ABB ACS880-07CLC, Hardware Manual

Page 1: ...ABB industrial drives Hardware manual ACS880 07CLC drives ...

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Page 3: ...e manual ACS880 07CLC drives Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation 9 Start up 2018 ABB Oy All Rights Reserved 3AXD50000131457 Rev A EN EFFECTIVE 2018 03 09 ...

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Page 5: ...n code 22 Use of component designations 22 Quick installation commissioning and operation flowchart 23 Terms and abbreviations 23 Related manuals 3 Operation principle and hardware description 25 Contents of this chapter 25 Operation principle 26 Charging 27 Overview diagrams 27 Overview diagram of the drive 32 6 pulse 12 pulse and 24 pulse connections 34 Cabinet line up and layout examples 37 Ove...

Page 6: ...54 Moving the unpacked drive cabinet 54 Lifting the cabinet with a crane 55 Moving the cabinet on rollers 55 Moving the cabinet on its back 56 Final placement of the cabinet 57 Fastening the cabinet to the floor and wall or roof 57 General rules 58 Fastening the cabinet marine units 59 Joining cabinet sections together 63 Miscellaneous 63 Cable duct in the floor below the cabinet 63 Arc welding 5 ...

Page 7: ...rive and the power cables against thermal overload 77 Protecting the motor against thermal overload 77 Protecting the drive against ground faults 77 Residual current device compatibility 77 Implementing the emergency stop function 78 Implementing the Safe torque off function 78 Implementing the Power loss ride through 78 Implementing a bypass connection 78 Supplying power for the auxiliary circuit...

Page 8: ...us adapter and pulse encoder interface modules 102 Wiring of optional modules 7 Control units of the drive 103 Contents of this chapter 103 General 104 ZCU 14 layout and connections 105 ZCU 14 default I O connection diagram 107 BCU x2 control unit layout and connections 109 Default I O diagram of the inverter control unit A41 110 External power supply for the control unit XPOW 110 DI6 as a PTC sen...

Page 9: ...battery 139 Cleaning the control panel 140 Control units 140 BCU control unit types 140 Replacing the memory unit 140 Replacing the BCU control unit battery 12 Internal cooling circuit 143 Contents of this chapter 143 Applicability 143 Internal cooling system 144 Connection to a cooling unit 144 Connection to an ACS880 1007LC cooling unit 145 Connection to a custom cooling unit 145 General require...

Page 10: ...ata for main contactor breaker control 164 General 164 K3 contact data 165 K640 contact data 165 Electrical power network specification 166 Motor connection data 166 Efficiency 166 Protection classes 167 Ambient conditions 168 Materials 168 Applicable standards 169 CE marking 169 Compliance with the European Low Voltage Directive 169 Compliance with the European EMC Directive 169 Compliance with t...

Page 11: ... off function 189 Contents of this chapter 189 Description 190 Compliance with the European Machinery Directive 190 Wiring 190 Activation switch 190 Cable types and lengths 191 Grounding of protective shields 192 Frame n R8i inverter unit internal power supply 193 Single channel connection of activation switch 194 Multiple inverter units internal power supply 195 Multiple inverter units external p...

Page 12: ...d routing the cables of a custom resistor 207 Minimizing electromagnetic interference 207 Maximum cable length 207 Placing custom brake resistors 208 Protecting the brake system against thermal overload 208 Thermal protection of the resistors 208 Protecting the resistor cable against short circuits 208 Mechanical installation of custom brake resistors 209 Electrical installation of custom brake re...

Page 13: ...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 WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity which can cause injury or death or dam...

Page 14: ...awings Secure the drive cabinet to the floor to prevent it from toppling over The cabinet has a high center of gravity When you pull out heavy components or power modules there is a risk of overturning Secure the cabinet also to the wall when necessary Be careful when handling a tall module The module overturns easily because it is heavy and has a high center of gravity Whenever possible secure th...

