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ABB ACS880-17, Hardware Manual

The ABB ACS880-17 is a high-performance industrial drive designed for precise control of various applications. Unlock its full potential with the comprehensive Hardware Manual, available for free download at 88.208.23.73:8080. This manual offers detailed instructions and valuable insights, ensuring optimal utilization of this exceptional product.

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The Safe torque off function   231

WARNING!

 The Safe torque off functionality is only achieved through the XSTO 

connector of the inverter control unit [A41]. True Safe torque off functionality is not 
achieved through the XSTO connectors of other control units such as the supply 

control unit [A51].

The Safe torque off function is supported by any ACS880 inverter unit firmware. It is not 
supported by supply or brake firmware.

WARNING!

 (With permanent magnet or synchronous reluctance [SynRM] motors 

only) In case of a multiple IGBT power semiconductor failure, the inverter system 
can produce an alignment torque which maximally rotates the motor shaft by 

180/

p

 (with permanent magnet motors) or 180/2

p

 (with synchronous reluctance [SynRM] 

motors) degrees regardless of the activation of the Safe torque off function. 

p

 denotes the 

number of pole pairs.

Notes

:

•

If a running inverter is stopped by using the Safe torque off function, the inverter 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 inverter and machinery using the 
appropriate stop mode before activating the Safe torque off function.

•

The Safe torque off function overrides all other functions of the inverter unit.

•

The Safe torque off function is ineffective against deliberate sabotage or misuse.

•

The Safe torque off function has been designed to reduce the recognized hazardous 
conditions. In spite of this, it is not always possible to eliminate all potential hazards. 
The assembler of the machine must inform the final user about the residual risks.

Maintenance

After the operation of the circuit is validated at start-up, the STO function shall be 
maintained by periodic proof testing. In high demand mode of operation, the maximum 
proof test interval is 20 years. In low demand mode of operation, the maximum proof test 
interval is 2 years. The test procedure is given in section 

Acceptance test procedure

 (page 

229

).

Note:

 See also the Recommendation of Use CNB/M/11.050 (published by the European 

co-ordination of Notified Bodies) concerning dual-channel safety-related systems with 
electromechanical outputs:

•

When the safety integrity requirement for the safety function is SIL 3 or PL e (cat. 3 or 
4), the proof test for the function must be performed at least every month.

•

When the safety integrity requirement for the safety function is SIL 2 (HFT = 1) or PL d 
(cat. 3), the proof test for the function must be performed at least every 12 months.

The STO function of the inverter does not contain any electromechanical components.

In addition to proof testing, it is a good practice to check the operation of the function when 
other maintenance procedures are carried out on the machinery.

Include the Safe torque off operation test described above in the routine maintenance 
program of the machinery that the inverter runs.

If any wiring or component change is needed after start up, or the parameters are restored, 
follow the test given in section 

Acceptance test procedure

 (page 

229

).

Use only ABB approved spare parts.

Record all maintenance and proof test activities in the machine logbook.

Summary of Contents for ACS880-17

Page 1: ...ABB industrial drives Hardware manual ACS880 37 drives ...

Page 2: ...0094606 FSO 12 safety functions module user s manual 3AXD50000015612 User s manual for Prevention of unexpected start up Q950 for ACS880 07 17 37 drives 3AUA0000145922 User s manual for Emergency stop stop category 0 Q951 for ACS880 07 17 37 drives 3AUA0000119895 User s manual for Emergency stop stop category 1 Q952 for ACS880 07 17 37 drives 3AUA0000119896 User s manual for Prevention of unexpect...

Page 3: ......

Page 4: ......

Page 5: ...re manual ACS880 37 drives 3AXD50000020437 Rev A EN EFFECTIVE 2015 02 06 2015 ABB Oy All Rights Reserved 1 Safety instructions 4 Mechanical installation Table of contents 6 Electrical installation 9 Start up ...

Page 6: ......

Page 7: ... commissioning and operation flowchart 27 Terms and abbreviations 28 Safety data SIL PL 29 3 Operation principle and hardware description Contents of this chapter 31 Operation principle 31 Supply unit 31 AC voltage and current waveforms 32 Charging 32 Inverter unit 32 Overview circuit diagram of the drive 33 Cabinet line up and layout examples 34 Frame 1 R8i 1 R8i 34 Frame 2 R8i 2 R8i 36 Frame 3 R...

Page 8: ...nation key 53 4 Mechanical installation Contents of this chapter 57 Examining the installation site 57 Necessary tools 58 Checking the delivery 58 Moving and unpacking the drive 59 Moving the drive in its packaging 59 Lifting the crate with a forklift 59 Lifting the crate with a crane 60 Moving the crate with a forklift 61 Removing the transport package 62 Moving the unpacked drive cabinet 62 Lift...

Page 9: ...eld 80 Additional US requirements 81 Conduit 81 Armored cable shielded power cable 81 Planning the braking system 81 Selecting the control cables 81 Shielding 81 Signals in separate cables 82 Signals allowed to be run in the same cable 82 Relay cable type 82 Control panel cable length and type 82 Routing the cables 82 Separate control cable ducts 83 Continuous motor cable shield or enclosure for e...

Page 10: ...7 Connecting emergency stop push buttons options Q951 Q952 Q963 Q964 Q978 Q979 97 Wiring the starter for auxiliary motor fan options M602 M610 97 Wiring the thermistor relay s options L505 and 2L505 98 Wiring the Pt100 relays options 2L506 3L506 5L506 and 8L506 99 Powering the heating and lighting equipment options G300 G301 and G313 100 Wiring ground fault monitoring for IT ungrounded systems opt...

Page 11: ...129 Safe torque off 130 Safety functions X12 130 SDHC memory card slot 130 Control unit connector data 131 8 Installation checklist Contents of this chapter 135 Warnings 135 Checklist 135 9 Start up Contents of this chapter 137 Start up procedure 137 Checks Settings with no voltage connected 138 Powering up the auxiliary circuit of the drive 138 Setting up the supply unit parameters 139 Setting up...

Page 12: ...inverter module 159 LCL filter 160 Replacing the LCL filter 160 Capacitors 164 Reforming the capacitors 164 Fuses 165 Replacing the AC fuses in the incoming cubicle 165 Replacing the AC fuses in the LCL filter module or supply module cubicle frame 3 R8i 3 R8i and up 165 Replacing the DC fuses in the supply module cubicle frame 2 R8i 2 R8i and up 166 Replacing the DC fuses in the inverter module cu...

Page 13: ...rking 189 C tick marking 189 EAC Eurasian Conformity marking 189 Tightening torques 189 Electrical connections 189 Mechanical connections 189 Insulation supports 190 Cable lugs 190 Disclaimers 190 Generic disclaimer 190 Cyber security disclaimer 190 13 Dimensions What this chapter contains 191 Cabinet line up dimensions 192 Dimension tables 192 1 R8i 1 R8i 192 ACS880 37 1110A 3 1010A 5 1110A 5 066...

Page 14: ...on motor terminal cubicle 214 Frame 1 R8i 1 R8i without sine output filter 214 Inverter module cubicle with two R8i modules bottom cable exit 214 Inverter module cubicle with two R8i modules top cable exit 215 Inverter module cubicle with three R8i modules bottom cable exit 215 Inverter module cubicle with three R8i modules top cable exit 216 Sine filter E206 cubicle 1000 mm bottom cable exit 216 ...

Page 15: ...city of the braking equipment 238 Custom resistors 238 Calculating the maximum braking power Pbr 239 Selecting and routing the cables of a custom resistor 240 Minimizing electromagnetic interference 240 Maximum cable length 240 EMC compliance of the complete installation 240 Placing custom brake resistors 240 Protecting the system against thermal overload 240 Thermal protection of the resistors 24...

Page 16: ...16 ...

Page 17: ...mage to the equipment They also tell you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment General warning tells about conditions other than those caused by electricity which can cau...

Page 18: ... Use the designated lifting points shown in the drawing below Do not tilt the module It will overturn very easily because it is heavy and its center of gravity is high Make sure that the module does not topple over when you move it on the floor Open the support legs Whenever possible secure the module also with chains Do not leave the module unattended on a sloping floor Do not use the module inst...

Page 19: ... from drawing the dust inside the drive Do not cover the air inlet and outlet when the drive is running Make sure that there is sufficient cooling See section Examining the installation site page 57 Before you connect voltage to the drive make sure that the cabinet doors are closed Keep the doors closed during operation 50 150 mm max Support the top and bottom of the module when extracting it from...

Page 20: ...en minutes Too frequent power ups can damage the charging circuit of the DC capacitors Make sure that any safety circuits for example emergency stop and Safe torque off are validated at start up See chapter The Safe torque off function page 223 For other safety functions see their separate instructions Note If you select an external source for the start command and it is on the drive will start im...

Page 21: ...nnection is not possible Lock the disconnectors to open position and attach a warning notice to them Disconnect any external power sources from the control circuits before you do work on the control cables After you disconnect the drive always wait for 5 minutes to let the intermediate circuit capacitors discharge before you continue 3 Protect any other energized parts in the work location against...

Page 22: ...e terminals of the drive are at a dangerous voltage when the input power is on regardless of whether the motor is running or not The DC bus brake chopper and brake resistors if any are at a dangerous voltage External wiring can supply dangerous voltages to the relay outputs of the control units of the drive The Safe torque off function does not remove the voltage from the main and auxiliary circui...

