500TF 0293A-3 160000 Mersen SC32AR69V500TF 0363A-3 315000 Mersen SC32AR69V630TF 0442A-3...
Page 257 The fuses restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive. Obey local regulations. Fuse (one fuse per phase) Input cur- Drive type rent UL class / ACS880-17-… Manufacturer Type Size = 400 V 0105A-3 Bussmann...
Page 258 258 Technical data Fuse (one fuse per phase) Input cur- Drive type rent UL class / ACS880-17-… Manufacturer Type Size 0210A-7 Bussmann 170M5408 0271A-7 Bussmann 170M5410 0330A-7 Bussmann 170M6410 0370A-7 Bussmann 170M6411 0430A-7 Bussmann 170M6411 Dimensions and weights Height Depth...
Page 259 Technical data 259 Height Width Depth Weight Frame size IP22/42 IP54 0101A-5 2145 84.45 2315 91.14 23.62 25.43 0124A-5 2145 84.45 2315 91.14 23.62 25.43 0156A-5 2145 84.45 2315 91.14 23.62 25.43 0180A-5 2145 84.45 2315 91.14 23.62 25.43 0190A-5 2145 84.45 2315...
Page 260 260 Technical data Free space requirements Front Side Above * 5.91 15.75 * Measured from the base plate of the cabinet top. > 400 mm (15.75 in.) Door opening:...
Page 261 This table shows typical heat dissipation values, required air flow and noise at the nominal ratings of the drive. The heat loss values can vary depending on product configuration, voltage, cable conditions, motor efficiency and power factor. To obtain more accurate values for given conditions, use ABB DriveSize tool (http://new.abb.com/drives/softwaretools/drivesize). Air flow...
Page 262 262 Technical data Air flow Heat dissipation Noise Drive type +E206 +E206 +E206 ACS880-17-… /min /min dB(A) dB(A) 0271A-7 2100 1279 10.49 0.93 0330A-7 2100 1279 13.09 0370A-7 2100 1279 14.71 0430A-7 2100 1279 16.53 Additional heat dissipation of sine filter (option +E206)
Page 263 Technical data 263 Cooling data Sine filter(s) used Drive type Heat dissipa- Air flow tion ACS880-17-… Type /h (ft /min) 0302A-5 B84143V0390S229 1.57 0361A-5 B84143V0390S229 1.57 0414A-5 B84143V0390S229 1.557 0460A-5 NSIN0900-6 3.16 2000 (1177) 0503A-5 NSIN0900-6 3.46 2000 (1177) = 690 V...
Page 264 264 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) 1308 3 × 50 + 25 1613 1230 3 ×...
Page 265 Technical data 265 Mechanical connections ￭ Size Max. torque Strength class 6 N·m (53 lbf·in) 10 N·m (7.4 lbf·ft) 24 N·m (17.7 lbf·ft) Insulation supports ￭ Size Max. torque Strength class 5 N·m (44 lbf·in) 9 N·m (6.6 lbf·ft) 18 N·m (13.3 lbf·ft) 31 N·m (23 lbf·ft) Cable lugs ￭...
Page 266 266 Technical data North America ￭ Terminals L1, L2, L3, U2, V2, W2 Grounding terminals Frame Max. phase conductor Tightening Tightening Busbar bolt size size torque torque size – Hole Bolt size spacing AWG/kcmil lbf·ft lbf·ft M12 (7/16") × 1 350 MCM 15…30 M10 (3/8")
Page 267 Technical data 267 Frame R11 Copper compression Aluminum Cable cross section cable lugs compression cable Connection method (DIN 46235) lugs (DIN 46329) Maximum cable lug diameter (including possible shrink hose) for R11 is 33 mm (1.3 in). Frame R6i+R6i and R7i+R7i Copper compression Aluminum Cable cross section...
