Page 1 ABB industrial drives Hardware manual ACS880-04XT drive module packages (500 to 1200 kW)
Page 2 List of related manuals Drive hardware manuals and guides Code (English) Drive/converter/inverter safety instructions Multilingual code: 3AXD50000037978 ACS880-04XT drive module packages (500 to 1200 kW) 3AXD50000025169 hardware manual ACS-AP-x Assistant control panels user’s manual 3AUA0000085685 BCU-02/12/22 control units hardware manual...
Page 3 Update notice 1 Update notice The notice concerns the ACS880-04XT hardware manuals listed below. Contents of the notice: Checking the compatibility of the drive with IT (ungrounded) and corner- grounded delta systems, identifying different types of electrical power systems, disconnecting EMC filter and ground-to-phase varistor.
Page 4 2 Update notice Corner-grounded and midpoint-grounded 690 V delta systems  WARNING! Do not install the drive on a 690 V corner-grounded or midpoint- grounded delta system. Disconnecting the EMC filter and ground-to-phase varistor does not prevent damage to the drive. Disconnection table ...
Page 5 Update notice 3 EMC filter ARFI-10 (ordering code 68241561) Check from this table if you have to remove EMC filter ARFI-10 or ground-to-phase varistor (VAR screw). Frame Symmetrically Corner-grounded and IT systems (ungrounded or size grounded TN systems midpoint-grounded delta high-resistance-grounded (TN-S systems) systems...
Page 6 4 Update notice The line-to-ground voltages in relation to the line-to-line voltage of the electrical power system types are shown below. Electrical power system type L1-G L2-G L3-G 0.58·X 0.58·X 0.58·X Symmetrically grounded TN system (TN- S system) 1.0·X 1.0·X Corner-grounded delta system (nonsymmetrical) 0.5·X...
Page 7 Update notice 5 Internal EMC option +E200  Disconnect the filter grounding wire (EMC AC) and ground-to-phase varistor grounding wire (VAR) before you connect the drive to the supply network. Insulate the end of the wire and attach it. The wires are located at the side of the drive module next to the circuit board compartment.
Page 9 Hardware manual ACS880-04XT drive module packages (500 to 1200 kW) Table of contents 1. Safety instructions 6. Installation instructions 10. Start-up  2017 ABB Oy. All Rights Reserved. 3AXD50000025169 Rev D EFFECTIVE: 2017-06-01...
Page 11 Table of contents List of related manuals ........... 2 1.
Page 12 ABB air inlet and outlet kits ........
Page 13 Typical power cable sizes ..........76 Alternative power cable types .
Page 14 Package drawings ........... 95 Checking the delivery .
Page 15 Installing the roof and door (Rittal parts) ........130 Installing the roof and door (ABB air filters and roof) ......131 Removing the protective covering from the drive module air outlet .
Page 16 12. Maintenance Contents of this chapter ..........157 Maintenance intervals .
Page 17 Modules used ............185 Fuses (IEC) .
Page 18 R11 with options “Full size input and output cable connection terminals and PE busbar” and “IP20 shrouds for covering the input and motor cabling area” ....207 R11 with options “Full size input and output cable connection terminals and PE busbar”...
Page 19 Providing feedback on ABB Drives manuals ....... . . 251...
Page 21 Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 22 16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the drive module and do maintenance work on it. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 23 Safety instructions 17 • To prevent the drive module from falling, attach its top lifting lugs with chains to the cabinet frame before you push the module into the cabinet and pull it from the cabinet. Work carefully preferably with help from another person as shown below. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back 3AUA0000088632...
Page 24 18 Safety instructions Electrical safety in installation, start-up and maintenance Precautions before electrical work  These warnings are for all personnel that do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 25 Safety instructions 19 Additional instructions and notes  WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you are not a qualified electrician, do not do installation or maintenance work. •...
Page 26 20 Safety instructions Grounding  These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase. •...
Page 27 Safety instructions 21 Additional instructions for permanent magnet motor drives Safety in installation, start-up and maintenance  These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death and equipment malfunction can occur.
Page 28 22 Safety instructions...
Page 29 Introduction to the manual 23 Introduction to the manual Contents of this chapter This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.
Page 30 Ordering information gives ordering information on additional components available from ABB for the drive module installation. Technical data contains the technical specifications of the drive module, e.g., the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings.
Page 31 Introduction to the manual 25 Step-by-step drawings for installing full cabling panels (option) in a Rittal TS 8 400 mm wide cabinet shows how to install a drive module with full cabling panels into a Rittal TS 8 cabinet. Step-by-step drawings for a flat installation example in Rittal TS 8 600 mm wide cabinet shows how to install the drive module in flat position into a Rittal TS 8 cabinet.
Page 32 26 Introduction to the manual Task Check the insulation of the supply cable, the motor and the Checking the insulation of the assembly (page motor cable and the resistor cable (if present). 100) Standard drive modules Installing the drive module into a cabinet (page 123) •...
Page 33 Introduction to the manual 27 Terms and abbreviations Term/Abbreviation Explanation AIBP Input bridge protection board Drive control unit BPOW Power supply board BGDR Gate driver board Common mode filtering DDCS Distributed drives communication system; a protocol used in optical fiber communication Direct torque control Electromagnetic compatibility...
Page 34 28 Introduction to the manual Term/Abbreviation Explanation Optional safety functions module High-threshold logic IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type widely used in converters due to their easy controllability and high switching frequency. Input/Output IT system Type of supply network that has no (low-impedance) connection to ground/earth. Programmable logic controller Radio-frequency interference SAFUR...
Page 35 Operation principle and hardware description 29 Operation principle and hardware description Contents of this chapter This chapter describes the operating principle and construction of the drive module packages.
Page 36 30 Operation principle and hardware description Product overview The ACS880-04XT is a drive module package (drive) for controlling asynchronous AC induction motors, permanent magnet motors, AC induction servomotors. The drive consists of two drive modules (ACS880-04 +P943) and a separate control unit.
Page 37 Operation principle and hardware description 31 Drive connection examples  6-pulse connection 6-pulse connection No additional protection for the input and motor No additional protection for the input and motor cables against thermal overload is needed. cables against thermal overload is needed. WARNING! Make sure that both contactors close at the same time.
Page 38 32 Operation principle and hardware description 12-pulse connection 6-pulse connection Protection against thermal overload for the input Protection against thermal overload for the input cables with fuses is needed. cables with fuses is needed. WARNING! Make sure that both contactors WARNING! Make sure that both contactors close at the same time.
Page 39 Operation principle and hardware description 33 Layout Standard drive module configuration  Lifting lugs Fastening bracket Input cable connection busbars (L1/U1, L2/V1, L3/W1) and DC+ and DC- busbars Circuit board compartment Output cable connection busbars (T1/U2, T2/V2, T3/W2) and brake resistor connection busbars (R+ and R- with option +D150) External control unit Main cooling fans...
Page 40 34 Operation principle and hardware description Drive module configuration with IP20 shrouds (option) and full-size  output cable connection terminals (option) Drive module Common mode filter (+E208) Upper front cover Pedestal Lower front cover External control unit Clear plastic shrouds attached See the next page for the part descriptions.
