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ABB ACS880-07 Hardware Manual - Mechanical Installation

Manual is about: single drive

Summary of ACS880-07

  • Page 1

    Abb industrial drives hardware manual acs880-07 drives (45 to 630 kw, 50 to 700 hp).

  • Page 2

    List of related manuals you can find manuals and other product documents in pdf format on the internet. See section document library on the internet on the inside of the back cover. For manuals not available in the document library, contact your local abb representative. The qr code below opens an o...

  • Page 3: Hardware Manual

    Hardware manual acs880-07 drives (45 to 630 kw, 50 to 700 hp) 3aua0000105718 rev d en effective: 2014-01-21 2014 abb oy. All rights reserved. 1. Safety instructions 4. Mechanical installation table of contents 6. Electrical installation 10. Start-up.

  • Page 5: Table of Contents

    5 table of contents 1. Safety instructions contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ge...

  • Page 6

    6 csa approved (option +c134) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 resistor braking (options +d150 and +d151) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 emc filters (options + e200, +e201, +e202, +e210) . . . . . . . . . . . . . . ....

  • Page 7

    7 additional requirements for abb motors of types other than m2_, m3_, m4_, hx_ and am_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 additional requirements for the braking applications . . . . . . . . . . . . . . . . . . . . . . . 69 a...

  • Page 8

    8 connecting a motor temperature sensor to the drive i/o . . . . . . . . . . . . . . . . . . . . . . . . 85 6. Electrical installation contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 warnings . . . . . . . . . . . . . . . ...

  • Page 9

    9 installation of safety functions modules (frames r6 to r9) . . . . . . . . . . . . . . . . . . . 114 installation of safety functions modules (frames r10 and r11) . . . . . . . . . . . . . . . . 115 case 1: fso-xx safety functions module on slot 2 . . . . . . . . . . . . . . . . . . . . . . . 115 ...

  • Page 10

    10 12. Maintenance contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 preventive maintenance interval ...

  • Page 11

    11 ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 auxiliary circuit power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 materials . . . . . . . . . . . . . . . . . . . . . ...

  • Page 12

    12 planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 selecting the brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 selecting and routing the external brake resistor cables . . . . . ....

  • Page 13: Safety Instructions

    Safety instructions 13 1 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 wa...

  • Page 14

    14 safety instructions general safety in installation, start-up and maintenance these instructions are for all personnel that install the drive and do maintenance work on it. Warning! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • for frames r6 ...

  • Page 15

    Safety instructions 15 • do not use the module installation ramp with plinth heights which exceed the maximum height marked on the ramp. (the maximum plinth height is 50 mm [1.97 in] when the telescopic ramp is fully retracted and 150 mm [5.91 in] when the ramp is fully extended.) • secure the modul...

  • Page 16

    16 safety instructions note: • if you select an external source for start command and it is on, the drive will start immediately after fault reset unless you configure the drive for pulse start. See the firmware manual. • when the control location is not set to local, the stop key on the control pan...

  • Page 17

    Safety instructions 17 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. • do not install a drive with emc filter option ...

  • Page 18

    18 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 and equipment malfunction can occur, and electromagnetic interference can increase. • if you are not a q...

  • Page 19: Drives

    Safety instructions 19 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...

  • Page 20

    20 safety instructions.

  • Page 21: Introduction to The Manual

    Introduction to the manual 21 2 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. Targe...

  • Page 22: Related Manuals

    22 introduction to the manual electrical installation gives instructions on wiring the drive. Control unit of frames r6 to r9 contains the default i/o connection diagram, descriptions of the terminals and technical data for the control unit. Control unit of frames r10 and r11 contains the default i/...

  • Page 23: Terms and Abbreviations

    Introduction to the manual 23 terms and abbreviations unpack and check the units (only intact units may be started up). Examine that all necessary option modules and equipment are present and correct. Mount the drive. Mechanical installation (page 53 ) if the drive has been non- operational for more...

  • Page 24

    24 introduction to the manual fepl-01 optional ethernet powerlink adapter module fena-11 optional ethernet adapter module for ethernet/ip™, modbus tcp and profinet io protocols fena-21 optional ethernet adapter module for ethernet/ip™, modbus tcp and profinet io protocols, 2-port flon-01 optional lo...

  • Page 25: Operation Principle and

    Operation principle and hardware description 25 3 operation principle and hardware description contents of this chapter this chapter briefly describes the operation principle and construction of the drive. Product overview the acs880-07 is an air-cooled cabinet-installed drive for controlling asynch...

  • Page 26

    26 operation principle and hardware description single-line circuit diagram of the drive q1 main switch-disconnector (switch fuse in frames r6 to r8, switch-disconnector and separate fuses in frames r9 to r11, or molded case circuit breaker and separate fuses [option +f289 for us market only]) q2 op...

  • Page 27

    Operation principle and hardware description 27 block diagram of the brake and dc options (+d150, +d151 and +h356) a drive module cubicle t1 drive module b brake resistor cubicle 1 rectifier. Converts alternating current and voltage to direct current and voltage. 2 dc link. Dc circuit between rectif...

  • Page 28

    28 operation principle and hardware description general information on the cabinet layout example cabinet line-up 1 frames r6 to r8: drive module cubicle. Frames r9 to r11: two cubicles with one door (main switch and power cabling cubicle and drive module cubicle) 2 brake resistor cubicle with optio...

  • Page 29

    Operation principle and hardware description 29 cabinet layout of frames r6 to r8 the cabinet layout without shrouds is shown below. 1 drive control panel 12 control unit, see page 119 . 2 door switches and lights, see page 41 . 13 optional terminal block for external control unit connections (x504,...

  • Page 30

    30 operation principle and hardware description cabinet layout of frames r6 to r8 with option +c129 the cabinet layout without shrouds is shown below. 1 drive control panel 11 buffering module c22 2 door switches and lights, see page 41 . 12 swing-out frame 3 main switch handle 13 mounting plate wit...

  • Page 31

    Operation principle and hardware description 31 cabinet layout of frames r6 to r8 with options +c129 and +f289 option +c129 +f289 is available for us market only. The cabinet layout without shrouds is shown below. 1 drive control panel 9 auxiliary voltage transformer (t21) 2 door switches and lights...

  • Page 32

    32 operation principle and hardware description 15 control cable lead-throughs 20 control unit, see page 119 . 16 motor cable lead-throughs 21 optional terminal block for external control unit connections (x504, option +l504) 17 ground bar 22 common mode filter (option +e208) 18 motor cable connecti...