Page 23: ... of the grounding conductors is sufficient See section Selecting the power cables page 76 Obey the local regulations Connect the power cable shields to protective earth PE of the drive to make sure of personnel safety Make a 360 grounding of the power and control cable shields at the cable entries to suppress electromagnetic disturbances In a multiple drive installation connect each drive separate...

Page 24: ...nnot rotate during work Make sure that no other system like hydraulic crawling drives can rotate the motor directly or through any mechanical connection like felt nip rope etc Measure that the installation is de energized Use a multimeter with an impedance of at least 1 Mohm Make sure that the voltage between the drive output terminals U2 V2 W2 and the grounding PE busbar is close to 0 V Make sure...

Page 25: ...ematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Contents of the manual This manual contains the instructions and information for the basic drive configuration The chapters of the manual are briefly described below Safety instructions gives safety instructions for the installation start up operation and maintenance of the drive Introduction to the man...

Page 26: ...ntation Resistor braking describes selection protection wiring and start up of optional brake choppers and resistors The chapter also contains technical data Related documents See List of related manuals on the inside of the front cover Categorization by frame size and option code Some instructions technical data and dimension drawings which concern only certain frame sizes are marked with the sym...

Page 27: ...nt and correct Mount the drive Mechanical installation page 57 If the drive has been non operational for more than one year the DC link capacitors need to be reformed page 164 Route the cables Routing the cables page 82 Check the insulation of the supply cable the motor and the motor cable Checking the insulation of the assembly page 89 If the drive is about to be connected to an IT ungrounded sys...

Page 28: ...Net IP Modbus TCP and PROFINET IO protocols FENA 21 Optional Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols 2 port FEPL 01 Optional Ethernet POWERLINK adapter module FIO 01 Optional digital I O extension module FIO 11 Optional analog I O extension module FLON 01 Optional LonWorks adapter module FPBA 01 Optional PROFIBUS DP adapter module Frame size Relates to the cons...

Page 29: ...ity The categories are B 1 2 3 and 4 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 MTTFd EN ISO 13849 1 Mean time to dangerous failure The total number of life units the number of dangerous undetected failures during a particular measurement interval under stated conditions PFD IEC 61508...

Page 30: ...30 Introduction to the manual ...

Page 31: ... ABB synchronous reluctance SynRM motors The drive consists of several cubicles that contain the supply and motor terminals 1 to 6 IGBT supply module s forming the supply unit line side converter 1 to 6 inverter modules forming the inverter unit motor side converter and optional equipment The actual arrangement of the cubicles varies from type to type and the selected options Some optional equipme...

Page 32: ...ffectively filters the high frequency over 1 kHz harmonics Charging Charging is needed to power up the DC link capacitors smoothly Discharged capacitors cannot be connected to the full supply voltage The voltage must be increased gradually until the capacitors are charged and ready for normal use The drive contains a resistive charging circuit consisting of fuses contactor and charging resistors T...

Page 33: ...replaced by an air circuit breaker Q1 by selecting option F255 Larger drive types have an air circuit breaker as standard equipment Drives with an air circuit breaker have AC fuses only at the input of each LCL filter 6 Charging switch fuse Q3 7 Charging contactor Q4 8 Charging resistors R4 x 9 LCL filter R3 x 10 Supply module T1 x 11 Common mode filters R1 x at the output of each supply module 12...

Page 34: ... ACU Contains control electronics and customer I O connections See page 40 B Supply and inverter module cubicle Contains the supply module LCL filter inverter module and switchgear as well as the power cable terminals 1 Main switch disconnector Q1 1 2 Charging switch Q3 3 Drive control panel see page 46 4 Door switches and lights see page 44 A B 1 2 3 4 ...

Page 35: ...nput terminals behind LCL filter module 4 Main switch disconnector Q1 1 behind mounting plate 5 AC fuses behind mounting plate 6 Fuse disconnectors for auxiliary voltage F20 x 7 Main contactor Q2 1 8 Charging fuse switch Q3 9 Charging contactor 10 Charging resistors 11 Supply module 12 Inverter module 13 Output terminals behind inverter module 6 A 2 11 12 7 8 10 9 4 1 3 5 13 ...

Page 36: ...odules together with an LCL filter module D Inverter module cubicle Contains two R8i inverter modules As standard the motor cables are run from each inverter module to the motor unless the drive is equipped with option H359 common motor terminal cubicle H366 common output terminals or E206 sine filters 1 Main switch disconnector Q1 1 2 Grounding earthing switch Q9 1 option F259 3 Drive control pan...

Page 37: ... 8 Auxiliary voltage switch Q21 9 Charging switch Q3 10 Incoming cubicle cooling fan 11 DC fuses at the output of each supply module and at the input of each inverter module 12 LCL filter module 13 Supply modules 14 Inverter modules The output terminals are located behind each module Each module must be individually connected to the motor using separate cables unless the drive is equipped with opt...

Page 38: ...ules D Supply module cubicle 2 Contains three R8i supply modules E Inverter module cubicle Contains three R8i inverter modules As standard the motor cables are run from each inverter module to the motor unless the drive is equipped with option H359 common motor terminal cubicle H366 common output terminals or E206 sine filters 1 Main circuit breaker Q1 2 Grounding earthing switch Q9 1 option F259 ...

Page 39: ...ounding earthing switch Q9 1 option F259 9 Charging contactor behind auxiliary equipment 10 AC fuses 11 LCL filter modules 12 Supply modules 13 DC fuses at the output of each supply module and at the input of each inverter module 14 Inverter modules The output terminals are located behind each module Each module must be individually connected to the motor using separate cables unless the drive is ...

Page 40: ...e I O of the inverter control unit is wired to this block 4 Inverter control unit A41 Three optional I O extension encoder interface or fieldbus adapter modules can be installed on the unit Additional modules are installed on item 13 See chapter Control units of the drive page 123 22 Grounding clamping point for control cables 5 Auxiliary voltage circuit breaker F112 On the secondary of transforme...

Page 41: ...breakers F22 and F102 On the secondary of transformers T21 item 28 and T101 item 27 respectively 13 FEA 03 extension adapter option L515 See item 4 31 Input voltage setting for auxiliary voltage transformer T101 item 27 14 Switch and circuit breaker for externally supplied motor space heater option G313 The terminals X313 are located on the back of the detachable mounting plate 32 Input voltage se...

Page 42: ... on the inverter control unit See page 95 and Control units of the drive page 123 These terminals are optionally wired to terminal block X504 in the auxiliary control cabinet of the drive L1 L2 L3 PE U2 V2 W2 M 3 L1 L2 L3 PE Fxx Slots 1 2 and 3 1 7 6 10 4 2 3 Slot 4 5 X205 X12 X13 8 Inverter control unit A41 Supply control unit A51 V1T R 9 11 13 12 14 ACS880 37 Fxxx Module type Slots Analog and di...

Page 43: ...s 10 Terminal blocks for customer connections installed in the drive cabinet For the locations see Auxiliary control cubicle ACU layout page 40 Wiring details are given starting on page 97 11 Supply unit consisting of one or more supply modules and LCL filters 12 DC link 13 Inverter unit consisting of one or more inverter modules 14 Optional brake chopper D150 and resistors D151 ...

Page 44: ... for the supply unit 5 E STOP RESET Emergency stop reset push button with emergency stop options only 6 EARTH FAULT Ground earth fault light with option Q954 7 Reserved for application engineered equipment 8 EMERGENCY STOP Emergency stop push button with emergency stop options only 1 2 3 4 5 6 7 8 OFF OFF Run enable signal off starting the supply unit not allowed ON Run enable signal on starting t...

Page 45: ...lose the main disconnecting device auxiliary voltage must be switched on and the grounding switch if present must be open Auxiliary voltage switch Q21 The auxiliary voltage switch controls the supply to the auxiliary voltage transformers The transformer feeds the control circuits inside the drive such as cooling fans relays and measuring equipment The switch is fitted with fuses Note Frame 1 R8i 1...

Page 46: ...nel link see section Panel bus Control of several units from one control panel page 119 The control panel can be removed by pulling it forward from the top edge and reinstalled in reverse order For the use of the control panel see ACS AP assistant control panel user s manual 3AUA0000085685 English and the firmware manual Control by PC tools There is a USB connector on the front of the panel that c...

Page 47: ...This option provides the degree of protection of IP42 UL type 1 Filtered The air inlet gratings are covered with a metallic mesh between the inner metallic grating and the outer plastic grating IP54 option B055 This option provides the degree of protection of IP54 UL type 12 It provides the cabinet air inlets with filter housings containing folded board air filter mats between the inner metallic g...

Page 48: ...le conduit entry plain plate without ready made holes all components UL Listed Recognized maximum supply voltage 600 V Related options H358 cable conduit entry 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 all components UL CSA listed recogn...

Page 49: ...or external interruptible control voltage option G307 The option provides terminals for connecting external interruptible control voltage to the control unit and control devices when the drive is not running See also Supplying power for the auxiliary circuits on page 86 Connecting an auxiliary voltage supply UPS option G307 on page 97 circuit diagrams delivered with drive for the actual wiring Out...

Page 50: ...ctice two or three inverter modules mounted in the same cubicle The bridging balances the motor current between the modules which allows more cabling options For example it is possible to use a number of cables that could not otherwise be evenly distributed between the inverter modules Additional markings G340 Equipment pin numbers are marked with snap on markers on wires between modules and on wi...

Page 51: ...terminal block at the factory for customer control wiring The terminals are spring loaded Cables accepted by the terminals solid wire 0 08 to 4 mm2 stranded wire with ferrule 0 14 to 2 5 mm2 stranded wire without ferrule 0 08 to 2 5 mm2 28 to 12 AWG Stripping length 10 mm Note The optional modules inserted in the slots of the control unit or optional FEA 03 extension adapter are not wired to the a...