Page 15: ... manual Depending on the wiring and parametrization of the drive the stop key on the control panel may not stop the drive Only authorized persons are allowed to repair a malfunctioning drive Work on the liquid cooling system These instructions are intended for all personnel that do installation commissioning and maintenance work on the liquid cooling system WARNING Obey these instructions If you i...

Page 16: ...d when the drive is powered With the doors open a risk of a potentially fatal electric shock arc flash or high energy arc blast exists 2 Clearly identify the work location 3 Disconnect all possible voltage sources Lock and tag Open the main disconnecting device of the drive Open the charging switch if present WARNING The charging switch is not necessarily located within or nearby the drive cubicle...

Page 17: ...he supply module cubicle s Locate the measurement points XACx in front of each array of input terminals Each input terminal is connected to a specific pin of the measurement point For example a drive with six supply modules has two supply module cubicles and three measurement points XAC1 XAC2 XAC3 The picture below shows a cubicle with two modules Measurement point Input terminals AC fuses Measure...

Page 18: ...he drive DC bus is at a dangerous voltage If brake chopper and resistor are in use they are at a dangerous voltage Option D150 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 circuits The function is not effective against deliberate sabotage or misuse Optical co...

Page 19: ...inimum size of the protective earthing conductor must comply with the local safety regulations for high protective earthing conductor current equipment See standard IEC EN 61800 5 1 4 3 5 5 2 Additional instructions for permanent magnet motor drives Safety in installation start up maintenance These are additional warnings concerning permanent magnet motor drives The other safety instructions in th...

Page 20: ...ge that can damage or destroy the capacitors in the intermediate circuit of the drive Safety in operation WARNING Make sure that the motor cannot be run into overspeed e g driven by the load Motor overspeed causes overvoltage that can damage or destroy the capacitors in the intermediate circuit of the drive 20 Safety instructions ...

Page 21: ...tions technical data and dimension drawings which concern only certain frame sizes are marked with the symbol of the frame size The frame size indicates the number of power modules that form the supply and inverter units respectively For example the marking 2 D8D 2 R8i refers to a drive that has a supply unit consisting of two frame D8D supply modules and an inverter unit consisting of two frame R...

Page 22: ...1 Ambient conditions page 167 Check the installation site Mechanical installation page 49 Unpack and check the drive only intact units may be started up Make sure that all necessary optional modules and equipment are present and correct Install the drive mechanically Routing the cables page 75 Route the cables Electrical installation page 83 Connect the power cables Connect the control cables Inst...

Page 23: ...e inverter module supply module brake chopper module etc Power module Radio frequency interference RFI Safe torque off IEC EN 61800 5 2 STO Supply module s under control of one control board and related components Supply unit Related manuals Code Name Drive hardware manuals and guides 3AXD50000131457 ACS880 07CLC drives hardware manual 3AUA0000085685 ACX AP x assistant control panels user s manual...

Page 24: ...ACS880 07CLC manuals See www abb com drives documents for all manuals on the Internet 24 Introduction to the manual ...

Page 25: ...trolled it cannot control the DC link voltage or limit the charging current of the DC link capacitors at the power up Notes The installer must provide an external main disconnecting device which meets the local safety regulations The installer must provide an external main contactor or breaker as the drive does not have an internal main contactor or breaker The installer must either provide an ext...

Page 26: ...ircuit powers up the DC capacitors of the drive smoothly Discharged capacitors cannot be directly connected to full supply voltage The charging current must be limited until the capacitors are charged and ready for normal use An internal charging circuit is available by specifying option F272 Drives with F272 have a charging switch on the supply unit cubicle door as well as terminals for the conne...

Page 27: ...rged at power up See section Charging page 26 4 DC bus 5 Inverter DC fuses 6 Inverter modules Converts direct current and voltage to alternating current and voltage Depending on drive type there is only one module or several modules connected in parallel 7 Motor 8 Brake chopper DC fuses 9 Brake chopper Conducts surplus energy from the intermediate DC circuit of the drive to the brake resistor when...