  • Page 33

    Operation principle and hardware description 33 cabinet layout of frame r9 the cabinet layout is shown below. See also the next page. A – main breaker and power cabling cubicle b – drive module cubicle 1 drive control panel 9 buffering module 2 operating switch 10 swing-out frame 3 main switch handl...

  • Page 34

    34 operation principle and hardware description the cabinet layout without shrouds, with the swing-out frame open is shown below. A – main breaker and power cabling cubicle b – drive module cubicle 1 auxiliary voltage transformer (t21) 8 control unit, see page 119 . 2 swing-out frame 9 optional term...

  • Page 35

    Operation principle and hardware description 35 cabinet layout of frame r9 with options +c129 and +f289 the cabinet layout is shown below. See also the next page. A – main breaker and power cabling cubicle b – drive module cubicle 1 drive control panel 10 buffering module 2 operating switch 11 swing...

  • Page 36

    36 operation principle and hardware description the cabinet layout with the swing-out frame open is shown below. 1 control cable lead-through 7 connection terminals for external brake resistor and dc cables 2 swing-out frame 8 line contactor (option +f250) 3 drive module 9 connection terminals for o...

  • Page 37

    Operation principle and hardware description 37 cabinet layout of frames r10 and r11 the cabinet layout is shown below. See also the next page. A – main breaker and power cabling cubicle b – drive module cubicle 1 drive control panel - see the next page. 2 operating switch - - 3 main switch handle -...

  • Page 38

    38 operation principle and hardware description the cabinet layout without shrouds, with the swing-out frame open is shown below. A – main breaker and power cabling cubicle b – drive module cubicle 1 main fuses for control devises, ip54 fan transformer (with option +b055), v-meter (option +g334), st...

  • Page 39

    Operation principle and hardware description 39 overview of power and control connections the diagram shows the power connections and control interfaces of the drive. 1 2 3 analog and digital i/o extension modules, feedback interface modules and fieldbus communication modules can be inserted into sl...

  • Page 40

    40 operation principle and hardware description the layout of external control connection terminals at the side of the drive cabinet is shown below. -x250 1 1 2 2 3 3 4 4 -x951 1 1 2 2 3 3 4 4 5 5 6 6 -x968 1 1 2 2 3 3 4 4 5 5 6 6 7 7 -x954 1 1 2 2 3 3 4 4 -x601 pe pe u u v v w w 1 1 2 2 3 3 4 4 5 5...

  • Page 41

    Operation principle and hardware description 41 door switches and lights main switch-disconnector q1 the switch-disconnector handle switches the main voltage to the drive on and off. Label in english label in local language description 1 ready - ready pilot light (option +g327) 2 run - run pilot lig...

  • Page 42

    42 operation principle and hardware description control panel the acs-ap-i is the user interface of the drive. It provides the essential controls such as start/stop/direction/reset/reference, and the parameter settings for the control program. One control panel can be used to control several drives ...

  • Page 43

    Operation principle and hardware description 43 all cabinet options is ip20. The live parts inside the cabinet are protected against contact with clear plastic shrouds or metallic gratings. Ip42 and ul type 1 filtered (option +b054) this option provides the degree of protection of ip42 (ul type 1 fi...

  • Page 44

    44 operation principle and hardware description csa approved (option +c134) the option includes the following accessories and features: • us/csa type main switch fuse • bottom entry and exit of cables • us cable conduit entry (plain plate without ready-made holes) • 115 vac control voltage when need...

  • Page 45

    Operation principle and hardware description 45 see also • connecting the external power supply cables for the cabinet heater and lighting and motor heater (options +g300, +g301 and +g313) • auxiliary circuit power consumption on page 192 • circuit diagrams delivered with drive for the actual wiring...

  • Page 46

    46 operation principle and hardware description us/uk gland/conduit plate (option +h358) the option provides us/uk conduit plates (plain 3 m steel plates without any ready-made holes). Us/uk conduit plates are provided as standard with options +c129 and +c134 instead of the standard cable entries. A...

  • Page 47

    Operation principle and hardware description 47 the customer connects ptc sensors to the thermistor relay and the terminals of the auxiliary relay of the normally open contact, for example, to • main breaker control circuit of the drive for opening the breaker in case of motor overtemperature or • a...

  • Page 48: Type Designation Label

    48 operation principle and hardware description type designation label the type designation label includes an iec and nema rating, appropriate markings, a type designation and a serial number, which allow identification of each unit. The type designation label is located on the front cover. An examp...

  • Page 49

    Operation principle and hardware description 49 c134 csa approved (us/csa type main switch fuse, bottom entry and exit of cables, 115 v ac auxiliary voltage, cable conduit entries, all components ul/csa listed or recognized, max. Supply voltage 600 v) c128 air inlet through bottom c130 channeled air...

  • Page 50

    50 operation principle and hardware description cabling h350 bottom entry (only with +c129) h352 bottom exit (only with +c129) h351 top entry of cables (included with +c129) h353 top exit of cables (included with +c129) h356 dc cable connection busbars h358 cable conduit entry (included with +c129 a...

  • Page 51

    Operation principle and hardware description 51 p912 seaworthy packing p913 special color p929 container packing safety functions q950 prevention of unexpected start with fso-11 q951 emergency stop of category 0 with opening the main breaker/contactor, see also +g331 q952 emergency stop of category ...

  • Page 52

    52 operation principle and hardware description.

  • Page 53: Mechanical Installation

    Mechanical installation 53 4 mechanical installation contents of this chapter this chapter describes the mechanical installation procedure of the drive. Examining the installation site examine the installation site: • the installation site is sufficiently ventilated or cooled to transfer away the dr...

  • Page 54: Necessary Tools

    54 mechanical installation note: for easy maintenance, do not install the drives of frames r10 and r11 on a higher level than the floor in front of it. Otherwise the ramp supplied with the drive cannot be used when replacing the drive modules that run on wheels. Necessary tools the tools required fo...

  • Page 55

    Mechanical installation 55 moving and unpacking the drive move the drive in its original pallet, preferably in the original package to installation site as shown below to avoid damaging the cabinet surfaces and door devices. When you use a pallet truck, check its load capacity before you move the dr...

  • Page 56: Checking The Delivery

    56 mechanical installation unpacking the transport package unpack the transport package as follows: 1. Undo the screws that hold the wooden elements of the transport crate together. 2. Remove the elements. 3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undo...