Page 41 Operation principle and hardware description 35 Option Option Clear plastic shroud to be attached onto the Metallic shroud. With optional full-size input drive module input power cabling (a). Lead- power cable connection terminals, the shroud through shroud for side cabling (b). includes a ground bar.
Page 42 36 Operation principle and hardware description Drive module for flat mounting (option) with IP20 shrouds (option)  Front view of an assembled drive module for flat mounting is shown below. This option adds flat mounting brackets to the standard drive module configuration. The pedestal has been removed in this assembly.
Page 43 Operation principle and hardware description 37 Drive module with full power cabling panels (option)  Accessories Assembled drive module Input power cabling panel Rubber grommet Side guides Input power cabling panel to be attached to the drive cabinet Output power cabling panel Output power cabling panel to be attached to the drive cabinet Top guide plate...
Page 44 38 Operation principle and hardware description Drive module configuration with power cable connection terminals  on the right-hand side of the drive module (option) Lifting lugs Fastening bracket Input cable connection busbars (L1/U1, L2/V1, L3/W1) and DC+ and DC- busbars Circuit board compartment cooling fans Circuit board compartment Output cable connection busbars (T1/U2, T2/V2, T3/W2) and brake resistor connection busbars (R+...
Page 45 Operation principle and hardware description 39 Control unit  See section Drive module configuration with IP20 shrouds (option) and full-size output cable connection terminals (option) on page 34. Control panel  ACS-AP-I Assistant control panel (option) DPMP-01 door mounting kit (option) The control panel is ordered separately and can be mounted on the cabinet door using optional DPMP-01 mounting platform.
Page 46 40 Operation principle and hardware description XPOW BCU control unit ACS880-04- V10 V20 xxxx-x+P943 BPOW BGDR t° UDC+ UDC- T1/U2 L1/U1 T2/V2 L2/V1 T3/W2 L3/W1 X3 1 V10 V20 BPOW BGDR t° UDC+ UDC- T1/U2 L1/U1 T2/V2 L2/V1 T3/W2 L3/W1 ACS880-04-xxxx-x+P943...
Page 47 Operation principle and hardware description 41 1, 2,3 Analog and digital I/O extension modules, feedback interface modules and fieldbus communication modules can be inserted into slots 1, 2 and 3. See section Type designation key on page 45. Slot 4 for RDCO-0x Connector X12 for the FSO-xx safety functions module Memory unit (see page 166) I/O terminal blocks.
Page 48 42 Operation principle and hardware description External control unit connection cables  The cables for connecting the drive module and control panel to the control unit are shown below. The length of the cables is 3 meters (9.8 feet). See sections Connecting the control unit to the drive module (page 114) and...
Page 49 Operation principle and hardware description 43 Type designation labels A type designation label is attached to the drive modules. The type designation label of the drive module package is delivered in an envelope. Drive module package label  The type designation label includes a rating, markings, a type designation and a serial number, which allow individual recognition of each drive module package.
Page 50 44 Operation principle and hardware description Drive module label  The type designation label includes a rating, markings, a type designation and a serial number, which allow individual recognition of each drive module. Type designation, see section Type designation key on page 45.
Page 51 +E200. The main selections are described below. Not all selections are available for all types. Code Description Drive module package code, e.g., ACS880-04XT-1610A-5. Drive module code, e.g., ACS8880-04-880A- 5+P943 Product series ACS880 ACS880 product series...
Page 52 46 Operation principle and hardware description...
Page 53 Limitation of liability You must always plan and make the installation 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. Installation positions of the drive module You can put the drive module in the bookshelf or flat position or on its back in a cabinet.
Page 54 48 Guidelines for planning the cabinet installation Planning the layout of the cabinet Plan a spacious layout to ensure easy installation and maintenance. Sufficient cooling air flow, obligatory clearances, cables and cable support structures all require space. Place the control board(s) away from: •...
Page 55 Guidelines for planning the cabinet installation 49 Layout example with IP20 shrouds (option)  3AXD50000023774...
Page 56 50 Guidelines for planning the cabinet installation Layout example with IP20 shrouds (option) and one “drive module  with power cable connection terminals on the right-hand side” (option) 3AXD50000023774...
Page 57 Guidelines for planning the cabinet installation 51 Layout example, doors closed  This diagram shows a cabinet layout example with the input power cable lead-through from top and the motor cable lead-through from bottom. Air inlet for the drive module 1b Air inlet for the other equipment Air inlet for circuit boards and DC and output busbars Air outlet with an extra exhaust fan for the drive module...
Page 58 52 Guidelines for planning the cabinet installation Layout example, doors open (standard configuration)  This diagram shows a layout example for standard drive modules L1/U1 L1/U1 L2/V1 L2/V1 L3/W1 L3/W1 T3/W2 T3/W2 T2/V2 T2/V2 T1/U2 T1/U2 A – A...
Page 59 Guidelines for planning the cabinet installation 53 1 Supporting frame of the cabinet 8 Motor cable including the protective ground conductor of the drive module 2 Vertical (2a, 2b) and horizontal (2c, 2d) air 9 Drive module control unit baffles that separate the cool and hot areas (leak-proof lead-throughs).
Page 60 54 Guidelines for planning the cabinet installation Layout example, doors open with IP20 shrouds (option)  Layout example for one module is shown below. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A 1 Supporting frame of the cabinet 8 Motor cable including the protective ground conductor of the drive module Vertical (2a) and horizontal (2b) air baffles 9 Drive module control unit...
Page 61 Guidelines for planning the cabinet installation 55 Layout example, doors open with IP20 shrouds (option) and “drive  module with power cable connection terminals on the right-hand side” (option) Layout example for one drive module is shown below. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2...
Page 62 Always fasten the drive module from its fastening points to the cabinet. For details, see the module installation instructions. WARNING! Do not fasten the cabinet by electric welding. ABB does not assume any liability for damages caused by electric welding as the welding circuit can...
Page 63 Guidelines for planning the cabinet installation 57 Planning the cabinet placement on a cable channel Note the following when you plan to place the cabinet on a cable channel: • The cabinet structure must be sturdy enough. If the whole cabinet base is not supported from below, the cabinet weight will lie on the sections that the floor carries.
Page 64 58 Guidelines for planning the cabinet installation • We recommend 360° high frequency grounding of the motor cable shields at their entries. The grounding can be implemented by a knitted wire mesh screening as shown below. Cable Cable tie Strain relief Bare cable shield Knitted wire mesh Cabinet lead-through plate...
Page 65 This is critical for proper cooling of the drive module. Minimum air inlets are four Rittal air filters (SK 3243.200 for a 600 mm wide cabinet) or two ABB air inlet filters (see section Cabinet ventilation on page 171).
Page 66 60 Guidelines for planning the cabinet installation Preventing the recirculation of hot air Prevent hot air circulation outside the cabinet by leading the outcoming hot air away from the area where the inlet air to the cabinet is taken. Possible solutions are listed below: •...