Page 52: ...vertemperature supervision of motors equipped with Pt100 sensors For example three sensors measure the temperature of the motor windings and two sensors the temperature of the bearings The sensor resistance increases linearly as the temperature rises The relay releases at an adjustable wake up level and indicates motor overtemperature through its change over contact The relay provides connection t...

Page 53: ...uest No Description 1 Type designation see section Type designation key below 2 Frame size 3 Ratings 4 Valid markings 5 Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing year and week respectively The remaining digits complete the serial number so that there are no two units with the same number CODE DESCRIPT...

Page 54: ...ns of supply inverter modules Resistor braking D150 Brake choppers D151 Brake resistors Filters E202 EMC filter for first environment TN grounded system category C2 E206 Sine output filter Line options F255 Main air circuit breaker instead of line contactor F259 Grounding earthing switch Cabinet equipment G300 Cabinet and module heating elements external supply G301 Cabinet lighting G307 Terminals...

Page 55: ...504 Additional I O terminal block L505 Thermistor relay 1 or 2 pcs L506 Pt100 relay 2 3 5 or 8 pcs L508 FDCO 02 optical DDCS communication adapter module L513 ATEX certified thermal protection with PTC sensors 1 or 2 pcs L514 ATEX certified thermal protection with Pt100 relays 3 5 or 8 pcs L515 FEA 03 I O extension adapter module L516 FEN 21 resolver interface module L517 FEN 01 TTL incremental en...

Page 56: ...ergency stop category 1 with safety relays by activating the Safe torque off function Q965 Safely limited speed with FSO 21 and encoder Q971 ATEX certified safe disconnection function Q972 FSO 21 safety functions module Q973 FSO 12 safety functions module Q978 Emergency stop configurable for category 0 or 1 with FSO xx safety functions module by opening the main breaker contactor Q979 Emergency st...

Page 57: ... behind the unit is of non flammable material There is enough free space above the drive to enable cooling air flow service and maintenance The floor that the unit is installed on is of non flammable material as smooth as possible and strong enough to support the weight of the unit Check the floor flatness with a spirit level The maximum allowed deviation from the surface level is 5 mm in every 3 ...

Page 58: ...truck check load capacity slate spud bar jack and rollers Pozidriv and Torx screwdrivers torque wrench set of wrenches or sockets Checking the delivery The drive delivery contains drive cabinet line up optional modules if ordered installed onto the control unit at the factory appropriate drive and optional module manuals delivery documents Check that there are no signs of damage Before attempting ...

Page 59: ...aging the cabinet surfaces and door devices When you are using a pallet truck check its load capacity before you move the drive The drive cabinet is to be moved in the upright position The center of gravity of the cabinet is high Be therefore careful when moving the unit Avoid tilting Moving the drive in its packaging Lifting the crate with a forklift ...

Page 60: ...60 Mechanical installation Lifting the crate with a crane max 20 Position each sling as close to a transverse board as possible We recommend the use of transverse spreader bars Lifting point ...

Page 61: ...Mechanical installation 61 Moving the crate with a forklift Free width for fork tines 750 mm 29 5 ...

Page 62: ...is mounted onto the transport pallet by undoing the fastening screws 4 Remove the plastic wrapping Moving the unpacked drive cabinet Lifting the cabinet with a crane Lift the drive cabinet using its lifting eyes The lifting eyes can be removed after the cabinet is in its final position but their mounting holes must be blocked to retain the degree of protection Note The minimum allowed height of th...

Page 63: ...lose to its final location Remove the rollers by lifting the unit with a crane forklift pallet truck or jack Moving the cabinet on its back WARNING Transportation of the cabinet on its back is only allowed with the BLCL LCL filter modules and sine filters option E206 removed from the cabinet Support the cabinet from below alongside the cubicle seams Cabinet back panel Support ...

Page 64: ...ical installation Final placement of the cabinet Move the cabinet into its final position with a slate bar spud bar Place a piece of wood between the edge of the cabinet and the bar to protect the cabinet frame ...

Page 65: ...t requires 320 mm 12 28 of free space above the filter compartment Leave some space w at the side where the cabinet outmost hinges are to allow the doors to open sufficiently The doors must open 120 to allow supply or inverter module replacement Note 1 Any height adjustment must be done before fastening the units or shipping splits together Height adjustment can be done by using metal shims betwee...

Page 66: ...ended maximum distance between the clamps in the front edge is 800 mm 31 5 2 If floor mounting at the back is not possible fasten the top of the cabinet to the wall with L brackets not included in the delivery bolted to the lifting bar fastening holes 1 Fasten the cabinet to the floor through the bottom fastening holes with M10 to M12 3 8 to 1 2 bolts The recommended maximum distance between the f...

Page 67: ...binet to the floor and roof wall as follows 1 Bolt the unit to the floor through the holes in each flat bar at the base of the cabinet using M10 or M12 screws 2 If there is not enough room behind the cabinet for installation clamp the rear ends of the flat bars 3 Remove the lifting lugs and bolt the fastening brackets into the lifting lug holes Fasten the top of the cabinet to the rear wall and or...

Page 68: ... Air inlet through the bottom option C128 WARNING Make sure that the incoming air is sufficiently clean If not dust goes into the cabinet The outlet filter on the cabinet roof prevents dust from going out The collected dust can cause drive malfunction and danger of fire Air outlet duct on the cabinet roof option C130 The ventilation system must keep the static pressure in the air outlet duct suffi...

Page 69: ...g is not recommended However if arc welding is the only mounting option connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0 5 meters 1 6 of the welding point Note The thickness of the zinc coating of the cabinet frame is 100 to 200 micrometers 4 to 8 mil WARNING Make sure that the return wire is connected correctly Welding current must not return via a...

Page 70: ...70 Mechanical installation ...

Page 71: ...y liability whatsoever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Selecting the supply disconnecting device The drive is equipped with a main disconnecting device Depending on the size of the drive the disconnecting device is a switch ...

Page 72: ... drive output voltage If the motor and drive are not of the same size consider the following operation limits of the drive control program motor nominal voltage range 1 6 2 UN motor nominal current range 1 6 2 IN of the drive in DTC control and 0 2 IN in scalar control The control mode is selected by a drive parameter Protecting the motor insulation and bearings The drive employs modern IGBT inver...

Page 73: ... and frame size NEMA 500 134 hp PN 469 hp or NEMA 500 frame size NEMA 580 PN 469 hp or frame size NEMA 580 ABB motors Random wound M2_ M3_and M4_ UN 500 V Standard N N CMF 500 V UN 600 V Standard du dt N du dt N du dt CMF or Reinforced N N CMF 600 V UN 690 V cable length 150 m Reinforced du dt N du dt N du dt CMF 600 V UN 690 V cable length 150 m Reinforced N N CMF Form wound HX_and AM_ 380 V UN 6...

Page 74: ...rmediate DC circuit voltage of the drive is increased from the nominal level by resistor braking check with the motor manufacturer if additional output filters are needed in the applied drive operation range Abbr Definition UN Nominal AC line voltage ÛLL Peak line to line voltage at motor terminals which the motor insulation must withstand PN Motor nominal power du dt du dt filter at the output of...

Page 75: ...uirements 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 Additional requirements for non ABB high output and IP23 motors The rated output power of high output motors is higher than what is s...

Page 76: ...cable sizes Select a cable rated for at least 70 C maximum permissible temperature of conductor in continuous use For US see Additional US requirements page 81 The inductance and impedance of the PE conductor cable grounding wire must be rated according to permissible touch voltage appearing under fault conditions so that the fault point voltage will not rise excessively when a ground fault occurs...

Page 77: ... electromagnetic emission of the whole drive system as well as the stress on motor insulation bearing currents and wear The protective conductor must always have an adequate conductivity The table below shows the minimum cross sectional area related to the phase conductor size according to IEC 61439 1 when the phase conductor and the protective conductor are made of the same metal Cross sectional ...

Page 78: ... 3 240 72 Cu 2 3 150 70 TBA 0620A 3 3 3 185 57 Cu 2 3 240 120 TBA 0870A 3 4 3 240 72 Cu 3 3 240 120 TBA 1110A 3 4 3 300 88 Cu 3 3 300 150 TBA 1210A 3 5 3 240 72 Cu 4 3 240 120 TBA 1430A 3 6 3 240 72 Cu 4 3 300 150 TBA 1700A 3 7 3 240 72 Cu 6 3 240 120 TBA 2060A 3 9 3 240 72 Cu 7 3 240 120 TBA 2530A 3 9 3 300 88 Cu 8 3 240 120 TBA UN 500 V 0420A 5 2 3 185 57 Cu 2 3 150 70 TBA 0570A 5 3 3 185 57 Cu ...

Page 79: ... 70 TBA 0870A 3 4 3 240 72 Cu 3 3 240 120 TBA 1110A 3 6 3 185 57 Cu 4 3 240 120 TBA 1210A 3 6 3 240 72 Cu 6 3 150 70 TBA 1430A 3 8 3 185 57 Cu 6 3 185 95 TBA 1700A 3 8 3 240 72 Cu 6 3 240 120 TBA 2060A 3 9 3 240 72 Cu 6 3 300 150 TBA 2530A 3 12 3 240 72 Cu 9 3 240 120 TBA UN 500 V 0420A 5 2 3 240 72 Cu 2 3 150 70 TBA 0570A 5 3 3 185 57 Cu 2 3 240 120 TBA 0780A 5 4 3 185 57 Cu 3 3 150 70 TBA 1010A ...