  • Page 57

    Mechanical installation 57 lifting the drive cabinet lift the drive cabinet using its lifting lugs. Maximum allowed lifting angle of ip22 (ul type 1) and ip42 (ul type 1 filtered) cabinets is 30°. Allowed minimum height of lifting slings of ip54 (ul type 12) cabinets is 2 meters (6.5 ft). Ip54 ip22/...

  • Page 58

    58 mechanical installation moving the cabinet on rollers final placement of the cabinet remove the wooden bottom frame which is part of the shipment. 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, fork-lift...

  • Page 59: Marine Units)

    Mechanical installation 59 fastening the cabinet to the floor and wall or roof (non- marine units) general rules • the drive must be installed in an upright vertical position. • the cabinet can be installed with its back against a wall (a), or back-to-back with another unit (b). • leave 400 mm (15.7...

  • Page 60

    60 mechanical installation fastening methods fasten the cabinet to the floor by using clamps along the edge of the cabinet bottom, or by bolting the cabinet to the floor through the holes inside (if they are accessible). Alternative 1 – clamping alternative 2 – using the holes inside the cabinet 1. ...

  • Page 61: Units)

    Mechanical installation 61 fastening the cabinet to the floor and roof/wall (marine units) follow the general rules given in section general rules on page 59 . See the dimension drawing delivered with the drive for the locations of the fastening holes in the flat bars below the cabinet and for faste...

  • Page 62: Miscellaneous

    62 mechanical installation miscellaneous cable duct in the floor below the cabinet a cable duct can be constructed below the 500 mm wide middle part of the cabinet. The cabinet weight lies on the two 50 mm wide transverse sections which the floor must carry. Prevent the cooling air flow from the cab...

  • Page 63

    Mechanical installation 63 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: where example the cabinet has 3 exit openings of 315 mm diameter. The rated air flow of the c...

  • Page 64

    64 mechanical installation.

  • Page 65: Guidelines For Planning The

    Guidelines for planning the electrical installation 65 5 guidelines for planning the electrical installation contents of this chapter this chapter contains instructions for planning the electrical installation of the drive. Some instructions are mandatory to follow in every installation, others prov...

  • Page 66

    66 guidelines for planning the electrical installation examining the compatibility of the motor and drive use an asynchronous ac induction motor, permanent magnet synchronous motor, ac induction servomotor or abb synchronous reluctance motor (synrm motor) with the drive. Several induction motors can...

  • Page 67

    Guidelines for planning the electrical installation 67 requirements table the following table shows how to select the motor insulation system and when an optional drive du/dt and common mode filters and insulated n-end (non-drive end) motor bearings are required. Ignoring the requirements or imprope...

  • Page 68

    68 guidelines for planning the electrical installation the abbreviations used in the table are defined below. Additional requirements for explosion-safe (ex) motors if you will use an explosion-safe (ex) motor, follow the rules in the requirements table above. In addition, consult the motor manufact...

  • Page 69

    Guidelines for planning the electrical installation 69 additional requirements for abb motors of types other than m2_, m3_, m4_, hx_ and am_ use the selection criteria given for non-abb motors. Additional requirements for the braking applications when the motor brakes the machinery, the intermediate...

  • Page 70

    70 guidelines for planning the electrical installation additional requirements for non-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). The table below shows the requirements for random- wound...

  • Page 71

    Guidelines for planning the electrical installation 71 additional data for calculating the rise time and the peak line-to-line voltage if you need to calculate the actual peak voltage and voltage rise time considering the actual cable length, proceed as follows: • peak line-to line voltage: read the...

  • Page 72: Selecting The Power Cables

    72 guidelines for planning the electrical installation selecting the power cables general rules select the input power and motor cables according to local regulations: • select a cable capable of carrying the drive nominal current. See section ratings (page 175 ) for the rated currents. • select a c...

  • Page 73

    Guidelines for planning the electrical installation 73 typical power cable sizes the table below gives copper and aluminum cable types with concentric copper shield for the drives with nominal current. For the cable sizes accepted by the drive cabinet lead- throughs and connection terminals, see pag...

  • Page 74

    74 guidelines for planning the electrical installation 1. The cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one on top of the other, ambient temperature 30 °c, pvc insulation, surface temperature 70 °c (en 60204-1 and iec 60364-5-52/2001). For ot...

  • Page 75

    Guidelines for planning the electrical installation 75 not allowed power cable types 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 above, or iec 61439...

  • Page 76: Planning The Braking System

    76 guidelines for planning the electrical installation six conductor (3 phases and 3 ground) type mc continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers (trade names in parentheses): • anixter wire & cable (philsheath) • bicc general corp (ph...

  • Page 77: Routing The Cables

    Guidelines for planning the electrical installation 77 routing the cables route the motor cable away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. The motor cable, input power cable and control cables should be installed on separate tray...

  • Page 78: Protection

    78 guidelines for planning the electrical installation 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: • european union: install the equipment in a metal enclosure wit...

  • Page 79

    Guidelines for planning the electrical installation 79 protecting the drive and the input power and motor cables against thermal overload the drive protects itself and the input and motor cables against thermal overload when the cables are sized according to the nominal current of the drive. No addi...

  • Page 80: (Option +Q957)

    80 guidelines for planning the electrical installation note : pressing the stop key on the control panel of the drive, or turning the operating switch of the drive from position “1” to “0” does not generate an emergency stop of the motor or separate the drive from dangerous potential. See the approp...

  • Page 81: Drive

    Guidelines for planning the electrical installation 81 for wiring instructions, safety data and more information on the functions provided by the options, see fso-11 user’s manual (3aua0000097054 [english]). Declaration of conformity see page 197 . Implementing the power-loss ride-through function i...

  • Page 82: Motor

    82 guidelines for planning the electrical installation if there are power factor compensation capacitors in parallel with the three phase input of the drive: 1. Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may...

  • Page 83

    Guidelines for planning the electrical installation 83 implementing a bypass connection if bypassing is required, employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line. Make sure with interlocking that the contactors canno...

  • Page 84

    84 guidelines for planning the electrical installation switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in local control mode) or with the external stop signal (drive in remote control mode). 2. Open the main contactor ...

  • Page 85

    Guidelines for planning the electrical installation 85 1) relay outputs; 2) varistor; 3) rc filter; 4) diode connecting a motor temperature sensor to the drive i/o warning! Iec 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipme...

  • Page 86

    86 guidelines for planning the electrical installation.

  • Page 87: Electrical Installation

    Electrical installation 87 6 electrical installation contents of this chapter this chapter gives instructions on the wiring the drive. Warnings warning! If you ar not a qualified electrician do not do the installation work described in this chapter. Obey the instructions in chapter safety instructio...