Page 67 Guidelines for planning the cabinet installation 61 Bookshelf mounting with IP20 shrouds (option)  This diagram shows the air baffle position inside an example cabinet. For dimensions of the baffle, see page 213. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 B – B C –...
Page 68 62 Guidelines for planning the cabinet installation Bookshelf mounting (standard drive module configuration)  This diagram shows air baffle positions inside an example cabinet. For the descriptions, see the next page. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 C – C A - A B - B D –...
Page 69 Guidelines for planning the cabinet installation 63 1a Air flow to the drive module, max. 40 °C Drive module (104 °F) 1b Air inlet to the drive circuit boards and DC and Disconnector and fuses output busbars 2a Vertical air baffle that separates the cool and Contactor hot areas in the cabinet 2b Vertical air baffle...
Page 70 64 Guidelines for planning the cabinet installation Flat mounting (option)  This diagram shows air baffle positions inside an example cabinet. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A C – C B – B Air flow to the drive module, max. 40 °C Disconnector and fuses (104 °F) Air inlet to the drive circuit boards and DC and...
Page 71 Guidelines for planning the cabinet installation 65 Flat mounting (option) with IP20 shrouds (option)  This diagram shows air baffle positions inside an example cabinet. For dimensions of the baffle, see page 215. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A B –...
Page 72 • height 2000 mm (78.74 in.). Other installation positions Contact your local ABB representative for more information. Drive module on its back  If you install the drive module on its back, make sure that the hot cooling air that flows...
Page 73 Use a cubicle heater if there is a risk of condensation in the cabinet. Although the primary function of the heater is to keep the air dry, it may also be required for heating at low temperatures. ABB air inlet and outlet kits See section Cabinet ventilation...
Page 74 68 Guidelines for planning the cabinet installation...
Page 75 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 obeyed, the drive can experience problems that the warranty does not cover.
Page 76 Examining the compatibility of the motor and drive Use an asynchronous AC induction motor, permanent magnet motor, AC induction servomotor or ABB synchronous reluctance motor (SynRM motor) with the drive. Several induction motors can be connected at a time. Select the motor size and drive type from the rating tables in chapter Technical data basis of the AC line voltage and motor load.
Page 77 The following table shows how to select the motor insulation system and when optional ABB du/dt filters, insulated N-end (non-drive end) motor bearings and ABB common mode filters are required. Failure of the motor to fulfill the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the motor warranty.
Page 78 If you use an explosion-safe (EX) motor, obey the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ Use the selection criteria given for non-ABB motors.
Page 79 Additional requirements for ABB high-output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347:2001. This table shows the requirements for ABB random-wound motor series (for example, M3AA, M3AP and M3BP).
Page 80 74 Guidelines for planning the electrical installation Additional data for calculating the rise time and the peak line-to-line voltage The diagrams below show the relative peak line-to-line voltage and rate of change of voltage as a function of the motor cable length with and without a du/dt filter in use. To calculate the actual peak voltage for a certain cable length read the relative Û...
Page 81 Guidelines for planning the electrical installation 75 Selecting the power cables General rules  Select the input power and motor cables according to local regulations: • Select a cable capable of carrying the drive nominal current. See section Ratings (page 179) for the rated currents. •...
Page 82 76 Guidelines for planning the electrical installation Typical power cable sizes The tables below give copper and aluminum cable types with concentric copper shield for the drive modules with nominal current. See also Terminal and lead-through data for the power cables on page 187.
Page 83 Guidelines for planning the electrical installation 77 2) See page 32. 3) The supply cables are connected to a common switch or breaker, see page 31. The whole input current flows through common cabling and you can use the recommended cables for that. The connection from the switch to the drive modules inside the cabinet can be made with busbars.
Page 84 78 Guidelines for planning the electrical installation 1) The cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40 °C (104 °F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or earth (directly buried).
Page 85 Guidelines for planning the electrical installation 79 Alternative power cable types  The recommended and not allowed power cable types to be used with the drive are presented below. Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield.
Page 86 80 Guidelines for planning the electrical installation Motor cable shield  If the motor cable shield is used as the sole protective earth conductor of the motor, make sure that the conductivity of the shield is sufficient. See subsection General rules on page 75, or IEC 61800-5-1.
Page 87 Relay cable type  The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel cable length and type  In remote use, the cable connecting the control panel to the drive must not exceed three meters (10 ft).
Page 88 82 Guidelines for planning the electrical installation A diagram of the cable routing is shown below. Control cables min 200 mm (8 in.) 90 ° Input power cable Motor cable Drive min 300 mm (12 in.) Power cable Motor cable, brake cable min 500 mm (20 in.) Control cables Separate control cable ducts...
Page 89 The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers. There are also limitations pertaining to the short-circuit capacity of the supply network. Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known.
Page 90 84 Guidelines for planning the electrical installation Drive module type Frame size ABB molded case circuit breaker (Tmax) Product ID (Type) ACS880-04-880A-5 1SDA062770R1 (T7H 1000 PR231/P LS/I In=1000A 3p F F) = 690 V ACS880-04-330A-7 1SDA054412R1 (T5H 630 PR221DS-LS/I In=630 3p F F)
Page 91 Guidelines for planning the electrical installation 85 Protecting the drive and the input power and motor cables against  thermal overload See section Drive connection examples on page 31. The drive protects itself and the motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive.
Page 92 86 Guidelines for planning the electrical installation Note: The EMC filter of the drive includes capacitors connected between the main circuit and the frame. These capacitors and long motor cables increase the ground leakage current and can cause fault current circuit breakers to function. Connecting drive modules to a common DC system We do not recommend to connect the drive modules to a common DC system.
Page 93 Guidelines for planning the electrical installation 87 Declaration of Conformity  See page 193.
Page 94 88 Guidelines for planning the electrical installation Implementing the Power loss ride-through function Implement the power loss ride-through function as follows: 1. Check that the power-loss ride-through function of the drive is enabled with parameter 30.31 Undervoltage control in the ACS880 primary control program. 2.
Page 95 Guidelines for planning the electrical installation 89 Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate. See also section Implementing a bypass connection on page 89. When you have selected to use DTC motor control mode and motor ramp stop, open the contactor as follows: 1.
Page 96 90 Guidelines for planning the electrical installation Example bypass connection  An example bypass connection is shown below. Drive main switch Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor Drive main contactor on/off control Motor power supply selection (drive or direct-on-line) Start when motor is connected direct-on-line Stop when motor is connected direct-on-line Switching the motor power supply from drive to direct-on-line...
Page 97 Guidelines for planning the electrical installation 91 Switching the motor power supply from direct-on-line to drive 1. Stop the motor with S42. 2. Switch the motor power supply from direct-on-line to the drive with S40. 3. Close the main contactor of the drive with switch S11 (-> turn to position ST for two seconds and leave to position 1).
Page 98 92 Guidelines for planning the electrical installation Implementing a motor temperature sensor connection WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non-conductive but not connected to the protective earth. To connect a motor temperature sensor and other similar components to the drive, you have four alternatives: 1.