Page 268 268 Technical data Location and size of power cable connection terminals ￭ R8 input and motor cable terminals Distance between adjacent terminals is 25 mm (0.98 in) for drives without option +E202 and 50 mm (1.97 in) for drives with option +E202.
Page 269 Technical data 269 R8 input and motor cable terminal dimensions – bottom entry and exit...
Page 270 270 Technical data R8 input and motor cable terminal dimensions – top entry and exit (options +H351 and +H353)
Page 271 Technical data 271 R6i+R6i and R7i+R7i input cable terminal - bottom entry Distance between adjacent terminals is 100 mm (3.94 in). R6i+R6i and R7i+R7i motor cable terminal - bottom exit Distance between adjacent terminals is 116 mm (4.57 in).
Page 272 272 Technical data R6i+R6i and R7i+R7i input and motor cable terminal - top entry and exit Distance between adjacent terminals is 67 mm (2.64 in).
Page 273 Technical data 273 R6i+R6i and R7i+R7i input and motor cable terminal dimensions - bottom entry and exit...
Page 274 274 Technical data R6i+R6i and R7i+R7i input and motor cable terminal dimensions - top entry and exit (options +H351 and +H353)
Page 275 Technical data 275 R11 input cable terminals Distance between adjacent terminals is 80 mm (3.15 in). R11 motor cable terminals Distance between adjacent terminals is 80 mm (3.15 in).
Page 276 276 Technical data R11 input and motor cable terminal dimensions – bottom entry and exit...
Page 277 Technical data 277 R11 input and motor cable terminal dimensions – top entry and exit (options +H351 and +H353) Terminals for connecting external resistors...
Page 278 278 Technical data Sine filter (+E206) cubicle, 400 mm: motor cable terminals Sine filter (+E206) cubicle, 600 mm: motor cable terminals...
Page 279 Electrical power network specification Voltage ( U ACS880-17-xxxxx-3 drives: 380…415 VAC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage level. 3 ~ 400 V AC. ACS880-17-xxxxx-5 drives: 380…500 VAC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage levels.
Page 280 280 Technical data Short-circuit cur- The drive is suitable for use on a circuit capable of delivering not more than 100,000 rent protection (UL rms symmetrical amperes at 600 V maximum when the input cable is protected 508A) with class T fuses. Short-circuit cur- The drive is suitable for use on a circuit capable of delivering not more than 100,000 rent protection...
Page 281 Note: Longer motor cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and characteristics. Contact ABB for more information. Note that a sine filter (option +E206) at the drive output also causes a voltage decrease.
Page 282 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 283 Standard package Road, rail, air, sea (in 2K12: Transportation Not allowed. container). without temperature and Cardboard box humidity control allowed. Special vehicle Horizontal requirements: Preferred for air and courier. ABB recommends the use of container desiccant bags in sea transportation.
Page 284 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 285 Technical data 285 Auxiliary circuit power consumption Cabinet heater and 150 W lighting (options +G300 and +G301) External uninterruptible 150 W power supply (option 210 W with MCS-B 7.5-110-240/24 power supply unit or +G307) 220 W with EMPARRO 10-100-240/24 power supply unit Motor heater (option According to heater type +G313)
Page 286 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 287 Technical data 287 Applicable standards Standard Information European electrical safety EN 61800-5-1:2007 + A1:2017 + Adjustable speed electrical power drive systems - Part 5-1: Safety A11:2021 requirements – Electrical, thermal and energy IEC 61800-5-1:2007 + Amd1:2016 EMC performance EN 61800-3:2004 + A1:2012 Adjustable speed electrical power drive systems - Part 3: EMC re- quirements and specific test methods IEC 61800-3:2004 + A1:2011...
Page 288 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. KC mark Product complies with Korean Registration of Broadcasting and Communications Equipment Clause 3, Article 58-2 of Radio Waves Act.
Page 289 Technical data 289 Note: A professional is a person or organization having necessary skills in installing and/or starting up power drive systems, including their EMC aspects. Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment.