  • Page 88

    88 electrical installation motor and motor cable 1. Check that the motor cable is disconnected from the drive output terminals u2, v2 and w2. 2. Measure the insulation resistance between each phase conductor and the protective earth conductor using a measuring voltage of 1000 v dc. The insulation re...

  • Page 89: Connecting The Power Cables

    Electrical installation 89 connecting the power cables connection diagram 1 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 72 ). 2 360-degree grounding is recommended ...

  • Page 90

    90 electrical installation layout of the power cable connection terminals and lead-throughs (frames r6 to r8) note: 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 dr...

  • Page 91

    Electrical installation 91 layout of the power cable connection terminals and lead-throughs (frames r6 to r8 with option +c129) 3 1 power cable lead-throughs 2 strain relief 3 ground bar 4 input cable power connection terminals l1, l2 and l3 5 motor cable connection terminals u2, v2, w2 2 5 4 1 3.

  • Page 92

    92 electrical installation layout of the power cable connection terminals and lead-throughs (frames r6 to r8 with options +c129+f289) 6 3 6 motor cable lead-through 7 ground bar for motor cables 8 motor cable connection terminals u2, v2, w2 8 7 5 1 4 1 input power cable lead-through 2 control cable ...

  • Page 93

    Electrical installation 93 layout of the input and motor cable connection terminals (frame r9) 1 1 w2 v2 u2 l1 l2 l3 1 1 cable routing from below is shown with the arrows. 1 strain relief l1, l2, l3 input power cable terminals u2, v2, w2 motor cable terminals 2 main switch-disconnector 2.

  • Page 94

    94 electrical installation layout of the power cable connection terminals and lead-throughs (frame r9 with option +c129) 2 1 power cable lead-through 2 strain relief 3 ground bar 4 input cable power connection terminals l1, l2 and l3 5 motor cable connection terminals u2, v2, w2 3 1 4 5 2 2.

  • Page 95

    Electrical installation 95 layout of the input and motor cable connection terminals (frames r10 and r11) w2 v2 u2 l1 l2 l3 1 1 strain relief l1, l2, l3 input power cable terminals u2, v2, w2 motor cable terminals 2 pe terminal 2.

  • Page 96

    96 electrical installation lead-through of external resistor and dc cables run the external brake resistor cables and dc cables into the drive cabinet through the power cable lead-throughs at the base of the drive module cubicle. In frames r6 to r8 the connection terminals are in the drive module. I...

  • Page 97

    Electrical installation 97 pe pe 8 pe 13 11 7 8 12 13.

  • Page 98

    98 electrical installation connection procedure (us) 1. Do the steps in section precautions before electrical work on page 16 before you start the work. 2. Open the cabinet door. 3. Open the swing-out frame (if installed). 4. Plan cable access and mark the conduit plate accordingly for the input and...

  • Page 99

    Electrical installation 99 dc connection (option +h356) the udc+ and udc- terminals are intended for common dc configurations of a number of drives, allowing regenerative energy from one drive to be utilized by the other drives in motoring mode. Contact your local abb representative for further inst...

  • Page 100

    100 electrical installation grounding the outer shields of the control cables at the cabinet lead-through applicability this section applies to drives without solid cable conduit plate (no options +c129, +h351, +h353, +h358). Procedure ground the outer shields of all control cables 360 degrees at th...

  • Page 101

    Electrical installation 101 note for top entry of cables: when each cable has its own rubber grommet, sufficient ip and emc protection can be achieved. However, if very many control cables come to one cabinet, plan the installation beforehand as follows: 1. Make a list of the cables coming to the ca...

  • Page 102

    102 electrical installation routing the control cables inside the cabinet (frames r6 to r8) +h351, +c129 +c129+f289.

  • Page 103

    Electrical installation 103 routing the control cables inside the cabinet (frame r9) +h351, +c129, +c129+f289.

  • Page 104

    104 electrical installation routing the control cables inside the cabinet (frames r10 and r11) note: leave some slack in the control wiring to allow the removing of the control unit assembly plate when the drive module is replaced..

  • Page 105

    Electrical installation 105 connecting the control unit cables units without additional i/o terminal block (option l504): ground the pair-cable shields and all grounding wires to the clamp below the control unit as shown below. Units with additional i/o terminal block (option l504): ground the pair-...

  • Page 106

    106 electrical installation leave the other ends of the control cable 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 ...

  • Page 107

    Electrical installation 107 wiring the thermistor relay(s) (options +l505 and +2l505) the external wiring of option +2l505 (two thermistor relays) is shown below. For example, one relay can be used to monitor the motor windings, the other to monitor the bearings. The maximum contact load capacity is...

  • Page 108

    108 electrical installation wiring the pt100 relays (options +2l506, +3l506, +5l506 and +8l506) external wiring of eight pt100 sensor modules is shown below. Contact load capacity 250 v ac 10 a. For the actual wiring, see the circuit diagram delivered with the drive. 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

  • Page 109

    Electrical installation 109 connecting the external power supply cables for the cabinet heater and lighting and motor heater (options +g300, +g301 and +g313) see the circuit diagrams delivered with drive. Connect the external power supply wires for the cabinet heater and lighting to terminal block x...

  • Page 110: Transformer (T21)

    110 electrical installation wiring ground fault monitoring for it ungrounded systems (option +q954) we recommend to connect alarm 1 for drive tripping and alarm 2 for alarm signals in order to avoid unnecessary trippings due to the ground fault monitor self testing with alarm 2. Setting the voltage ...

  • Page 111: Connecting A Pc

    Electrical installation 111 connecting a pc warning! Do not connect the pc directly to the control panel connector of the control unit as this can cause damage. Connect a pc to the drive with an usb data cable (usb type a usb type mini-b) as follows: 1. Lift the usb connector cover on the control pa...

  • Page 112: Panel Bus

    112 electrical installation controlling several drives from one control panel through panel bus one control panel (or pc) can be used to control several drives by constructing a panel bus. 1. Connect the panel to one drive using an ethernet (eg. Cat5e) cable. • use menu – settings – edit texts – dri...

  • Page 113: Installing Option Modules

    Electrical installation 113 installing option modules mechanical installation of i/o extension, fieldbus adapter and pulse encoder interface modules see page 39 for the available slots for each module. Install the option modules as follows: warning! Obey the instructions in chapter safety instructio...