Page 99 Installation instructions 93 Installation instructions Contents of this chapter This chapter contains the general installation instructions for the drive modules. Safety WARNING! If you are not a qualified electrician do not do the installation work described in this chapter. Obey the instructions in chapter Safety instructions.
Page 100 94 Installation instructions Moving and unpacking the unit WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. The drive modules are packed into two similar transport packages tied together with bands.
Page 101 Installation instructions 95 Package drawings  The package of one drive module is shown below. 3AUA0000101742 Transport package contents With option “IP20 shrouds for covering the input and motor cabling area”: Clear plastic shrouds. With option “Full power cabling panels to be attached to a cabinet (IP20)”: Input cabling panel parts. See below for the box contents.
Page 102 96 Installation instructions With option “Power cable connection terminals on the right- hand side”: Top and bottom brackets and handle (item 6 in the package drawing on the previous page) Top bracket Bottom bracket Handle Screw package 3AXD10000407466 Box B1 contents with option “IP20 shrouds for covering the input and motor cabling area”...
Page 103 Installation instructions 97 Box B1 contents with option “Full power cabling panels to be attached to a cabinet (IP20)”: Input power cabling panel parts Screw package Paper fill Input power cabling panel Cardboard tray Top cardboard cover Support Bands Plastic bag Rubber grommet Grounding busbar to be connected to the input power...
Page 104 98 Installation instructions Box B2 contains additionally this box with option “Full size input cable connection terminals and PE busbar” Metallic shroud with ground bar Paper fill Input cable connection terminal L3/W1 Input cable connection terminal L2/V1 Input cable connection terminal L1/U1 Cardboard box Screws and insulators in a plastic...
Page 105 Installation instructions 99 Accessories box contents Screw package, includes also spacers for FSO module installation Rubber grommets for control unit cable lead-through holes in the middle front cover of the drive module Bracket for attaching the drive module from top to Rittal cabinet punched section.
Page 106 100 Installation instructions Checking the delivery Check that all items listed in section Moving and unpacking the unit on page present. Check that there are no signs of damage. Before attempting installation and operation, check the information on the type designation label of the drive to verify that the unit is of the correct type.
Page 107 Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, consult the manufacturer’s instructions.
Page 108 102 Installation instructions Installing the bottom grille for IP20 degree of protection • If IP20 degree of protection is needed from the bottom side, install the bottom grille as shown below.
Page 109 Installation instructions 103 Checking the compatibility with IT (ungrounded) systems EMC filter +E200 is not suitable for use in an IT (ungrounded) system. If the drive is equipped with filter +E200, disconnect the filter grounding wire before connecting the drive to the supply network.
Page 110 104 Installation instructions For an installation example on how to install the drive module without pedestal in flat position in a Rittal TS 8 cabinet, see appendix Step-by-step drawings for a flat installation example in Rittal TS 8 600 mm wide cabinet on page 247.
Page 111 Installation instructions 105 Option “Power cable connection terminals on the right-hand side of  the drive module” For an installation example of the drive module with option “Power cable connection terminals on the right-hand side of the drive module” into a Rittal cabinet, see chapter Step-by-step drawings for option “Power cable connection terminals on the right-hand side of the drive module”...
Page 112 106 Installation instructions Alternatives for grounding the drive module  You can ground the drive module from its top back to the cabinet frame with these alternatives: 1. from the grounding hole 2. to a Rittal punched section: with the fastening bracket. Tapping screw M6×12 Torx T30 (Hex) 9 N·m Installing the ARFI-10 EMC filter (option) See ARFI-10 EMC filter installation guide (3AFE 68317941 [English).
Page 113 Installation instructions 107 Power cable connection diagram example (6-pulse)  UDC+ UDC+ UDC- UDC- T1/ T2/ T3/ (PE) (PE) 3 ~ M Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor (see page 75).
Page 114 108 Installation instructions Note 1: If there is a symmetrically constructed grounding conductor on the motor cable in addition to the conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor ends. Do not use an asymmetrically constructed motor cable. Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.
Page 115 Installation instructions 109 Power cable connection diagram example (6-pulse and 12-pulse)  (PE) PE (PE) (PE) (PE) UDC+ UDC+ UDC- UDC- T1/ T2/ T3/ 3 ~ M Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor (see page 75).
Page 116 110 Installation instructions 360-degree grounding is recommended if shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board. 360-degree grounding is required. Line contactor Common mode filter du/dt filter or sine filter (options) Use a separate grounding cable if the shield does not meet the requirements of IEC 61439-1 (see page 75) and there is no symmetrically constructed grounding conductor in the cable (see page 80).
Page 117 Installation instructions 111 If the DC cables are run outside the cabinet, ground the cable shield 360° at one end only. UDC+ UDC+ UDC- UDC- T2/ T3/ 6. Make sure that all power is disconnected and reconnection is not possible. Use proper safe disconnect procedures according to local codes.
Page 118 112 Installation instructions Mounting the external control unit See BCU-02/12/22 control units hardware manual (3AUA0000113605 [English]). Layout and connections of the control unit Description I/O terminals (see the 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...
Page 119 Installation instructions 113 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XDIO Digital input/outputs XD24 XPOW XD2D Drive-to-drive link XD24 +24 V output (for digital inputs) XRO2 XETH Ethernet port (eg. for PC communication) XDIO XPOW External power input XRO1 Relay output RO1...
Page 120 114 Installation instructions Connecting the control unit to the drive module WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. Routing the control unit cables into the drive module ...
Page 121 Installation instructions 115 Connections to the control unit  Connect the fiber optic, power supply and BGDR cables to the control unit as follows:. BPOW BCU control unit ZINT/SOIA BCU control unit X3: 1 XPOW:1 (+24VI) Drive module 1 X3: 2 XPOW:2 (GND) ZINT: V1;...
Page 122 116 Installation instructions Default I/O connection diagram  Drive-to-drive link XD2D Drive-to-drive link BGND Shield RS485 connection X485 Not in use BGND Shield Relay outputs XRO1…XRO3 Ready 250 V AC / 30 V DC Running 250 V AC / 30 V DC Fault Faulted(-1) 250 V AC / 30 V DC...
Page 123 Installation instructions 117 Notes: The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (24…12 AWG). The torque is 0.5 N·m (5 lbf·in). See section Drive-to-drive link (page 119). See chapter Safe torque off (page 120).
Page 124 118 Installation instructions DI6 (XDI:6) as PTC sensor input A PTC sensor can be connected to this input for motor temperature measurement as follows. The sum of the sensor resistances must not exceed the threshold resistance of the digital input at the motor normal operating temperature. Do not connect both ends of the cable shield directly to ground.
Page 125 Installation instructions 119 AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) Three Pt100, Pt1000 or PTC sensors or one KTY84 sensor for motor temperature measurement can be connected between an analog input and output as shown below. Do not connect both ends of the cable shields directly to ground.