Page 80: ...ection General rules above or IEC 61439 1 To effectively suppress radiated and conducted radio frequency emissions the cable shield conductivity must be at least 1 10 of the phase conductor conductivity The requirements are easily met with a copper or aluminum shield The minimum requirement of the motor cable shield of the drive is shown below It consists of a Symmetrical shielded cable with three...

Page 81: ...s to the drive enclosure and motor frame Use separate conduits for input power motor brake resistor and control wiring When conduit is employed type MC continuous corrugated aluminum armor cable or shielded cable is not required A dedicated ground cable is always required Note Do not run motor wiring from more than one drive in the same conduit Armored cable shielded power cable Six conductor 3 ph...

Page 82: ...raided 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 be longer than three meters 10 ft Cable type shielded CAT 5e or better Ethernet patch cable with RJ 45 ends Routing the cables Route the motor cable away from other cable routes Motor cables...

Page 83: ...ontactors 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 with 360 degree grounding for the shields of both the incoming and outgoing cable or connect the shields of the cables otherwise together US Install the equipment in a metal enclosure in a way that the conduit or motor cable shie...

Page 84: ...for the total motor load It may not trip due to an overload in one motor circuit only Protecting the motor against thermal overload According to regulations the motor must be protected against thermal overload and the current must be switched off when overload is detected The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary Depe...

Page 85: ...pter The Safe torque off function page 223 Implementing the Prevention of unexpected start up function The drive can be equipped with a Prevention of unexpected start up POUS function either with an FSO xx safety functions module option Q950 or with a safety relay option Q957 The POUS function enables short time maintenance work like cleaning on the non electrical parts of the machinery without sw...

Page 86: ...ntrol program WARNING Make sure that the flying restart of the motor will not cause any danger If you are in doubt do not implement the Power loss ride through function The main contactor of the drive opens in a power loss situation When the power returns the contactor closes However if the power loss situation lasts so long that the drive trips on undervoltage it must be reset and started again t...

Page 87: ...ck that the power factor compensation unit is suitable for use in systems with AC drives ie harmonic generating loads In such systems the compensation unit should typically be equipped with a blocking reactor or harmonic filter Implementing a safety switch between the drive and the motor We recommend to install a safety switch between the permanent magnet synchronous motor and the drive output The...

Page 88: ...rmistor and other similar components to the digital inputs of the drive can be implemented in three alternate ways 1 There is double or reinforced insulation between the thermistor and live parts of the motor 2 Circuits connected to all digital and analog inputs of the drive are protected against contact and insulated with basic insulation the same voltage level as the drive main circuit from othe...

Page 89: ...structions can cause injury or death Checking the insulation of the assembly Drive Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive Every drive has been tested for insulation between the main circuit and the chassis at the factory Also there are voltage limiting circuits inside the drive which cut down the testing voltage aut...

Page 90: ...tructions on how to do this contact your local ABB representative WARNING If a drive with EMC filter E202 is installed on an IT system an ungrounded power system or a high resistance grounded over 30 ohm power system the system will be connected to earth potential through the EMC filter capacitors of the drive This may cause danger or damage the unit Attaching the device stickers to the cabinet do...

Page 91: ...01 tap settings 690 V units 500 V 1 480 V 2 460 V 3 440 V 4 415 V 5 400 V 6 380 V 7 U1 8 TP1 9 TP2 10 T21_X1 or T101_X1 T21_X2 or T101_X2 1 230 V 2 3 4 N 5 Θ 690 V 1 660 V 2 600 V 3 575 V 4 540 V 5 525 V 6 7 U1 8 TP1 9 TP2 10 T21_X1 or T101_X1 T21_X2 or T101_X2 1 230 V 2 3 4 N 5 Θ ...

Page 92: ...C3 A3 B3 a1 b1 c1 a2 b2 c2 575 V A1 B1 C1 C3 A3 B3 a1 b1 c1 a2 b2 c2 540 V A1 B1 C1 C4 A4 B4 a1 b1 c1 a2 b2 c2 525 V A1 B1 C1 C4 A4 B4 a1 b1 c1 a2 b2 c2 500 V A1 B1 C1 C4 A4 B4 a1 b1 c1 a2 b2 c2 480 V A1 B1 C1 C5 A5 B5 a1 b1 c1 a2 b2 c2 460 V A1 B1 C1 C5 A5 B5 a1 b1 c1 a2 b2 c2 440 V A1 B1 C1 C5 A5 B5 a1 b1 c1 a2 b2 c2 415 V A1 B1 C1 C6 A6 B6 a1 b1 c1 a2 b2 c2 400 V A1 B1 C1 C6 A6 B6 a1 b1 c1 a2 b...

Page 93: ...ontrol cables at the cabinet lead through below 3 Route the control cables as described in section Routing the control cables inside the cabinet page 95 4 Connect the control cables as described starting on page 95 Grounding the outer shields of the control cables at the cabinet lead through Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions as follows 1 Loos...

Page 94: ...cient 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 cabinet 2 Sort the cables going to the left into one group and the cables going to the right into another group to avoid unnecessary crossing of cables inside the cabinet 3 Sort the cables in each group according t...

Page 95: ...allow the frame to open fully Connecting to the inverter control unit A41 Connect the conductors to the appropriate terminals see page 123 of the control unit or terminal block X504 option L504 Connect the inner twisted pair shields and all separate grounding wires to the grounding clamps below the control unit The drawing below represents a drive with additional I O terminal block option L504 Wit...

Page 96: ...the shields unconnected or ground them indirectly via a high frequency capacitor with a few nanofarads eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points ...

Page 97: ... Q952 Q963 Q964 Q978 Q979 Connect external emergency stop push buttons according to the circuit diagrams delivered with the drive Wiring the starter for auxiliary motor fan options M602 M610 Connect the power supply wires for the auxiliary motor fan to terminal blocks X601 X605 according to the circuit diagrams delivered with the drive 1 2 PE 4 5 N L X307 PE 1 1 Internal wiring of UPS supervision ...

Page 98: ...ing see the circuit diagram delivered with the drive 1 2 3 4 5 6 7 8 9 10 11 12 25 26 27 28 X506 T T 1 n PTC 6 5 1 n PTC 1 PTC sensors monitored by relay K74 RG R1 R2 RN 1 5 kohm 2 External reset for relay K74 to be bridged for autoreset functionality 3 PTC sensors monitored by relay K75 RG R1 R2 RN 1 5 kohm 4 External reset for relay K75 to be bridged for autoreset functionality 5 Overheat indica...

Page 99: ...e circuit diagram delivered with the drive 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 X506 T 1 Pt100 2 1 T T T T T T T 3 1 Internal wiring of the windings overheat modules 1 3 overtemperature contact open 2 Internal wiring of the bearings overheat module 4 and 5 overtemperature contact open 3 Internal wiring of the windings overheat modules 6 8 overtemperature...

Page 100: ...heater and lighting to terminal block X300 at the back of the mounting plate Connect the motor heater wiring to terminal block X313 as shown below Maximum external power supply 16 A 1 2 PE 4 5 N L X300 PE 1 Internal wiring of the cabinet heater heater off fault contact open 1 1 2 3 4 5 6 7 PE2 PE1 N L N L X313 PE 1 Internal wiring of the motor space heater supervision heater off fault contact open...

Page 101: ...2 for alarm signals in order to avoid unnecessary trippings due to the ground fault monitor self testing with Alarm 2 1 2 3 4 X954 Alarm 1 Alarm 2 1 Internal wiring Ground fault alarm 1 No ground fault contact closed Contact load capacity 250 V AC 2 A 2 Internal wiring Ground fault alarm 2 No ground fault contact closed Contact load capacity 250 V AC 8 A 1 2 ...

Page 102: ... drive as well as the example drawings presented in this manual starting on page 214 Connection diagram without option H366 All parallel connected inverter modules are to be cabled separately to the motor 360 earthing is to be used at cable lead throughs WARNING The cabling from all inverter modules to the motor must be physically identical considering cable type cross sectional area and length U2...

Page 103: ... H366 option only interconnects the outputs of inverter modules within the same cubicle not modules installed in different cubicles Therefore when the drive has more than three inverter modules make sure that the load is distributed evenly between the modules In case of two inverter cubicles of two modules connect the same number of cables to each cubicle In case of one inverter cubicle with three...

Page 104: ...ons If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Precautions before electrical work page 21 before you start the work 2 Open the inverter module cubicle door 3 Remove the screws holding the front cover plate Lift the cover plate somewhat to release it 4 Disconnect the wiring at the top of the fan carriage 5 Remove the two screws at the bottom of...

Page 105: ...Electrical installation 105 4 5 3 6 7 ...

Page 106: ...er optic cabling Move the disconnected wiring aside 7 Attach the module extraction ramp included to the base of the cabinet so that the tabs on the mounting bracket enter the slots on the ramp WARNING Do not use the ramp included in the drive delivery with other plinth heights than what the drive has 8 Remove the two screws at the bottom front of the module WARNING Before you proceed make sure the...

Page 107: ...Electrical installation 107 5 6 4 3 ...

Page 108: ...108 Electrical installation 7 8 8 ...

Page 109: ...Electrical installation 109 9 10 ...

Page 110: ...ductor The dimensions of the output busbars are shown in chapter Technical data 6 Connect the phase conductors of the motor cable to the U2 V2 and W2 terminals You can temporarily remove the plastic insulators b between the busbars to make the connecting work easier WARNING The plastic insulators b between the busbars must be in place when the inverter is powered 7 Connect the shield and any groun...