  • Page 114

    114 electrical installation installation of safety functions modules (frames r6 to r9) mount the safety functions module next to the control unit as described below. Warning! Obey the instructions in chapter safety instructions . If you ignore them, injury or death, or damage to the equipment can oc...

  • Page 115

    Electrical installation 115 installation of safety functions modules (frames r10 and r11) install the safety functions module next to the control unit as described below. Change the mounting plate of the module as shown in fso-11 user’s manual (3aua0000097054 [english]). Warning! Obey the instructio...

  • Page 116

    116 electrical installation 2 3 5 4.

  • Page 117

    Electrical installation 117 case 2: fso-xx safety functions module above the control unit install the safety functions module next to the control unit as described below. Change the original mounting plate of the module to the alternative plate included in the module package. Warning! Obey the instr...

  • Page 118

    118 electrical installation.

  • Page 119: Contents Of This Chapter

    Control unit of frames r6 to r9 119 7 control unit of frames r6 to r9 contents of this chapter this chapter contains the default i/o connection diagram, descriptions of the terminals and technical data for the control unit (zcu-12) of drive frames r6 to r9..

  • Page 120: Layout

    120 control unit of frames r6 to r9 layout the layout of external control connection terminals of the control unit is shown below. X13 description xpow external power input xai analog inputs xao analog outputs xd2d drive-to-drive link xro1 relay output 1 xro2 relay output 2 xro3 relay output 3 xd24 ...

  • Page 121

    Control unit of frames r6 to r9 121 default i/o connection diagram of frames r6 to r9 xpow external power input 1 +24vi 24 v dc, 2 a 2 gnd xai reference voltage and analog inputs 1 +vref 10 v dc, r l 1…10 kohm 2 -vref -10 v dc, r l 1…10 kohm 3 agnd ground 4 ai1+ speed reference 0(2)…10 v, r in > 200...

  • Page 122

    122 control unit of frames r6 to r9 notes: 1) current [0(4)…20 ma, r in = 100 ohm] or voltage [ 0(2)…10 v, r in > 200 kohm] input selected with jumper j1. Change of setting requires reboot of control unit. 2) current [0(4)…20 ma, r in = 100 ohm] or voltage [ 0(2)…10 v, r in > 200 kohm] input selecte...

  • Page 123

    Control unit of frames r6 to r9 123 ai1 and ai2 as pt100 and kty84 sensor inputs (xai, xao) three pt100 sensors or one kty84 sensor for motor temperature measurement can be connected between an analog input and output as shown below. (alternatively, you can connect the kty to fen-11 analog /i/o exte...

  • Page 124

    124 control unit of frames r6 to r9 di6 (xdi:6) as ptc sensor input ptc sensors 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 n...

  • Page 125: Technical Data

    Control unit of frames r6 to r9 125 this diagram shows the wiring of the drive-to-drive link for frames r6 to r9. Safe torque off (xsto) for the drive to start, both connections (out1 to in1 and in2) must be closed. By default, the terminal block has jumpers to close the circuit. Remove the jumpers ...

  • Page 126

    126 control unit of frames r6 to r9 digital inputs/outputs dio1 and dio2 (xdio:1 and xdio:2) input/output mode selection by parameters. Dio1 can be configured as a frequency input (0…16 khz with hardware filtering of 4 microseconds) for 24 v level square wave signal (sinusoidal or other wave form ca...

  • Page 127

    Control unit of frames r6 to r9 127 ground isolation diagram xpow +24vi 1 gnd 2 xai +vref 1 -vref 2 agnd 3 ai1+ 4 ai1- 5 ai2+ 6 ai2- 7 xao ao1 1 agnd 2 ao2 3 agnd 4 xd2d b 1 a 2 bgnd 3 xro1, xro2, xro3 nc 1 com 2 no 3 nc 1 com 2 no 3 nc 1 com 2 no 3 xd24 diil 1 +24vd 2 dicom 3 +24vd 4 diognd 5 xdio ...

  • Page 128

    128 control unit of frames r6 to r9.

  • Page 129: R11

    Control unit of frames r10 and r11 129 8 control unit of frames r10 and r11 contents of this chapter this chapter contains the default i/o connection diagram, descriptions of the terminals and technical data for the control unit (zcu-14) of drive frames r10 and r11..

  • Page 130: Layout

    130 control unit of frames r10 and r11 layout the layout of the external control connection terminals of the control unit is shown below. Description xpow external power input xai analog inputs xao analog outputs xd2d drive to drive link xro1 relay output ro1 xro2 relay output ro2 xro3 relay output ...

  • Page 131

    Control unit of frames r10 and r11 131 default i/o connection diagram of frames r10 and r11 relay outputs xro1…xro3 ready 250 v ac / 30 v dc 2 a no 3 com 2 nc 1 running 250 v ac / 30 v dc 2 a no 3 com 2 nc 1 faulted(-1) 250 v ac / 30 v dc 2 a no 3 com 2 nc 1 external power input xpow 24 v dc, 2 a gn...

  • Page 132

    132 control unit of frames r10 and r11 notes: 1) current [0(4)…20 ma, r in = 100 ohm] or voltage [ 0(2)…10 v, r in > 200 kohm] input selected with jumper j1. Change of setting requires reboot of control unit. 2) current [0(4)…20 ma, r in = 100 ohm] or voltage [ 0(2)…10 v, r in > 200 kohm] input sele...

  • Page 133: Ground Isolation Diagram

    Control unit of frames r10 and r11 133 ground isolation diagram xpow +24vi 1 gnd 2 xai +vref 1 -vref 2 agnd 3 ai1+ 4 ai1- 5 ai2+ 6 ai2- 7 xao ao1 1 agnd 2 ao2 3 agnd 4 xd2d b 1 a 2 bgnd 3 xro1, xro2, xro3 nc 1 com 2 no 3 nc 1 com 2 no 3 nc 1 com 2 no 3 xd24 diil 1 +24vd 2 dicom 3 +24vd 4 diognd 5 xd...

  • Page 134

    134 control unit of frames r10 and r11.

  • Page 135: Installation Checklist

    Installation checklist 135 9 installation checklist contents of this chapter this chapter contains an installation checklist which you must complete before you start up the drive. Warnings warning! Obey the instructions in chapter safety instructions . If you ignore them, injury or death, or damage ...

  • Page 136

    136 installation checklist there is an adequately sized protective earth (ground) conductor between the drive and the switchboard, and the conductor has been connected to appropriate terminal. Proper grounding has also been measured according to the regulations. There is an adequately sized protecti...