Page 126 The control unit has an on-board data logger that collects real-time data from the inverter module power stages 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 127 Installation instructions 121 Connecting a control panel With DPMP-01 door mounting platform (option), connect the control panel to the control unit as follows: 1. Connect an Ethernet cable to the RJ-45 connector of the control panel. 2. Connect the other end of the cable to the X13 connector of the control unit.
Page 128 122 Installation instructions Controlling several drives from one control panel through panel bus One control panel (or PC) can be used to control several drive module packages by constructing a panel bus. Each drive module package must be equipped with a control panel mounting platform or an FDPI-02 module (available separately).
Page 129 Installation instructions 123 Connecting a PC You need a control panel to connect a PC to the drive module. Connect the control panel to the drive control unit as described in section Connecting a control panel on page 121. WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage.
Page 130 124 Installation instructions...
Page 131 In this chapter, the drive module is installed in a 600 mm wide Rittal TS 8 cabinet in a bookshelf way of mounting. The module is placed in an upright position on the cabinet bottom with its front facing the cabinet door. Available alternative ABB parts are also given. Limitation of liability Always obey the general rules given in this chapter and local laws and regulations.
Page 132 Punched section with mounting flange, outer mounting level for 600 mm horizontal TS 4396.500 Support rails SK 3243.200 / Air filter 323 mm × 323 mm. Remove the filter mats. For alternative ABB air filters, see section Air inlet kits page 171. ABB 3AUA0000117003...
Page 133 Installation example – standard, optional IP20 shrouds and power cable connection terminals 127 Attach the drive module to the cabinet Step-by-step drawings for an installation example of drive module with optional IP20 For the standard drive module configuration, shrouds and input and output terminals in connect the power cables to the drive module Rittal TS 8 600 mm wide cabinet on page 241.
Page 134 128 Installation example – standard, optional IP20 shrouds and power cable connection terminals Connecting the power cables and installing the IP20 shrouds (if present) Step Task (motor cables, standard drive module configuration) Run the motor cables to the cabinet. Ground the cable shields 360 degrees at the cabinet lead- through Connect the twisted shields of the motor cables to the grounding terminal of the drive module.
Page 135 Installation example – standard, optional IP20 shrouds and power cable connection terminals 129 Task (input cables, options “Full size input cable connection terminals and PE busbar” and Step IP20 shrouds for covering the input cabling area” included Step drill carefully sufficiently big holes to the lead-through clear plastic shroud for the cables to the connected.
Page 136 130 Installation example – standard, optional IP20 shrouds and power cable connection terminals Installing the roof and door (Rittal parts) This drawing shows a layout tested by ABB. Rittal 7967.000 Rittal 3326.200 592 [23.31] 3AUA0000145776 Door Install these gratings as close to each other as possible. Remove the filter mats.
Page 137 Installation example – standard, optional IP20 shrouds and power cable connection terminals 131 Installing the roof and door (ABB air filters and roof) This drawing shows a layout tested by ABB. ABB 3AUA0000125202 (IP20) ABB 3AUA0000114971 (IP42) ABB 3AUA0000117003 (IP20)
Page 138 132 Installation example – standard, optional IP20 shrouds and power cable connection terminals Removing the protective covering from the drive module air outlet  WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature.
Page 139 TS8 cabinets together. Available alternative ABB parts are also given. Limitation of liability Always obey the general rules given in this chapter and local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches local laws and/or other regulations.
Page 140 TS 8106.235 Side panels for the cabinet SZ/DK 7967.000 (one Spacers for roof plate / ABB roof set = four pieces) / Note: For alternative ABB outlet kits, see section Air outlet kits on page 173. ABB 3AUA0000125201 (IP20) ABB 3AUA0000114967 (IP42) TS 8612.160...
Page 141 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” 135 Overall flowchart of the installation process Step Task For instructions, see Install the Rittal parts and drive module Installing the mechanical accessories into the mechanical accessories into the cabinet.
Page 142 136 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” Connecting the power cables Power cable connection diagram example (6-pulse and 12-pulse)  (PE) PE (PE) (PE) (PE) UDC+ UDC- L3/U1 L2/V1 L1/W1 L1/U1 L2/V1 L3/W1 UDC- UDC+ UDC+ UDC- L3/U1 L2/V1 L1/W1...
Page 143 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” 137 Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor (see page 75). 360-degree grounding is recommended if shielded cable is used.
Page 144 138 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” 8. Twist the cable shields of the input cables into bundles and connect them and any separate ground conductors or cables to grounding busbar of the input cabling panel. 9.
Page 145 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” 139 An example installation without DC cabling is shown below. WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. L1/U1, L2/V1, L3/W1 102 mm (4 in.) T1/U2, T2/V2, T3/W2...
Page 146 140 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” Installing the drive module into the cabinet WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Handle the drive module carefully.
Page 147 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” 141 4. Attach the drive module lifting lugs to the cabinet frame with chains. 5. Push the drive module carefully into to the cabinet preferably with the help from another person.
Page 148 142 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)”...
Page 149 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” 143 Assembly drawing of installing the drive module to the cabinet (frame R10)
Page 150 144 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” Assembly drawing of installing the drive module to the cabinet (frame R11)
Page 151 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” 145 Assembly drawing of installing the roof and door This drawing shows a layout tested by ABB. If you use ABB air filters, place them vertically in the positions shown in the drawing on page 126.
Page 152 146 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” Removing the protective covering from the drive module air outlet  WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature.
Page 153 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” 147 Installing the rubber grommet  To get IP20 degree of protection for the drive module, install the input power cables through the rubber grommet. Install the grommet as follows: 1.
Page 154 148 Installation example with option “Full power cabling panels to be attached to a cabinet (IP20)” Modular design of Rittal TS8 cabinets  The design of the drive module with option “Full power cabling panels to be attached to a cabinet (IP20)”...
Page 155 Installation checklist 149 Installation checklist Contents of this chapter This chapter contains a list for checking the mechanical and electrical installation of the drive module. Installation checklist Go through the checklist below together with another person. WARNING! Obey the safety instructions in chapter Safety instructions.
Page 156 150 Installation checklist Check that … Drive option modules and other components Type and number of option modules and other equipment is correct. Option modules and other equipment are not damaged. Optional modules and terminals are labelled correctly. The placement of optional modules and other equipment inside the cabinet and on the cabinet door is correct.
Page 157 Installation checklist 151 Check that … Installation of the cabinet The drive cabinet has been attached to floor and also from top to the wall or roof. The ambient operating conditions agree with the specifications given in chapter Technical data. The cooling air will flow freely in and out of the drive cabinet, and air recirculation inside the cabinet will not be possible (air baffle plates are on place).
Page 158 152 Installation checklist...
Page 159 Start-up 153 Start-up Contents of this chapter This chapter describes the start-up procedure of the drive. Start-up procedure 1. Only qualified electricians are allowed to start-up the drive. 2. Make sure that the installation of the drive module has been checked according to the checklist in chapter Installation checklist, and that the motor and driven equipment are...
Page 160 For drives with resistor braking (option), see also section Start-up on page 233. • For drives with ABB du/dt filter, check that bit 13 of parameter 95.20 HW options word 1 is switched on. • For drives with ABB sine filter, check that parameter 95.15 Special HW settings is set to ABB sine filter.