Page 111: ...Electrical installation 111 2 360 grounding detail a b b 1 5 a 11 b a PE 10 7 5 6 8 ...

Page 112: ... in the cubicle 2 If not already in place attach the module extraction ramp included to the base of the cabinet so that the tabs on the mounting bracket enter the slots on the ramp 3 Push the module up the ramp and back into the cubicle Keep your fingers away from the edge of the module front plate to avoid pinching Keep a constant pressure with one foot on the base of the module to prevent the mo...

Page 113: ...nstructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Precautions before electrical work page 21 before you start the work 2 Open the door of the common motor terminal cubicle and remove the shrouding 3 Lead the cables into the common motor terminal cubicle Make the 360 earthing arrangement at the cable entry as...

Page 114: ...icle doors 9 At the motor connect the cables according to instructions from the motor manufacturer Pay special attention to the phase order For minimum radio frequency interference ground the cable shield 360 degrees at the lead through of the motor terminal box or ground the cable by twisting the shield so that the flattened shield is wider than 1 5 of its length Connecting an external brake resi...

Page 115: ...ection procedure WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Precautions before electrical work page 21 before you start the work 2 Open the door of the incoming cubicle or in the case of frame 1 R8i 1 R8i the door of the supply and inverter module cubicle 3 Frame 1 R8i 1 R8i only Rem...

Page 116: ...ductive sleeves and attach the grommets to the holes 10 Fasten the conductive sleeves to the cable shields with cable ties 11 Seal the slot between the cable and mineral wool sheet if used with sealing compound eg CSD F ABB brand name DXXT 11 code 35080082 12 Tie up the unused conductive sleeves with cable ties 13 Connect the twisted shields of the cables to the PE busbar of the cabinet 14 Connect...

Page 117: ...Electrical installation 117 PE 11 8 4 9 11 ...

Page 118: ...nt WARNING Do not connect the PC directly to the control panel connector of the inverter unit as this can cause damage 2 Remove the USB connector cover on the front of the control panel 3 Connect an USB cable Type A to Type Mini B between the USB connector on the control panel 3a and a free USB port on the PC 3b 4 The panel will display an indication whenever the connection is active 5 See the doc...

Page 119: ...me to the unit Use parameter 49 01 to assign the unit with a unique node ID number Set other parameters in group 49 if necessary Use parameter 49 06 to validate any changes Repeat the above for each unit 2 With the panel connected to one inverter unit link the inverter units together using Ethernet cables Each panel platform has two connectors 3 In the last unit switch bus termination on With a pa...

Page 120: ...damage to the equipment can occur 1 Stop the drive and do the steps in section Precautions before electrical work page 21 before you start the work 2 Open the door of the auxiliary control cubicle ACU 3 Remove the shrouding at the top of the cubicle 4 Locate the inverter control unit A41 5 Insert the module carefully into its position on the control unit 6 Fasten the mounting screw Note The screw ...

Page 121: ...ty functions module 1 Fasten the FSO xx safety functions module onto slot 3 of the inverter control unit A41 with four screws 2 Tighten the FSO xx electronics grounding screw 3 Connect the FSO xx data cable between FSO xx connector X110 and to BCU x2 connector X12 1 3 2 ...

Page 122: ...122 Electrical installation Wiring of option modules See the appropriate option module manual for specific installation and wiring instructions ...

Page 123: ...ilt in a metal housing The supply and inverter units of the ACS880 37 are each controlled by a dedicated BCU x2 control unit The designation of the supply control unit is A51 the inverter control unit is A41 Both are located in the ACU cubicle see the drawings in chapter Operation principle and hardware description and connect to the power modules ie supply and inverter modules respectively by fib...

Page 124: ...or for analog input AI1 I current U voltage AI2 Mode selector for analog input AI2 I current U voltage D2D TERM Termination switch for drive to drive link D2D DICOM DIOGND Ground selection Determines whether DICOM is separated from DIOGND ie the common reference for the digital inputs floats 7 segment display Multicharacter indications are displayed as repeated sequences of characters U is indicat...

Page 125: ...on to inverter modules 1 and 2 VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to inverter modules 3 7 BCU 12 22 only VxT transmitter VxR receiver V8T V8R V12T V12R Fiber optic connection to inverter modules 8 12 BCU 22 only VxT transmitter VxR receiver SD CARD Data logger memory card for inverter module communication BATT OK Real time clock battery voltage is higher than 2 8 V...

Page 126: ... kohm VREF 2 Ground AGND 3 Not in use 0 2 10 V Rin 200 kohm AI1 4 AI1 5 Not in use 0 4 20 mA Rin 100 ohm AI2 6 AI2 7 Analog outputs XAO Not in use AO1 1 AGND 2 Not in use AO2 3 AGND 4 Drive to drive link XD2D Not in use Shield 4 BGND 3 A 2 B 1 Safe torque off XSTO Safe torque off Both circuits must be closed for the supply unit to start IN1 and IN2 must be connected to OUT IN2 4 IN1 3 SGND 2 OUT 1...

Page 127: ...y default not in use DI6 6 Run enable 5 DIIL 7 Digital input outputs XDIO Output Ready DIO1 1 Output Running DIO2 2 Digital input output ground DIOGND 3 Digital input output ground DIOGND 4 Auxiliary voltage output XD24 24 V DC 200 mA 6 24VD 5 Digital input ground DICOM 6 24 V DC 200 mA 6 24VD 7 Digital input output ground DIOGND 8 Ground selection switch 7 DICOM DIOGND Analog inputs reference vol...

Page 128: ...l unit 9 Current 0 4 20 mA Rin 100 ohm or voltage 0 2 10 V Rin 200 kohm input selected by switch AI2 Change of setting requires reboot of control unit External power supply for the control unit XPOW The BCU x2 is powered from a 24 V DC 2 A supply through terminal block XPOW A second supply can be connected to the same terminal block for redundancy DI6 as a PTC sensor input PTC sensors can be conne...

Page 129: ...supply and inverter units the DIIL input is used for the connection of safety circuits The input is parametrized to stop the unit when the input signal is lost Drive to drive link The drive to drive link is a daisy chained RS 485 transmission line that allows basic master follower communication with one master drive and multiple followers Set termination activation switch D2D TERM to the ON positi...

Page 130: ...unit but not constitute a true safety function Safety functions X12 See section Implementing the functions provided by the FSO xx safety functions module option Q972 or Q973 page 86 and FSO 12 user s manual 3AXD50000015612 English SDHC memory card slot The BCU x2 has an on board data logger that collects real time data from the inverter module power stages to help fault tracing and analysis The da...

Page 131: ...g 0 04 ms digital filtering up to 8 ms 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 cannot be used DIO2 can be configured as a 24 V level square wave frequency output See the firmware manua...

Page 132: ...connection XSTO Connector pitch 5 mm wire size 2 5 mm2 Input voltage range 3 30 V DC Logic levels 0 5 V 1 17 V For the unit to start both connections must be 1 Current consumption 50 mA 24 V DC continuous per STO channel per inverter module EMC immunity according to IEC 61326 3 1 Safe torque off output XSTO OUT Connector pitch 5 mm wire size 2 5 mm2 To STO connector of inverter module See chapter ...

Page 133: ...23 NC 31 COM 32 NO 33 XD24 24VD 1 DICOM 2 24VD 3 DIOGND 4 XDIO DIO1 1 DIO2 2 DIOGND 3 DIOGND 4 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 DIIL 7 XSTO OUT1 1 SGND 2 IN1 3 IN2 4 Ground Common mode voltage between each AI input and AGND is 30 V Ground selector DICOM DIOGND settings All digital inputs and outputs share a common ground Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from the D...

Page 134: ...134 Control units of the drive ...

Page 135: ...with another person Check that The ambient operating conditions meet the specifications given in chapter Technical data The drive cabinet has been fixed to floor and if necessary due to vibration etc also from top to the wall or roof The cooling air will flow freely in and out of the drive cabinet If the drive will be connected to an IT ungrounded or a corner grounded TN network The optional EMC f...

Page 136: ...d to the appropriate terminals the phase order is correct and the terminals have been tightened Pull on the conductors to check The motor cable has been connected to the appropriate terminals the phase order is right and the terminals have been tightened Pull the conductors to check The motor cable and brake resistor cable if present has been routed away from other cables No power factor compensat...

Page 137: ...ame device designations are typically also used in the circuit diagrams These instructions cannot and do not cover all possible start up tasks of a customized drive Always refer to the delivery specific circuit diagrams when proceeding with the start up WARNING Only qualified electricians are allowed to do the work described in this chapter Note For certain options such as functional safety option...

Page 138: ... If the Safe torque off functionality is not used check that the STO input on all inverter modules is correctly wired to 24 V and ground Drives with ground fault monitoring for IT ungrounded systems option Q954 Adjust the settings of the ground fault monitor to suit the installation See the circuit diagrams of the delivery and IRDH275B Ground Fault Monitor Operating Manual by Bender code TGH1386en...

Page 139: ...the main circuit of the drive Switch the grounding switch Q9 1 option F259 off Close the main switch disconnector Q1 1 or main breaker Q1 With frame size 1 R8i 1 R8i this has already been done to power up the auxiliary circuit Note Do not use excessive force The main switch disconnector or main breaker can only be closed when the main input terminals L1 L2 L3 are powered and auxiliary voltage is s...

Page 140: ...140 Start up ...