  • Page 137: Start-Up

    Start-up 137 10 start-up contents of this chapter this chapter contains the start-up procedure of the drive. The default device designations (if any) are given in brackets after the name, for example “main switch-disconnector (q1)”. The same device designations are also used in the circuit diagrams,...

  • Page 138

    138 start-up powering up the drive close the cabinet doors. Make sure that it is safe to connect voltage. Ensure that: • cabinet doors are closed • nobody is working on the drive or circuits that have been wired from outside into the drive cabinet • cover of the motor terminal box is on. Close the m...

  • Page 139: Fault Tracing

    Fault tracing 139 11 fault tracing contents of this chapter this chapter describes the fault tracing possibilities of the drive. Leds warning and fault messages see the firmware manual for the descriptions, causes and remedies of the drive control program warning and fault messages. Where led color ...

  • Page 140

    140 fault tracing.

  • Page 141: Maintenance

    Maintenance 141 12 maintenance contents of this chapter this chapter contains preventive maintenance instructions. Maintenance intervals if installed in an appropriate environment, the drive requires very little maintenance. The table below lists the routine maintenance intervals recommended by abb....

  • Page 142

    142 maintenance cabinet cooling fan (internal) (r) r (r) (r) r (r) (r) r (r) (r) cabinet cooling fan (door) (r) r (r) (r) r (r) (r) r (r) (r) cabinet cooling fan (ip54) (r) r (r) (r) r (r) (r) r (r) (r) aging battery for control panel and zcu control unit r r to maintain optimal performance and reli...

  • Page 143: Ip42 / Ul Type 1 Filtered)

    Maintenance 143 cleaning the interior of the cabinet warning! Obey the instructions in chapter safety instructions . If you ignore them, injury or death, or damage to the equipment can occur. Warning! Use a vacuum cleaner with an antistatic hose and nozzle. Using a normal vacuum cleaner creates stat...

  • Page 144

    144 maintenance replacing the air filters (ip54 / ul type 12) check the air filters and replace if necessary (see page 192 for the correct filter types). Inlet (door) filters (ip54 / ul type 12) 1. Remove the fasteners at the top of the grating. 2. Lift the grating and pull it away from the door. 3....

  • Page 145: Heatsink

    Maintenance 145 heatsink the drive module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. When necessary, clean the heatsink as follows. Warning! Obey the instructions in chapter safety instructions . If you ignor...

  • Page 146

    146 maintenance replacing the cabinet “door” fans warning! Obey the 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 16 before you start th...

  • Page 147

    Maintenance 147 replacing the cabinet fans (frames r6 to r9) 1. For removing the fan mounting plate, see section replacing the drive module (frames r6 to r8) on page 156 (steps 1 to 3 and 13) or section replacing the drive module (frame r9) on page 161 (steps 1, 9 and 10). For frame r9 with option +...

  • Page 148

    148 maintenance replacing the drive module main fans (frames r6 to r8) warning! Obey the 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 1...

  • Page 149

    Maintenance 149 replacing the auxiliary cooling fan of the drive module (frames r6 to r9) warning! Obey the 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 electr...

  • Page 150

    150 maintenance replacing the drive module main fans (frame r9) warning! Obey the 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 16 befor...

  • Page 151

    Maintenance 151 replacing the drive module main fans (frames r10 and r11) warning! Obey the 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 pag...

  • Page 152

    152 maintenance replacing the circuit board compartment cooling fan (frames r10 and r11) warning! Obey the 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 electri...

  • Page 153

    Maintenance 153 replacing the ip54 (ul type 12) roof fan of frames r6 to r8 warning! Obey the 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 p...

  • Page 154

    154 maintenance replacing the ip54 (ul type 12) roof fan of frame r9 warning! Obey the 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 16 ...

  • Page 155

    Maintenance 155 replacing the ip54 (ul type 12) roof fan of frames r10 and r11 warning! Obey the 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 o...

  • Page 156

    156 maintenance replacing the drive module (frames r6 to r8) required in this replacing procedure: two persons, lifting chains, lifting device, a set of screw drivers and torque wrench with extension bar. A lifting device for acs880-07 drive modules is available from abb. For its installation and us...

  • Page 157

    Maintenance 157 16. Undo the upper mounting nuts of the drive module. 17. Undo the lower mounting nuts of the drive module. 18. Slide the drive module towards the end of the sliding bars. 19. Secure the drive module with chains from the lifting eyes. 20. Lift the module out of the cabinet with the l...

  • Page 158

    158 maintenance r6 to r8 3 2 4 7 5 6 8 5 6 9 9.

  • Page 159

    Maintenance 159 r6 to r8 10 r- r+ 11 +d150, +d151 udc+ udc- 12 +h356.

  • Page 160

    160 maintenance r6 to r9 13 14 15 15 16 17 19 18 19.

  • Page 161

    Maintenance 161 replacing the drive module (frame r9) required in the replacing procedure: two persons, lifting chains, lifting device, a set of screw drivers and torque wrench with extension bar. A lifting device for acs880-07 drive modules is available from abb. For its installation and use, see a...

  • Page 162

    162 maintenance 16. Slide the drive module towards the end of the sliding bars. 17. Secure the drive module with chains from the lifting eyes. 18. Lift the module out of the cabinet with the lifting device. 19. Install the new module in reverse order..

  • Page 163

    Maintenance 163 r9 3 2 4 7 5 6 5.

  • Page 164

    164 maintenance r9 9 8 10 11 13 12 154 12.

  • Page 165

    Maintenance 165 r9 16 15 17 15 17.

  • Page 166

    166 maintenance replacing the drive module (frames r10 and r11) this replacing procedure requires: two persons, installation ramp, a set of screw drivers and a torque wrench with an extension bar. The drawings show frame r11. The details in frame r10 are slightly different. Warning! Obey the instruc...

  • Page 167

    Maintenance 167 11. Fasten the extraction ramp to the cabinet base with two screws. 12. Attach the drive module lifting lugs to the cabinet lifting lug with chains. 13. Pull the drive module carefully out of the cabinet preferably with help from another person. 14. Install the new module in reverse ...

  • Page 168

    168 maintenance r10 and r11 4 5 2 7 6 3.

  • Page 169

    Maintenance 169 r10 and r11 8 9 7.

  • Page 170

    170 maintenance r10 and r11 10

  • Page 171

    Maintenance 171 r10 and r11 11b 11a.

  • Page 172: Capacitors

    172 maintenance r10 and r11 capacitors the drive intermediate circuit employs several electrolytic capacitors. Their lifespan depends on the operating time of the drive, loading and ambient temperature. Capacitor life can be prolonged by lowering the ambient temperature. Capacitor failure is usually...