Page 161 Fault tracing 155 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs with option DPMP-01 Where Color When the LED is lit Control panel POWER Green Control unit is powered and +15 V is supplied to the control mounting platform panel.
Page 162 156 Fault tracing...
Page 163 (www.abb.com/drivesservices).For more information, consult your local ABB Service representative ( www.abb.com/searchchannels). The maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance.
Page 164 Performance of on/off-site work (commissioning, tests, measurements or other work) Replacement of component Recommended annual maintenance actions by the user  ABB recommends these annual inspections to ensure the highest reliability and optimum performance. Action Target IP22 and IP42 air inlet and outlet meshes on the cabinet doors...
Page 165 Maintenance 159 Heatsink The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. Cleaning the interior of the heatsink  WARNING! Obey the safety instructions in chapter Safety instructions.
Page 166 For resetting the running time signal after a fan replacement, please contact ABB. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the circuit board compartment cooling fan ...
Page 167 Maintenance 161 Replacing the main cooling fans  WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
Page 168 162 Maintenance Replacing the standard drive module and drive module with option “IP20 shrouds for covering the input and motor cabling area” Note: The replacement module must be of the same type as the original module: same type code and same option codes. WARNING! Obey the safety instructions in chapter Safety instructions.
Page 169 Maintenance 163 9. Pull the drive module carefully out of the cabinet preferably with help from another person. 10. Install the new module in reverse order to the above.
Page 170 164 Maintenance Replacing the drive module with option “Full power cabling panels to be attached to a cabinet (IP20)” Note: The replacement module must be of the same type as the original module: same type code and same option codes. WARNING! Obey the safety instructions in chapter Safety instructions.
Page 171 Maintenance 165 8. Disconnect the power supply cable and the fiber optic cables from the external control unit and coil them on the top of the drive module. 9. To prevent the drive module from falling, attach its top lifting lugs with chains with chains to the cabinet frame.
Page 172 It is not possible to predict a capacitor failure. The capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if a capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts.
Page 173 Maintenance 167 Reduced run A “reduced run” function makes it possible to continue operation with one drive module if the other module is out of service, for example, because of maintenance work. In principle, reduced run is possible with only one module, but the physical requirements of operating the motor still apply;...
Page 174 168 Maintenance...
Page 175 Notes: • This chapter only lists the installation accessories available from ABB. All other parts must be sourced from a third party by the system integrator. For a listing, refer to the kit-specific installation instructions available at https://www151.abb.com/spaces/lvacdrivesengineeringsupport/content.
Page 176 170 Ordering information The control panel can be mounted on the cabinet door with the help of a door mounting kit. Type Description Ordering code Illustration Control panel with ACS-AP-W 3AXD50000025965 Bluetooth ACS-AP-I Control panel with 3AUA0000088311 Door mounting kit for flush mounting.
Page 177 Ordering information 171 Cabinet ventilation Air inlet kits  Mounting screws are included. Enclosure width / Kit code Ordering code Illustration Degree of protection 400 mm / IP20 A-4-X-021 3AUA0000117002 Instruction code: 3AUA0000116879 400 mm / IP42 A-4-X-024 3AUA0000117007 Instruction code: 3AUA0000116873 400 mm / IP54 A-4-X-027 3AXD50000009184 Instruction code: 3AXD50000009989...
Page 178 172 Ordering information Enclosure width / Kit code Ordering code Illustration Degree of protection 600 mm / IP20 A-6-X-022 3AUA0000117003 Instruction code: 3AUA0000116880 600 mm / IP42 A-6-X-025 3AUA0000117008 Instruction code: 3AUA0000116874 600 mm / IP54 A-6-X-028 3AXD50000009185 Instruction code: 3AXD50000009990 800 mm / IP20 A-8-X-023 3AUA0000117005...
Page 179 Ordering information 173 Enclosure width / Kit code Ordering code Illustration Degree of protection 800 mm / IP42 A-8-X-026 3AUA0000117009 Instruction code: 3AUA0000116875 800 mm / IP54 A-8-X-029 3AXD50000009186 Instruction code: 3AXD50000010001 Air outlet kits  Note: The fan is to be ordered separately. Enclosure width / Kit code Ordering code...
Page 180 174 Ordering information Enclosure width / Kit code Ordering code Illustration Degree of protection 400 mm / IP42 A-4-X-060 3AUA0000114968 800 mm / IP42 Instruction code: 3AUA0000115290 Note: Fan to be ordered separately 600 mm / IP42 A-6-X-061 3AUA00001149789 Instruction code: 3AUA0000115152 Note: Fan to be ordered separately 400 mm / IP54 (IEC)
Page 181 Ordering information 175 Enclosure width / Kit code Ordering code Illustration Degree of protection 600 mm / IP54 A-6-X-065 3AXD50000009189 (IEC) Instruction code: 3AXD50000010004 Note: Fan to be ordered separately 600 mm / IP54 A-6-X-066 3AXD50000010327 (UL) Instruction code: 3AXD50000010004 Note: Fan to be ordered separately Cooling fans One or two cooling fans are to be installed inside the air outlet compartment to ensure...
Page 182 176 Ordering information Enclosure width / Component Ordering code Degree of protection Name Data 800 mm / IP54 RB4C-355/170 3AXD50000006934 Capacitor MSB MKP 6/603/E1679 3AXD50000006959 Connector SPB2,5/7 (2.5 mm2, 12AWG) 3AXD50000000723 Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 3AXD50000000724 400 mm, 600 mm / IP20, R2E225-RA92-17 (230 V) 3AXD50000000514 IP42...
Page 183 Ordering information 177 Accessory kits Ordering code Full size input cable connection terminals and PE busbar. Not to be used with full 3AXD50000024518 power cabling panels which are to be attached to a cabinet. Full size output cable connection terminals. Not to be used with full power cabling 3AXD50000024519 panels which are to be attached to a cabinet.
Page 184 178 Ordering information...
Page 185 Technical data 179 Technical data Contents of this chapter This chapter contains the technical specifications of the drive, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Ratings The ratings of the drive module packages with 50 Hz and 60 Hz supply are given below. IEC RATINGS Drive type Frame...
Page 186 The power ratings apply to most IEC 34 motors at the nominal voltage of the drive. We recommend to select the drive, motor and gear combination for the required motion profile with the DriveSize dimensioning tool available from ABB.
Page 187 Technical data 181 When is derating needed  Derate the continuous output current of the drive if • ambient temperature exceeds +40 °C (+104 °F) or • drive is installed higher than 1000 m (3280 ft) above sea level • switching frequency is other than default •...
Page 188 Ex motor, sine filter, low noise Table below gives the deratings for these cases: • drive is used with an ABB motor for explosive atmospheres (Ex) and EX motor in Parameter 95.15 Special HW settings is enabled • sine filter given in the selection table on page is used and ABB sine filter in Parameter 95.15 Special HW settings is enabled...