Page 141: ...platform POWER Green Control unit is powered and 15 V is supplied to the control panel FAULT Red Drive in fault state Supply or inverter control unit A51 or A41 BATT OK Green Battery voltage of the real time clock is OK higher than 2 8 V When the LED is not lit battery voltage is below 2 8 V the battery is missing or the control unit is not powered PWR OK Green Internal voltage OK FAULT Red The co...

Page 142: ...142 Fault tracing ...

Page 143: ... intervals Consult your local ABB Service representative for more details on the maintenance On the Internet go to http www abb com drivesservices Component Years from start up 1 2 3 4 5 6 7 8 9 10 11 12 Cooling Internal cabinet cooling fans internal door and IP54 R R Supply and inverter module cooling fans speed controlled R Supply inverter and LCL filter module cooling fans direct on line 50 Hz ...

Page 144: ... I I Visual inspection I Visual inspection if needed in demanding operation conditions ambient temperature is constantly over 40 C especially dusty or humid environment cyclic heavy load or continuously high load R Replacement of component in normal operation conditions ambient temperature is below 40 C 104 F clean and non humid environment no cyclic heavy load or no continuously high load R Repla...

Page 145: ...ical work page 21 before you start the work 2 Open the cabinet doors 3 Clean the interior of the cabinet Use a vacuum cleaner and a soft brush 4 Clean the air inlets of the fans and air outlets of the module top 5 Clean the air inlet gratings on the doors see section Cleaning the door air inlets IP22 and IP42 on page 145 6 Close the doors Cleaning the door air inlets IP22 and IP42 1 Remove the fas...

Page 146: ...al wire side facing the door 5 Reinstall the grating in reverse order Cleaning the outlet roof filters IP54 The outlet roof filters in IP54 units can be accessed by pulling the gratings upwards Replacing the outlet roof filters IP54 1 Remove the front and back gratings of the fan by lifting them upwards 2 Remove the air filter mat 3 Place the new filter mat in the grating 4 Reinstall the grating i...

Page 147: ... antistatic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Stop the drive and do the steps in section Precautions before electrical work page 21 before you start the work 2 Remove the drive module from the cabinet 3 Remove the module cooling fan s See section Fans below 4 Blow dry clean compressed air not humid from bottom to top and simul...

Page 148: ...pter Safety instructions If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive if running and do the steps in section Precautions before electrical work page 21 before you start the work 2 Check the tightness of the cable connections Use the tightening torques given in chapter Technical data ...

Page 149: ...ABB Do not use other than ABB specified spare parts Replacing the cooling fan in the auxiliary control cubicle 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 page 21 before you start the work 2 Remove the shrouding from in front of th...

Page 150: ... death or damage to the equipment can occur 1 Stop the drive and do the steps in section Precautions before electrical work page 21 before you start the work 2 Remove the shrouding in front of the fan if any 3 Disconnect the fan wiring a 4 Remove the fastening screws a and finger guard b of the fan 5 Install the new fan in reverse order 4a 3 4 3a 4b ...

Page 151: ...he drive and do the steps in section Precautions before electrical work page 21 before you start the work 2 Lift the front and back gratings upwards and remove them 3 Loosen the mounting screws of the fan cover 4 Lift the cover off 5 Disconnect the fan supply wires 6 Loosen the mounting screws of the fan 7 Lift the fan off 8 Install the new fan in reverse order 2 3 4 2 3 3 5 6 6 6 6 ...

Page 152: ...nore 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 page 21 before you start the work 2 Open the cubicle door 3 Remove the screws holding the front cover plate Lift the cover plate somewhat to release it 4 Disconnect the fan wiring 5 Remove the unit below the fan 6 Remove the screws of the fan unit 7 Pull ou...

Page 153: ...Stop the drive if running and do the steps in section Precautions before electrical work page 21 before you start the work 2 Open the door 3 Remove the shroud in front of the fan 4 Remove the cover panel 5 Remove the bracket 6 Unplug the wiring of the fan assembly 7 Undo the screws of the fan assembly 8 Pull out the fan assembly 9 Unplug fan wire from the fan assembly 10 Undo the screws of the fan...

Page 154: ...154 Maintenance 4 5 6 7 8 6 10 10 ...

Page 155: ...tions If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive if running and do the steps in section Precautions before electrical work page 21 before you start the work 2 Open the door of the module cubicle 3 Remove the two M4 12 T20 screws which lock the fan holder 4 Pull the fan holder out of the module 5 Disconnect the fan cable 6 Remove the four M3 5 5 mm nuts...

Page 156: ...fan holder with the airflow direction arrow pointing towards the fan holder 9 Install and tighten the four nuts removed earlier 10 Connect the fan cable 11 Align and push the fan holder into the module 12 Install and tighten the two M4 12 T20 screws 9 8 10 11 12 ...

Page 157: ...em injury or death or damage to the equipment can occur 1 Stop the drive if running and do the steps in section Precautions before electrical work page 21 before you start the work 2 Open the door 3 Remove the screw in front of the fan unit 4 Unplug the fan power supply cable 5 Pull the fan unit out 6 Install a new fan in reverse order 3 5 ...

Page 158: ...injury or death or damage to the equipment can occur 1 Stop the drive if running and do the steps in section Precautions before electrical work page 21 before you start the work 2 Open the door 3 Remove the two screws in front of the fan unit 4 Unplug the fan power supply cable 5 Pull the fan unit out 6 Install a new fan in reverse order 3 5 ...

Page 159: ...nd do the steps in section Precautions before electrical work page 21 before you start the work 2 Remove the cooling fan of the supply module as described under Fans elsewhere in this chapter 3 Blow clean dry and oilfree compressed air through the module from bottom to top simultaneously using a vacuum cleaner at the air outlet to trap the dust Note Prevent the dust from entering adjoining equipme...

Page 160: ...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 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 if running and do the steps in section Precautions before electrical work page 21 before you start the ...

Page 161: ...verse order Mind you fingers Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back Note Be careful not to break the fastening screws tighten the fastening screws of the module to 22 N m 16 2 lbf ft and fastening bolts of the DC output busbars to 70 N m 51 6 lbf ft Plug the module signal wire set to the module signal connector Fasten the shr...

Page 162: ...162 Maintenance 5 6 3 4 7 ...

Page 163: ...Maintenance 163 6 8 7 11 10 9 ...

Page 164: ...ly followed by damage to the unit and an input cable fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements are available from ABB Do not use other than ABB specified spare parts Reforming the capacitors The capacitors must be reformed if the drive has been stored for a year or more See page 53 for information on finding out the manufacturing date For information o...

Page 165: ...of the order of the washers on the screws 5 Remove the screws nuts and washers from the old fuses and attach them to the new fuses Make sure to keep the washers in the original order 6 Insert the new fuses into their slots in the cubicle Pre tighten the nuts first by hand or by applying a torque of no more than 5 N m 3 7 lbf ft 7 Tighten the nuts to torque as follows Cooper Bussmann fuses 50 N m 3...

Page 166: ...ore you start the work 2 Open the door of the supply module cubicle 3 Remove the shrouding from in front of the fuses 4 Slacken the nuts of the headless screws of the fuses so that you can slide out the fuse blocks Make note of the order of the washers on the screws 5 Remove the screws nuts and washers from the old fuses and attach them to the new fuses Make sure to keep the washers in the origina...

Page 167: ...Maintenance 167 3 4b 4a 4b 8 ...

Page 168: ...ubicle 3 Remove the shrouding from in front of the fuses 4 Slacken the nuts of the headless screws of the fuses so that you can slide out the fuse blocks Make note of the order of the washers on the screws 5 Remove the screws nuts and washers from the old fuses and attach them to the new fuses Make sure to keep the washers in the original order 6 Insert the new fuses into their slots in the cubicl...

Page 169: ...clockwise until the lid opens 2 Replace the battery with a new CR2032 battery 3 Put the lid back and tighten it by turning it clockwise 4 Dispose of the old battery according to local disposal rules or applicable laws Cleaning See ACS AP x assistant control panels user s manual 3AUA0000085685 English ...

Page 170: ...emory unit when the control unit is powered WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in section Precautions before electrical work on page 21 before you start the work 2 Make sure that the control unit is not powered 3 Undo the fastening screw and pull the memory unit out 4 Install a memory u...

Page 171: ...ominal ratings Output ratings Light overload use Heavy duty use IN Imax PN SN ILd PLd IHd PHd A A kW kVA A kW A kW UN 400 V ACS880 37 0450A 3 450 590 250 312 432 200 337 160 ACS880 37 0620A 3 620 810 355 430 595 315 464 250 ACS880 37 0870A 3 870 1140 500 603 835 450 651 355 ACS880 37 1110A 3 1110 1450 630 769 1066 560 830 450 ACS880 37 1210A 3 1210 1580 710 838 1162 630 905 500 ACS880 37 1430A 3 1...

Page 172: ...37 2230A 7 2230 3350 2200 2665 2141 2000 1668 1600 ACS880 37 2770A 7 2770 4160 2700 3310 2659 2600 2072 2000 ACS880 37 3310A 7 3310 4970 3200 3956 3178 3000 2476 2400 UN Supply voltage range See also section Electrical power network specification page 180 IN Nominal output current available continuously with no over loading Imax Maximum output current Available for 10 seconds at start then as long...

Page 173: ...At altitudes from 1000 to 4000 m 3281 to 13123 ft above sea level the output currents must be derated by 1 for every 100 m 328 ft For a more accurate derating use the DriveSize PC tool Switching frequency derating Switching frequencies other than default can require output current derating Contact ABB for more information Output frequency derating Motor operation above 150 Hz can require type spec...