Page 290 290 Technical data and cables is sufficient. If in doubt, a supply transformer with static screening between the primary and secondary windings can be used. 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.
Page 291 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 292 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 293 Dimension drawings 293 Dimension drawings Contents of this chapter This chapter contains example dimension drawings.
Page 294 294 Dimension drawings R8 IP22 (UL Type 1) and option +B054 (IP42 [UL Type 1 Filtered])
Page 295 Dimension drawings 295 R8 IP54 (UL Type 12, option +B055), option +C129...
Page 296 296 Dimension drawings R8 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +D150, +D151...
Page 297 Dimension drawings 297 R8 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +E206...
Page 298 298 Dimension drawings R8 IP22 (UL Type 1): option +E202...
Page 299 Dimension drawings 299 R6i+R6i and R7i+R7i IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054)
Page 300 300 Dimension drawings R6i+R6i and R7i+R7i IP54 (UL Type 12, option +B055): option +C129...
Page 301 Dimension drawings 301 R6i+R6i and R7i+R7i IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +D150, +D151...
Page 302 302 Dimension drawings R6i+R6i and R7i+R7i IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +E206...
Page 303 Dimension drawings 303 R6i+R6i and R7i+R7i IP22 (UL Type 1): option +E202...
Page 304 304 Dimension drawings R6i+R6i and R7i+R7i IP54 (UL Type 12, option +B055): option +C128...
Page 305 Dimension drawings 305 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054)
Page 306 306 Dimension drawings R11 IP54 (UL Type 12, option +B055)
Page 307 Dimension drawings 307 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +C129, +H350, +H352...
Page 308 308 Dimension drawings R11 IP54 (UL Type 12, option +B055): option +C128...
Page 309 Dimension drawings 309 R11 IP54 (UL Type 12, option +B055): option +C129...
Page 310 310 Dimension drawings R11 IP54 (UL Type 12, option +B055): options +C129, +H350, +H352...
Page 311 Dimension drawings 311 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +D150...
Page 312 312 Dimension drawings R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): options +D150, +D151...
Page 313 Dimension drawings 313 R11 IP22 (UL Type 1) and IP42 (UL Type 1 Filtered, option +B054): option +E206...
Page 314 314 Dimension drawings R11 IP22 (UL Type 1): option +E202...
Page 315 The Safe torque off function 315 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 316 316 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 317 FPTC thermistor protection module can also be used. 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 318 318 The Safe torque off function Single ACS880-17 drive, internal power supply ￭ Dual-channel connection of activation switch (ZCU-12) OUT1 +24 V SGND Drive Control unit Activation switch Dual-channel connection of activation switch (ZCU-14) +24 V SGND Drive Control unit...
Page 319 The Safe torque off function 319 Single-channel connection of activation switch (ZCU-12) XSTO OUT1 +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 320 320 The Safe torque off function Multiple drives ￭ Internal power supply XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * "OUT1" in drives with ZCU-12 control unit...
Page 321 The Safe torque off function 321 External power supply 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * "OUT1" in drives with ZCU-12 control unit...
Page 322 322 The Safe torque off function 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 (refer the firmware manual of the drive).
Page 323 The Safe torque off function 323 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 324 324 The Safe torque off function Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...
Page 325 The Safe torque off function 325 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 (refer the firmware manual of the drive).
Page 326 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 323). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...
Page 327 The Safe torque off function 327 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 328 Refer 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 329 The Safe torque off function 329 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 330 330 The Safe torque off function...
Page 331 The Safe torque off function 331 • The STO is a type A (frames R8, R6i and R7i) or type B (frame R11) safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) •...
Page 332 332 The Safe torque off function Term or Reference Description abbreviation IEC/EN 61800-5-2 Safe torque off Proof test interval. T IEC 61508-6 is a parameter used to define the probabilistic failure rate (PFH or PFD) for the safety function or subsystem.
Page 333 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.

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