Page 189 Technical data 183 With other than recommended sine filters (see section Sine filters on page 238) and non- ABB Ex motors, contact ABB. Drive type Output ratings for special settings ACS880- Ex motor (ABB Ex motor) ABB sine filter Low noise mode...
Page 190 Contact ABB for operation above the recommended maximum output frequency or for the output current derating with output frequencies above 120 Hz and below the maximum output frequency.
Page 191 Technical data 185 Modules used Drive type Drive module Type Qty + size = 400 V ACS880-04XT-1010A-3 ACS880-04-585A-3+P943 2×R10 ACS880-04XT-1190A-3 ACS880-04-650A-3+P943 2×R10 ACS880-04XT-1330A-3 ACS880-04-725A-3+P943 2×R11 ACS880-04XT-1610A-3 ACS880-04-880A-3+P943 2×R11 = 500 V ACS880-04XT-1010A-5 ACS880-04-583A-5+P943 2×R10 ACS880-04XT-1160A-5 ACS880-04-635A-5+P943 2×R10 ACS880-04XT-1310A-5 ACS880-04-715A-5+P943 2×R11...
Page 192 186 Technical data Fuses (UL) UL fuses for branch circuit protection per NEC per drive module are listed below. Check that the operating time of the fuse is below 0.1 seconds. The operating time depends on the fuse type, supply network impedance and the cross-sectional area, material and length of the supply cable.
Page 193 Drive type Frame size Air flow per drive Heat Noise module dissipation per Drive Drive drive module module /min dB(A) dB(A) = 400 V ACS880-04XT-1010A-3 2×R10 1200 6409 ACS880-04XT-1190A-3 2×R10 1200 8122 ACS880-04XT-1330A-3 2×R11 1200 8764 ACS880-04XT-1610A-3 2×R11 1420 10578...
Page 194 See page 108. Electrical power network specification Voltage (U ACS880-04XT-xxxx-3 drives: 380…415 V AC 3-phase +10%/-15%. This is indicated in the type designation label as typical input voltage level 400 V AC. ACS880-04XT-xxxx-5 drives: 380...500 V AC 3-phase +10%/-15%. This is indicated in the type designation label as typical input voltage levels 400/480/500 V AC.
Page 195 Technical data 189 Motor connection data Motor types Asynchronous AC induction motors, permanent magnet motors and AC induction servomotors. Voltage (U 0…U , 3-phase symmetrical, U at the field weakening point Frequency resolution 0.01 Hz Current See section Ratings. Frequency (f 0…500 Hz For drives with du/dt filter: 200 Hz For drives with sine filter: 120 Hz...
Page 196 190 Technical data Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. Operation Storage Transportation installed for stationary in the protective in the protective package package Installation site altitude For TN and TT neutral- grounded network systems and IT non-...
Page 197 IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.
Page 198 192 Technical data CE marking A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low Voltage and EMC. The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component.
Page 199 Technical data 193 Declaration of Conformity...
Page 200 194 Technical data...
Page 201 Technical data 195 Compliance with EN 61800-3:2004 Definitions  EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality.
Page 202 Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in the hardware manual. 4. The drive is installed according to the instructions given in the hardware manual.
Page 203 Technical data 197 • The cables located within the motor circuit must be rated for at least 75 °C (167 °F) in UL-compliant installations. • Integral solid state short circuit protection does not provide branch circuit protection. The input cable must be protected with fuses. Suitable IEC fuses are listed on page and UL classified fuses on page 186.
Page 204 ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any...
Page 205 Dimension drawings 199 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules with optional parts for Rittal TS 8 cabinet assembly.
Page 206 200 Dimension drawings R10 with option +D150...
Page 207 Dimension drawings 201 R10 with options “Full size input and output cable connection terminals and PE busbar” and “IP20 shrouds for covering the input and motor cabling area”...
Page 208 202 Dimension drawings R10 with options “Full size input and output cable connection terminals and PE busbar” and “Power cable connection terminals on the right-hand side of the drive module”...
Page 209 Dimension drawings 203 R10 with option “Full power cabling panels”...
Page 210 204 Dimension drawings R10 with option “Full power cabling panels to be attached to a cabinet (IP20)” installed into a Rittal TS 8 cabinet...
Page 211 Dimension drawings 205 R10 with option “Flat mounting”...
Page 212 206 Dimension drawings R11 with option +D150...
Page 213 Dimension drawings 207 R11 with options “Full size input and output cable connection terminals and PE busbar” and “IP20 shrouds for covering the input and motor cabling area”...
Page 214 208 Dimension drawings R11 with options “Full size input and output cable connection terminals and PE busbar” and “Power cable connection terminals on the right-hand side of the drive module”...
Page 215 Dimension drawings 209 R11 with option “Full power cabling panels”...
Page 216 210 Dimension drawings Frame R11 with option “Full power cabling panels to be attached to a cabinet (IP20) installed into a Rittal TS 8 cabinet”...
Page 217 Dimension drawings 211 R11 with option “Flat mounting”...
Page 218 Bottom plate for option “Full power cabling panels to be attached to a cabinet (IP20)” in Rittal TS 8 400 mm wide cabinet installation Note: The bottom plate is not an ABB part. Put nut PEM-S-M8-2 or equal (2 pcs)
Page 219 Dimension drawings 213 Air baffles for the drive module with options “IP20 shrouds for covering the input and motor cabling area” and “Flat mounting” This drawing shows the dimensions of the hole in the air baffle around the drive module. The drawing also shows the correct vertical location area of the air baffle as measured from the top grill.
Page 220 Air baffles for option “Full power cabling panels to be attached to a cabinet (IP20)” in Rittal TS 8 400 mm wide cabinet installation Note: These air baffles are not ABB parts. External control unit See BCU-02/12/22 control units hardware manual (3AUA0000113605 [English]).
Page 221 Example circuit diagram 215 Example circuit diagram Contents of this chapter This chapter shows an example circuit diagram for a cabinet-installed drive module package.
Page 222 216 Example circuit diagram Example circuit diagram This diagram is an example for the main wiring of a drive cabinet. Note that the diagram includes components which are not included in a basic delivery (* option, ** to be acquired by the customer).
Page 223 Safe torque off function 217 Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, to construct safety or supervision circuits that stop the drive in case of danger (such as an emergency stop circuit).
Page 224 218 Safe torque off function The Safe torque off function of the drive complies with these standards: Standard Name EN 60204-1:2006 + AC:2010 Safety of machinery – Electrical equipment of machines – Part 1: General requirements IEC 60204-1:2016 IEC 61326-3-1:2008 Electrical equipment for measurement, control and laboratory use –...
Page 225 Safe torque off function 219 Wiring The following diagrams present examples of Safe torque off wiring for • Drive unit (two drive modules, internal power supply) on page • Drive unit, single channel STO connection on page • Drive unit (two drive modules, external power supply) on page 222.
Page 226 220 Safe torque off function Drive unit (two drive modules, internal power supply)  ACS880-04 ACS880-04...
Page 227 Safe torque off function 221 Drive unit, single channel STO connection  ACS880-04 XSTO +24 V SGND Notes: • Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL classification is given. • Pay special attention to avoiding any potential failure modes for the wiring. For example, use shielded cable.