Page 174: ...10A 5 1 BLCL 15 5 1 0810A 5 E205 1010A 5 2 R8i 2 R8i 2 0590A 5 1 BLCL 24 5 2 0590A 5 E205 1110A 5 2 R8i 2 R8i 2 0590A 5 1 BLCL 24 5 2 0590A 5 E205 1530A 5 2 R8i 2 R8i 2 0810A 5 1 BLCL 25 5 2 0810A 5 E205 1980A 5 3 R8i 3 R8i 3 0810A 5 2 BLCL 24 5 3 0740A 5 E205 2270A 5 3 R8i 3 R8i 3 0810A 5 2 BLCL 24 5 3 0810A 5 E205 UN 690 V 0320A 7 1 R8i 1 R8i 1 0340A 7 1 BLCL 13 7 1 0340A 7 E205 0390A 7 1 R8i 1 ...

Page 175: ...Bussmann 170M6411 0570A 5 570 3 900 670000 690 Cooper Bussmann 170M6413 0780A 5 780 3 1250 1950000 690 Cooper Bussmann 170M6416 1010A 5 1010 3 1600 3900000 690 Cooper Bussmann 170M6419 1110A 5 1110 3 1600 3900000 690 Cooper Bussmann 170M6419 1530A 5 1530 3 2500 7800000 690 Cooper Bussmann 170M7063 1980A 5 1980 6 2000 3950000 690 Cooper Bussmann 170M7062 2270A 5 2270 6 2000 3950000 690 Cooper Bussm...

Page 176: ... 1600 3900000 3 690 Cooper Bussmann 170M6419 UN 500 V 1010A 5 8 1100 1300000 3 690 Cooper Bussmann 170M6415 1110A 5 8 1250 1950000 3 690 Cooper Bussmann 170M6416 1530A 5 8 1400 2450000 3 690 Cooper Bussmann 170M6417 1980A 5 12 1400 2450000 3 690 Cooper Bussmann 170M6417 2270A 5 12 1400 2450000 3 690 Cooper Bussmann 170M6417 UN 690 V 0660A 7 4 1 800 995000 4 1250 Cooper Bussmann 170M6546 4 2 800 10...

Page 177: ...az A070GRB10T13 G330010 10 A 700 V AC Dimensions and weights See chapter Dimensions page 191 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 3 in is required for fan replacement of IP54 cabinets 320 mm 12 3 in 400 mm 15 75 in IP22 42 IP54 ...

Page 178: ... 2860 1680 17 75 ACS880 37 0780A 5 2860 1680 25 75 ACS880 37 1010A 5 5720 3370 31 77 ACS880 37 1110A 5 5720 3370 32 77 ACS880 37 1530A 5 5720 3370 46 77 ACS880 37 1980A 5 8580 5050 59 78 ACS880 37 2270A 5 8580 5050 69 78 UN 690 V ACS880 37 0320A 7 2860 1680 16 75 ACS880 37 0390A 7 2860 1680 19 75 ACS880 37 0580A 7 2860 1680 26 75 ACS880 37 0660A 7 5720 3370 30 77 ACS880 37 0770A 7 5720 3370 34 77 ...

Page 179: ...00A 3 2 NSIN 1380 6 2282 14 4000 2350 2000 1500 3310 2060A 3 2 NSIN 1380 6 2282 14 4000 2350 2000 1500 3310 2530A 3 3 NSIN 1380 6 3387 21 6000 3530 3000 2250 4960 UN 500 V 0420A 5 1 NSIN 0485 6 447 2 5 700 410 400 350 770 0570A 5 1 NSIN 0900 6 783 6 2000 1180 1000 550 1210 0780A 5 1 NSIN 0900 6 783 6 2000 1180 1000 550 1210 1010A 5 1 NSIN 1380 6 1201 8 2000 1180 1000 750 1650 1110A 5 1 NSIN 1380 6...

Page 180: ... 50 kA 1 s Frame 2 R8i 2 R8i and above Rated peak withstand current Ipk 105 kA Rated short time withstand current Icw 50 kA 1 s for units without air circuit breaker Icw 65 kA 1 s for units with air circuit breaker Overvoltage category OVCIII Power factor cosphi1 1 cosphi total 0 99 Harmonic distortion Harmonics are below the limits defined in IEEE519 Rsc THD Voltage THD Current 20 3 2 5 100 0 8 2...

Page 181: ...ndard IP42 option B054 IP54 option B055 Enclosure types UL50 UL Type 1 standard UL Type 1 Filtered option B054 UL Type 12 option B055 For indoor use only Overvoltage category IEC 60664 1 III Protective class IEC EN 61800 5 1 I Ambient conditions Environmental limits for the drive system are given below The drive is to be used in a heated indoor controlled environment Operation installed for statio...

Page 182: ...l conditions Part 3 Classification of groups of environmental parameters and their severities Section 1 Storage IEC EN 60721 3 1 1997 Classification of environmental conditions Part 3 Classification of groups of environmental parameters and their severities Section 2 Transportation Shock IEC 60068 2 27 2008 EN 60068 2 27 2009 Environmental testing Part 2 27 Tests Test Ea and guidance Shock Not all...

Page 183: ... parts and materials should be dismantled and separated Generally all metals such as steel aluminum copper and its alloys and precious metals can be recycled as material Plastics rubber cardboard and other packaging material can be used in energy recovery Printed circuit boards and DC capacitors C1 1 to C1 x need selective treatment according to IEC 62635 guidelines To aid recycling plastic parts ...

Page 184: ...e The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 2004 covers requirements stated for drives See section Compliance with EN 61800 3 2004 below Compliance with the European Machinery Directive The drive is an electronic product which is covered by the European Low Voltage Directive Howev...

Page 185: ...Technical data 185 Declaration of Conformity ...

Page 186: ...186 Technical data ...

Page 187: ...tended for use in complex systems in the second environment Category C2 The drive complies with the standard with the following provisions 1 The drive is equipped with EMC filter option E202 2 The motor and control cables are selected as specified in the hardware manual 3 The drive is installed according to the instructions given in the hardware manual 4 Maximum motor cable length is 100 meters 32...

Page 188: ...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 181 The maximum ambient air temperature is 40 C 104 F at rated current The current is derated for 40 to 50 C 104 to 122 F The drive is suitable for use in a ...

Page 189: ...lia and New Zealand A C tick mark is attached to each drive in order to verify compliance with the relevant standard IEC 61800 3 2004 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods mandated by the Trans Tasman Electromagnetic Compatibility Scheme For fulfilling the requirements of the standard see section Compliance with EN 61800 3 2004 ...

Page 190: ...tomer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or informat...

Page 191: ...lar form for each frame size with options page 192 Dimension drawing examples of selected line ups page 196 Location and size of input terminals page 210 Location and size of output terminals for drives without common motor terminal cubicle page 214 Location and size of output terminals for drives with common motor terminal cubicle H359 page 218 ...

Page 192: ...to modify the design at any time without notice Consult ABB for exact up to date information The tables are followed by selected dimension drawing examples Dimension tables 1 R8i 1 R8i Auxiliary control cubicle ACU Supply and inverter module cubicle Common motor terminal cubicle Sine filter cubicle Joining cubicle Brake chopper 1 Brake resistor 1 Brake chopper 2 Brake resistor 2 Shipping split wid...

Page 193: ...3200 400 400 800 600 400 400 3000 3000 400 400 800 600 300 400 400 3300 3300 400 400 800 600 1000 400 400 4000 4000 400 400 800 600 200 400 800 400 800 2400 2400 4800 400 400 800 600 300 400 800 400 800 2500 2400 4900 400 400 800 600 1000 200 400 800 400 800 3400 2400 5800 400 400 800 600 400 400 400 3400 3400 400 400 800 600 300 400 400 400 3700 3700 400 400 800 600 1000 200 400 400 400 3400 1200...

Page 194: ...0 800 600 1000 200 400 800 400 800 3600 2400 6000 400 600 200 800 600 1000 200 400 800 400 800 3800 2400 6200 400 600 800 600 400 400 400 3600 3600 400 600 200 800 600 400 400 400 3800 3800 400 600 800 600 300 400 400 400 3900 3900 400 600 200 800 600 300 400 400 400 4100 4100 400 600 800 600 200 400 800 400 800 400 800 2600 3600 6200 400 600 200 800 600 200 400 800 400 800 400 800 2800 3600 6400 ...

Page 195: ... motor terminal cubicle Inverter module cubicle 2 Shipping split widths Line up width 400 600 800 800 800 200 800 600 3600 1400 5000 400 600 800 800 800 200 800 400 600 3600 2000 5600 400 600 200 800 800 800 200 800 600 3800 1400 5200 400 600 200 800 800 800 200 800 600 600 3800 2000 5800 400 mm with bottom exit 600 mm with top exit 6 R8i 6 R8i Auxiliary control cubicle ACU Incoming cubicle ICU Ad...

Page 196: ...196 Dimensions Dimension drawing examples Frame 1 R8i 1 R8i ...

Page 197: ...Dimensions 197 Frame 1 R8i 1 R8i top cable entry exit H351 H353 ...

Page 198: ...198 Dimensions Frame 1 R8i 1 R8i with brake choppers and resistors D150 D151 ...

Page 199: ...Dimensions 199 Frame 1 R8i 1 R8i with sine output filter E206 ...

Page 200: ...200 Dimensions Frame 2 R8i 2 R8i eg ACS880 37 1110A 3 IP22 ...

Page 201: ...Dimensions 201 Frame 2 R8i 2 R8i eg ACS880 37 1210A 3 IP54 ...