  • Page 173: Memory Unit

    Maintenance 173 replacing the control panel battery the battery is housed on the rear of the control panel. Replace with a new cr 2032 battery. Dispose the old battery according to local disposal rules or applicable laws. Replacing the control unit battery 1. Stop the drive and do the steps in secti...

  • Page 174

    174 maintenance transferring the memory unit warning! Obey the 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 16 before you start the wor...

  • Page 175: Technical Data

    Technical data 175 13 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 nominal ratings for the drives ...

  • Page 176

    176 technical data 0650a-3 r10 650 730 650 355 634 355 477 250 0725a-3 r11 725 1020 725 400 715 400 566 315 0820a-3 r11 820 1020 820 450 810 450 625 355 0880a-3 r11 880 1100 880 500 865 500 725 *** 400 u n = 500 v 0096a-5 r6 96 148 96 55 91 55 77 45 0124a-5 r6 124 178 124 75 118 75 96 55 0156a-5 r7 ...

  • Page 177

    Technical data 177 definitions nema ratings drive type acs880-07- frame size input rating max. Current output ratings light-overload use heavy-duty use i 1n i max i ld p ld i hd p hd a a a kw hp a kw hp u n = 460 v 0096a-5 r6 96 148 96 55 75 77 45 60 0124a-5 r6 124 178 124 75 100 96 55 75 0156a-5 r7...

  • Page 178

    178 technical data derating ambient temperature derating in the temperature range +40…50 °c (+104…122 °f), the rated output current is derated by 1% for every added 1 °c (1.8 °f). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k): al...

  • Page 179: Fuses (Iec)

    Technical data 179 fuses (iec) the drive is equipped with ar fuses listed below. Drive type acs880-07- input current (a) ultrarapid (ar) fuses (one fuse per phase) a a 2 s v manufacturer type type with option +f289 size u n = 400 v 0105a-3 105 160 8250 690 bussmann 170m3814d 170m3414 1 0145a-3 145 2...

  • Page 180: Fuses (Ul)

    180 technical data note 1: see also implementing thermal overload and short-circuit protection on page 78 . Note 2: fuses with higher current rating than the recommended ones must not be used. Fuses with lower current rating can be used. Note 3: fuses from other manufacturers can be used if they mee...

  • Page 181: Dimensions and Weights

    Technical data 181 note 1: see also implementing thermal overload and short-circuit protection  on page 73 . Note 2:  fuses with higher current rating than the recommended ones must not be used. Fuses with lower current rating can be used. Note 3:  fuses from other manufacturers ...

  • Page 182: Free Space Requirements

    182 technical data free space requirements front side above * mm in. Mm in. Mm in. 150 5.91 - - 400 15.75 * measured from the base plate of the cabinet top. Note : 320 mm (12.28 in.) is required for fan replacement of ip54 cabinets. Door opening: 320 mm (12.28 in.) > 400 mm (15.75 in.) ip22/42 ip54 ...

  • Page 183

    Technical data 183 losses, cooling data and noise drive type frame air flow heat dissipation noise m 3 /h ft 3 /min w db(a) u n = 400 v acs880-07-0105a-3 r6 1750 1130 1795 67 acs880-07-0145a-3 r6 1750 1130 1940 67 acs880-07-0169a-3 r7 1750 1130 2440 67 acs880-07-0206a-3 r7 1750 1130 2810 67 acs880-0...

  • Page 184

    184 technical data terminal and lead-through data for the power cables iec us acs880-07-0425a-7 r11 2950 1837 6909 72 acs880-07-0470a-7 r11 2950 1837 8622 72 acs880-07-0522a-7 r11 2950 1837 9264 72 acs880-07-0590a-7 r11 2950 1837 10362 71 acs880-07-0650a-7 r11 3170 1978 11078 71 frame size number of...

  • Page 185

    Technical data 185 input and motor cable terminal dimensions of frames r6 to r7 input and motor cable terminal dimensions of frame r8 resistor and dc cable terminal dimensions of frames r6 to r8 top entry and exit: bottom entry and exit: top entry and exit: bottom entry and exit:.

  • Page 186

    186 technical data motor cable terminal dimensions of frame r9 – units with optional du/dt filter (+e205): motor cable terminal dimensions of frame r9 – units without optional du/dt filter (+e205): input cable terminal dimensions of frame r9: resistor and dc cable terminal dimensions of frames r9.

  • Page 187

    Technical data 187 input and motor cable terminal dimensions of frame r10 bottom entry and exit:.

  • Page 188

    188 technical data input and motor cable terminal dimensions of frame r10 top entry and exit:.

  • Page 189

    Technical data 189 input and motor cable terminal dimensions of frame r11 bottom entry and exit:.

  • Page 190

    190 technical data terminal data for the control cables see chapter control unit of frames r6 to r9 on page 119 or control unit of frames r10 and r11 on page 129 . Input and motor cable terminal dimensions of frame r11 top entry and exit:.

  • Page 191: Motor Connection Data

    Technical data 191 electrical power network specification voltage ( u 1 ) acs880-07-xxxxx-3 drives: 380…415 vac 3-phase +10%…-15% acs880-07-xxxxx-5 drives: 380…500 vac 3-phase +10%…-15% acs880-07-xxxxx-7 drives: 525…690 vac 3-phase +10%…-15% network type tn (grounded) and it (ungrounded) systems sho...

  • Page 192: Ambient Conditions

    192 technical data overvoltage category (iec 60664-1) iii protective class (iec/en 61800-5-1) i ambient conditions environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. Operation installed for stationary use storage in the protective...

  • Page 193: Applicable Standards

    Technical data 193 air filters of ip54 units inlet (door): aircomp 300-50 288 mm x 521 mm (abb code: 64640194) 688 mm x 521 mm (abb code 64748017) outlet (roof): airtex g150 2 pcs: 398 mm x 312 mm (abb code: 64722166) fire safety of materials (iec 60332-1) insulating materials and non-metallic items...

  • Page 194: Ce Marking

    194 technical data ce marking a ce mark is attached to the drive to verify that the drive complies with the provisions of the european low voltage and emc directives. The ce marking also verifies that the drive, in regard to its safety functions (such as safe torque off), conforms with the machinery...

  • Page 195

    Technical data 195 declaration of conformity (safe torque off) see also chapter safe torque off function on page 213 ..

  • Page 196

    196 technical data.