Page 228 222 Safe torque off function Drive unit (two drive modules, external power supply)  24 V DC ACS880-04 ACS880-04 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. STO inputs on the drive control unit de-energize. 3.
Page 229 Safe torque off function 223 Note: If the Safe torque off function is not used, close the circuit as shown below. The drive will not start, if the circuit is not closed. 1 2 3 4 5 6 7 8 XPOW XSTO XSTO OUT...
Page 230 224 Safe torque off function Acceptance test procedure  After wiring the Safe torque off function, validate its operation as follows. Note: If an FSO-xx safety functions module or an FPTC-0x module is installed, refer to its documentation. Action WARNING! Follow the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).
Page 231 Safe torque off function 225 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. STO inputs on the drive control unit de-energize, and the drive control unit cuts off the control voltage from the drive IGBTs. 3.
Page 232 See the drive firmware manual 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 233 Safe torque off function 227 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. Frame SIL/ SC PL SFF MTTF...
Page 234 228 Safe torque off function Abbr. Reference Description EN ISO 13849-1 Performance level. Levels a…e correspond to SIL IEC 61508 Systematic capability IEC 61508 Safe failure fraction (%) IEC 61508 Safety integrity level (1…3) SILCL IEC/EN 62061 Maximum SIL (level 1…3) that can be claimed for a safety function or subsystem IEC/EN 61800-5-2 Safe stop 1...
Page 235 Resistor braking 229 Resistor braking Contents of this chapter This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. Operation principle and hardware description The dive can be equipped with optional built-in brake chopper (+D150). Brake resistors are available as add-on kits.
Page 236 230 Resistor braking which two standard resistors are connected in parallel, two in series. The E value of the four-resistor assembly is four times the value specified for the standard resistor. Note: Both drive modules must have own brake resistors. A common brake resistor is not allowed.
Page 237 The maximum length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user- defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.
Page 238 Note: If an external brake chopper (outside the drive module) is used, a main contactor is always required. A thermal switch (standard in ABB resistors) is required for safety reasons. The thermal switch cable must be shielded and may not be longer than the resistor cable. Wire the switch to a digital input on the drive control unit as shown in the figure below.
Page 239 Resistor braking 233 Note: It is not possible to use only one brake chopper in the drive module package, brake resistors must be connected to both drive modules. • Connect the thermal switch of the brake resistor as described in section Protecting the system against thermal overload on page 232.
Page 240 234 Resistor braking Technical data Ratings  Drive type Drive module Internal brake Example brake resistor(s) per drive module ACS880- type chopper per drive 04XT- ACS8880-04- module Type brcont Rcont = 400 V 1010A-3 585A-3+P943 2xSAFUR200F500 1.35 10800 1190A-3 650A-3+P943 2xSAFUR200F500 1.35 10800...
Page 241 25 kg (55 lb) SAFUR200F500 30 kg (66 lb) 5 5 Ø 7 Ordering codes Brake resistor type ABB ordering code SAFUR125F500 68759285 SAFUR200F500 68759340 Terminals and cable lead-through data  See section Terminal and lead-through data for the power cables...
Page 242 236 Resistor braking...
Page 243 du/dt and sine filters 237 du/dt and sine filters Contents of this chapter This chapter describes how to select du/dt and sine filters for the drive. du/dt filters When is a du/dt filter needed?  See section Examining the compatibility of the motor and drive, page 70.
Page 244 880A-5 FOCH0875-70 721A-7 FOCH-0875-70 3AXD10000363510 Ordering codes  Filter type ABB ordering code FOCH-0610-70 68550483 FOCH-0875-70 3AUA0000125245 Description, installation and technical data of the FOCH filters  See FOCH du/dt filters hardware manual (3AFE68577519 [English]). Sine filters When is a sine filter needed? ...
Page 245 239 Description, installation and technical data of the sine filters  See Sine filters hardware manual (3AXD50000016814 [English]). For more information, contact ABB.
Page 246 240 du/dt and sine filters...
Page 247 Step-by-step drawings for an installation example of drive module with optional IP20 shrouds and input and output terminals in Rittal TS 8 600 mm wide cabinet 241 Step-by-step drawings for an installation example of drive module with optional IP20 shrouds and input and output terminals in Rittal TS 8 600 mm wide cabinet Tapping screw M6×12 Torx Combi screw M8×30 (Hex) Tapping screw M6×12 Torx...
Page 248 242 Step-by-step drawings for an installation example of drive module with optional IP20 shrouds and input and output terminals in Rittal TS 8 600 mm wide cabinet Combi screw M12×25 Hex 70 N·m Combi screw M8×16 Hex Hex nut M12 70 N·m 20 N·m Combi screw M12×25 Hex Combi screw M6×12 Torx T25...
Page 249 Step-by-step drawings for an installation example of drive module with optional IP20 shrouds and input and output terminals in Rittal TS 8 600 mm wide cabinet 243 Hex nut M12 70 N·m Washer M12 or equal Hex screw M12×35 full thread 70 N·m Washer M12 or equal Combi screw M4×10...
Page 250 244 Step-by-step drawings for an installation example of drive module with optional IP20 shrouds and input and output terminals in Rittal TS 8 600 mm wide cabinet...
Page 251 Tapping screw M6×12 (4 pcs) 8 N·m Rittal 4396.500 (3 pcs) ABB parts Pedestal guide plate Top guide plate Customer-made parts (not ABB or Rittal products) Air baffle Installation procedure See the dimension drawing on page (frame R10) or page (frame R11) for the positions of the parts to be installed.
Page 252 246 Step-by-step drawings for installing full cabling panels (option) in a Rittal TS 8 400 mm wide cabinet ABB parts Output cabling panel Side guide (2 pcs) Input cabling panel Telescopic extraction and insertion ramp Tapping screw M6×12 Torx T30 (Hex) (4 pcs) Combi screw M4×8 Torx...
Page 253 Rittal 8612.160 Combi screw M10×25 Hex 40 N·m Tapping screw M6×12 Torx T30 (Hex) 9 N·m Tapping screw M6×12 Torx T30 (Hex) 9 N·m Combi screw M10×25 Hex 40 N·m ABB parts Mounting bracket of option “Flat mounting” No pedestal...
Page 254 248 Step-by-step drawings for a flat installation example in Rittal TS 8 600 mm wide cabinet...
Page 255 8 N·m Combi screw M4×10 Torx T20 2 N·m M6×20 Torx T25 8 N·m ABB parts for option “Power cable connection terminals on the right-hand side of the drive module” Support for back top mounting bracket Handle Bottom mounting bracket...
Page 256 250 Step-by-step drawings for option “Power cable connection terminals on the right-hand side of the drive module” installation example in Rittal TS 8 600 mm wide cabinet...
Page 257 Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
Page 258 Contact us www.abb.com/drives www.abb.com/drivespartners 3AXD50000025169 Rev D (EN) 2017-06-01...

ABB ACS880-04XT Hardware Manual

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