Page 202: ...202 Dimensions Frame 2 R8i 2 R8i with main breaker F255 and common motor terminal cubicle H359 1 2 ...

Page 203: ...Dimensions 203 Frame 2 R8i 2 R8i with main breaker F255 and common motor terminal cubicle H359 2 2 ...

Page 204: ...204 Dimensions Frame 2 R8i 2 R8i with main breaker F255 and top entry top exit H351 H353 1 2 ...

Page 205: ...Dimensions 205 Frame 2 R8i 2 R8i with main breaker F255 and top entry top exit H351 H353 2 2 ...

Page 206: ...206 Dimensions Frame 3 R8i 3 R8i 1 2 ...

Page 207: ...Dimensions 207 Frame 3 R8i 3 R8i 2 2 ...

Page 208: ...208 Dimensions Frame 3 R8i 3 R8i with common motor terminal cubicle H359 1 2 ...

Page 209: ...Dimensions 209 Frame 3 R8i 3 R8i with common motor terminal cubicle H359 2 2 ...

Page 210: ...210 Dimensions Location and size of input terminals Frame 1 R8i 1 R8i bottom cable entry Frame 1 R8i 1 R8i top cable entry ...

Page 211: ...Dimensions 211 Frame 2 R8i 2 R8i with main switch disconnector 400 mm bottom cable entry Frame 2 R8i 2 R8i with main switch disconnector 400 mm top cable entry ...

Page 212: ...212 Dimensions Frame 2 R8i 2 R8i with main switch disconnector 600 mm bottom cable entry Frame 2 R8i 2 R8i with main switch disconnector 600 mm top cable entry ...

Page 213: ...Dimensions 213 Units with main breaker 600 mm bottom cable entry Units with main breaker 600 mm top cable entry ...

Page 214: ...nsions Location and size of output terminals units without common motor terminal cubicle Frame 1 R8i 1 R8i without sine output filter See page 210 Inverter module cubicle with two R8i modules bottom cable exit ...

Page 215: ...Dimensions 215 Inverter module cubicle with two R8i modules top cable exit Inverter module cubicle with three R8i modules bottom cable exit ...

Page 216: ...216 Dimensions Inverter module cubicle with three R8i modules top cable exit Sine filter E206 cubicle 1000 mm bottom cable exit ...

Page 217: ...Dimensions 217 Sine filter E206 cubicle 1000 mm top cable exit ...

Page 218: ...ze of output terminals units with common motor terminal cubicle Note See the dimension tables starting on page 192 as to which common motor terminal cubicle width is used with which drive type Cubicle width 300 mm bottom cable exit ...

Page 219: ...Dimensions 219 Cubicle width 300 mm double busbar version bottom cable exit Cubicle width 300 mm top cable exit ...

Page 220: ...220 Dimensions Cubicle width 300 mm double busbar version top cable exit Cubicle width 400 mm bottom cable exit ...

Page 221: ...Dimensions 221 Cubicle width 400 mm top cable exit Cubicle width 600 mm bottom cable exit ...

Page 222: ...222 Dimensions Cubicle width 600 mm top cable exit ...

Page 223: ...r semiconductors of the inverter output stage A see diagram below thus preventing the inverter from generating the torque required to rotate the motor If the motor is running when Safe torque off is activated it coasts to a stop The Safe torque off function has a redundant architecture that is both channels must be used in the safety function implementation The safety data given in this manual is ...

Page 224: ...locked out to the open position The contacts of the switch or relay must open close within 200 ms of each other An FSO xx safety functions module can also be used For more information see the FSO xx module documentation IEC 61508 1 2010 Functional safety of electrical electronic programmable electronic safety related systems Part 1 General requirements IEC 61508 2 2010 Functional safety of electri...

Page 225: ...ft between BCU control unit and last inverter module in the chain Note The voltage at the INx terminals of each inverter control unit or frame R8i inverter module must be at least 17 V DC to be interpreted as 1 Grounding of protective shields Ground the shield in the cabling between the activation switch and the control unit at the control unit Ground the shield in the cabling between two control ...

Page 226: ... XSTO K IN1 SGND XSTO OUT IN2 SGND 24VDC CH1 GND CH1 STO IN X52 24VDC CH2 FE To next inverter module GND CH2 24VDC CH1 GND CH1 STO OUT X51 24VDC CH2 FE GND CH2 24VDC CH1 GND CH1 STO IN X52 24VDC CH2 FE GND CH2 24VDC CH1 GND CH1 STO OUT X51 24VDC CH2 FE GND CH2 Inverter module Inverter module Control unit ...

Page 227: ...ff function 227 Multiple inverter units internal power supply 24 V OUT1 SGND IN1 IN2 Inverter unit OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 Inverter unit Inverter unit K XSTO Control unit XSTO Control unit XSTO Control unit ...

Page 228: ...ff function Multiple inverter units external power supply OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 Inverter unit 24 V Inverter unit Control unit Inverter unit 24 V DC K XSTO Control unit XSTO Control unit XSTO ...

Page 229: ... out by a competent person with adequate expertise and knowledge of the safety function as well as functional safety as required by IEC 61508 1 clause 6 The test procedures and report must be documented and signed by this person Acceptance test reports Signed acceptance test reports must be stored in the logbook of the machine The report shall include documentation of start up activities and test ...

Page 230: ... the wiring diagram Close the disconnector and switch the power on Test the operation of the STO function when the motor is stopped Give a stop command to the inverter if running and wait until the motor shaft is at a standstill Ensure that the inverter operates as follows Open the STO circuit The inverter generates an indication if one is defined for stopped state in parameter 31 22 see the firmw...

Page 231: ...ays possible to eliminate all potential hazards The assembler of the machine must inform the final user about the residual risks Maintenance After the operation of the circuit is validated at start up the STO function shall be maintained by periodic proof testing In high demand mode of operation the maximum proof test interval is 20 years In low demand mode of operation the maximum proof test inte...

Page 232: ...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 The following 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 temperature at 2 0 of time 60 C board t...

Page 233: ...reliability The categories are B 1 2 3 and 4 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 MTTFd EN ISO 13849 1 Mean time to dangerous failure The total number of life units the number of dangerous undetected failures during a particular measurement interval under stated conditions PFD I...

Page 234: ...234 The Safe torque off function ...

Page 235: ...the related technical data Operating principle The brake chopper handles the energy generated by a decelerating motor The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected ...

Page 236: ... D151 400 V ACS880 37 0450A 3 NBRA 659 2 SAFUR180F460 ACS880 37 0620A 3 ACS880 37 0870A 3 2 NBRA 659 2 2 SAFUR180F460 ACS880 37 1110A 3 ACS880 37 1210A 3 ACS880 37 1430A 3 3 NBRA 659 3 2 SAFUR180F460 ACS880 37 1700A 3 500 V ACS880 37 0420A 5 NBRA 659 2 SAFUR200F500 ACS880 37 0570A 5 ACS880 37 0780A 5 2 NBRA 659 2 2 SAFUR200F500 ACS880 37 1010A 5 ACS880 37 1110A 5 ACS880 37 1530A 5 3 NBRA 659 3 2 S...

Page 237: ...08 162 1815 862 1065 500 618 690 V NBRA 669 2 SAFUR200F500 1 35 404 54 835 287 257 167 149 2 NBRA 669 2 2 SAFUR200F500 1 35 807 108 1670 575 514 333 298 3 NBRA 669 3 2 SAFUR200F500 1 35 1211 162 2505 862 771 500 447 UN Nominal voltage R Resistance of specified resistors per chopper This is also the minimum allowed resistance of the resistor assembly Pbrmax Maximum short term 1 min every 10 mins br...

Page 238: ...tor assembly in which two resistors are connected in parallel two in series The ER value of the four resistor assembly is four times that of a single resistor Custom resistors Resistors other than those available as option D151 can be used provided that the resistance is not lower than the value given in the ratings table page 237 WARNING Never use a brake resistor with a resistance below the valu...

Page 239: ...s the braking is considered continuous The allowed continuous braking power is 10 of maximum braking power Pbrmax Example 2 The duration of a braking cycle T is three minutes The braking time tbr is 40 seconds Result The maximum allowed braking power for the cycle is 37 of the rated value given for the reference cycle 1 n Pbr tbr Pbrmax 60 s 2 Pbr Pbrmax n Number of braking pulses during a 10 minu...

Page 240: ... length The maximum length of the resistor cable s is 50 m 164 ft EMC compliance of the complete installation Note ABB has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling The EMC compliance of the complete installation must be considered by the customer Placing custom brake resistors Install the resistors outside the drive in a place where they are able...

Page 241: ... be implemented Use cable rated as follows twisted pair shielding recommended rated operating voltage between a conductor and ground U0 750 V insulation test voltage 2 5 kV Keep the cable as short as possible Protecting the resistor cable against short circuits The input fuses of the drive will also protect the resistor cable provided that the resistor cable is of the same type as the input cable ...

Page 242: ...ell as any separate PE conductor if present Connect the thermal switch of the brake resistor to the enable input X1 on the brake chopper control board Use cable specified under Thermal protection of the resistors page 241 If there are multiple thermal switches connect them in series WARNING The ENABLE input terminal block of the brake chopper is at intermediate circuit potential when the supply un...

Page 243: ...igating to www abb com searchchannels Product training For information on ABB product training navigate to www abb com drives and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www abb com drives and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product docu...

Page 244: ...www abb com drives www abb com drivespartners 3AXD50000020437 Rev A EN 2015 02 06 Contact us ...

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