  • Page 197

    Technical data 197 declaration of conformity (option +q973) see also section implementing the functions provided with the safety functions module fso-11 (option +q973) on page 80 ..

  • Page 198

    198 technical data.

  • Page 199

    Technical data 199 compliance with the en 61800-3:2004 definitions emc stands for e lectro m agnetic c ompatibility. 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 ...

  • Page 200: Ul Marking

    200 technical data category c3 the drive complies with the standard with the following provisions: 1. The drive is equipped with emc filter e200, e201 or e210. 2. The motor and control cables are selected as specified in the hardware manual. 3. The drive is installed according to the instructions gi...

  • Page 201: Csa Marking

    Technical data 201 ul checklist • the drive is to be used in a heated, indoor controlled environment. The drive must be installed in clean air according to enclosure classification. Cooling air must be clean, free from corrosive materials and electrically conductive dust. See page 192 . • the maximu...

  • Page 202: Disclaimer

    202 technical data disclaimer the manufacturer shall have no obligation hereunder with respect to any product which (i) has been improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident; (iii) has been used in a manner contrary to the manufacturer's instructions; or ...

  • Page 203: Dimension Drawings

    Dimension drawings 203 14 dimension drawings example dimension drawings with dimensions in millimeters and [inches] are shown below..

  • Page 204

    204 dimension drawings frame sizes r6 to r8 (ip22, ip42).

  • Page 205

    Dimension drawings 205 frame sizes r6 to r8 (ip54, option +b055).

  • Page 206: Frame Size R9 (Ip22, Ip42)

    206 dimension drawings frame size r9 (ip22, ip42).

  • Page 207

    Dimension drawings 207 frame size r9 (ip54, option +b055).

  • Page 208

    208 dimension drawings frame size r9 (marine unit, option +c121).

  • Page 209

    Dimension drawings 209 frame sizes r6 to r8 with option +f289 (ul type 1).

  • Page 210

    210 dimension drawings frame sizes r6 to r8 with option +f289 (ul type 12).

  • Page 211

    Dimension drawings 211 frame size r10 and r11 (ip22, ip42).

  • Page 212

    212 dimension drawings frame size r10 and r11 (ip54, ul type 12).

  • Page 213: Safe Torque Off Function

    Safe torque off function 213 15 safe torque off function contents of this chapter this chapter describes the safe torque off 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 s...

  • Page 214: Wiring

    214 safe torque off function the function also corresponds to prevention of unexpected start-up as specified by en 1037:1995 + a1:2008 and uncontrolled stop (stop category 0) as specified in en 60204-1:2006 + ac:2010. Compliance with the european machinery directive see section compliance with the e...

  • Page 215

    Safe torque off function 215 maximum cable lengths: • 30 m (100 ft) between activation switch (k) and drive control unit • 60 m (200 ft) between multiple drives • 60 m (200 ft) between external power supply and first drive. Note that the voltage at the inx terminals of each drive must be at least 17...

  • Page 216

    216 safe torque off function multiple drives (internal power supply) +24 v out1 sgnd in1 in2 acs880-07 zcu out1 sgnd in1 in2 out1 sgnd in1 in2 acs880-07 zcu acs880-07 zcu k.

  • Page 217

    Safe torque off function 217 multiple drives (external power supply) out1 sgnd in1 in2 out1 sgnd in1 in2 out1 sgnd in1 in2 acs880-07 zcu +24 v acs880-07 zcu acs880-07 zcu 24 v dc – + k.

  • Page 218: Operation Principle

    218 safe torque off function operation principle 1. The safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. Sto inputs on the drive control unit de-energize. 3. The control unit cuts off the control voltage from the drive igbts. 4. The control program gener...

  • Page 219: Use

    Safe torque off function 219 use 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 inverter igbts. 3. The control program gener...

  • Page 220: Maintenance

    220 safe torque off function notes: • if a running drive is stopped by using the safe torque off function, the drive will cut off the motor supply voltage and the motor will coast to a stop. If this causes danger or is not otherwise acceptable, stop the drive and machinery using the appropriate stop...

  • Page 221

    Safe torque off function 221 * according to table e.1 in en/iso 13849-1 • this temperature profile is used in safety value calculations: • 670 on/off cycles per year with t = 71.66 °c • 1340 on/off cycles per year with t = 61.66 °c • 30 on/off cycles per year with t = 10.0 °c • 32 °c board temperatu...

  • Page 222

    222 safe torque off function safety data (sil, pl) abbr. Reference description ccf en iso 13849-1 common cause failure (%) dc en iso 13849-1 diagnostic coverage fit iec 61508 failure in time: 1e-9 hours hft iec 61508 hardware fault tolerance mttf d en iso 13849-1 mean time to dangerous failure: (the...

  • Page 223: Resistor Braking

    Resistor braking 223 16 resistor braking contents of this chapter this chapter tells how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. Operation principle and hardware description the drive can be equipped with optional built-in brake chopper...

  • Page 224

    224 resistor braking note : a custom resistor can be selected within the limits imposed by the internal brake chopper of the drive: • the resistance value of the custom resistor is at least r min . The braking power capacity of the resistor can be calculated from the following equation: where warnin...

  • Page 225

    Resistor braking 225 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. Placing the brake resistor...

  • Page 226: Electrical Installation

    226 resistor braking electrical installation checking the insulation of the assembly follow the instructions given under brake resistor assembly on page 88 . Connection diagram see section connection diagram on page 89 . Connection procedure • connect the resistor cables to the r+ and r- terminals i...

  • Page 227: Technical Data

    Resistor braking 227 technical data ratings drive type internal brake chopper example brake resistor(s) p brcont r min type r e r p rcont kw ohm ohm kj kw u n = 400 v acs880-07-0105a-3 55 5.4 safur80f500 6 2400 6 acs880-07-0145a-3 75 5.4 safur80f500 6 2400 6 acs880-07-0169a-3 90 3.3 safur125f500 4 3...

  • Page 228

    228 resistor braking p brcont the internal brake chopper will withstand this continuous braking power. R min the minimum allowed resistance value of the brake resistor r resistance value for the listed resistor assembly e r short energy pulse that the resistor assembly withstands every 400 seconds p...

  • Page 229

    Further information product and service inquiries address any inquiries about the product to your local abb representative, quoting the type designation and serial number of the unit in question. A listing of abb sales, support and service contacts can be found by navigating to www.Abb.Com/searchcha...

  • Page 230

    Contact us www.Abb.Com/drives www.Abb.Com/drivespartners 3aua0000105718 rev d (en) 2014-01-21.