Page 28: ...nnecting device Breaker contactor Overcurrent and short circuit protection of input cabling B Supply module cubicle 5 AC fuses for protecting supply unit against short circuit ABB or third party 6 Internal charging kit ABB 7 Diode supply module ABB 8 DC link ACS880 304LC A019_1xD8D 6p internal charg overview diagr pdf Medium voltage low voltage switchboard 1 External installation outside drive cab...

Page 29: ...t and short circuit protection of input cabling B Supply module cubicle 6 AC fuses for protecting supply unit against short circuit ABB or third party 7 Internal charging kit ABB 8 Diode supply modules ABB 9 DC link ACS880 304LC A019_2xD8D 6p internal charg overview diagr pdf Medium voltage low voltage switchboard 1 External installation outside drive cabinet A Supply transformer 2 Charging switch...

Page 30: ...nt and short circuit protection of input cabling B Supply module cubicle 5 AC fuses for protecting supply unit against short circuit ABB or third party 6 Internal charging kit ABB 7 Diode supply modules ABB 8 DC link ACS880 304LC A019_2xD8D 12p internal charg overview diagr pdf Medium voltage low voltage switchboard 1 External installation outside drive cabinet A Supply transformer 2 Charging swit...

Page 31: ...ormer pre magnetizing circuit and drive charging circuit 4 Supply transformer 5 Overcurrent and short circuit protection of input cabling B Supply module cubicle 6 AC fuses for protecting supply unit against short circuit ABB or third party 7 Diode supply modules ABB 8 DC link ACS880 304LC A019_2xD8D 6p ext charg overview diagr pdf Medium voltage low voltage switchboard 1 External installation out...

Page 32: ...cting supply unit against short circuit ABB or third party 7 Diode supply modules ABB 8 DC link ACS880 304LC A019_2xD8D 12p ext charg overview diagr pdf Medium voltage low voltage switchboard 1 External installation outside drive cabinet A Switchgear including 2 Disconnecting device Breaker contactor Combined transformer pre magnetizing circuit and drive charging circuit 3 Supply transformer 4 Ove...

Page 33: ...t cabling 4 AC fuses for protecting supply unit against short circuit 5 Diode supply modules 1 3 4 1 3 5 12 pulse connection 2 2 4 5 ACS880 304LC A019 ACS880 307LC A019_6p 12p_conn diagr pdf 12 pulse connection 18 Operation principle and hardware description 1 Supply transformer 2 Switching equipment and fuses 3 Fuses for protecting input cabling 4 AC fuses for protecting supply unit against short...

Page 34: ...Cabinet line up and layout examples Frame 2 D8D 2 R8i A B C 1 8 4 3 5 6 7 7 9 9 8 10 11 12 13 14 15 16 34 Operation principle and hardware description ...

Page 35: ...age 143 2 ZCU 14 supply control unit See chapter Control units of the drive page 103 3 Frame D8D supply modules 4 AC fuses 5 Input terminals Each supply module has its own input terminals and must be cabled individually and identically from the supply switchgear The input cables must be at least 5 meters 16 4 ft in length 6 Mounting plates with terminal blocks for customer connections and space fo...

Page 36: ...oling cir cuit page 143 14 Behind mounting plate Fan Forces air inside the cubicle through the heat exchanger See chapter Internal cooling circuit page 143 15 Behind mounting plate and inverter module fans Output terminals Each inverter module must be individually connected to the motor using separate cables unless the drive is equipped with option H359 common motor terminal cubicle or H366 common...

Page 37: ...sion modules 1 2 3 Feedback interface modules 1 2 3 Fieldbus communication modules 4 RDCO xx DDCS communication option module standard equipment As standard a fiber optic link connects the supply and inverter control units 2 3 4 Additional modules can be installed on an optional FEA 03 extension adapter connected to an RDCO module on slot 4 Memory unit 5 Connection for FSO xx safety functions modu...

Page 38: ...cy stop push button with emergency stop options only 2 Emergency stop active light and reset with emergency stop options only 3 Charging switch with charging circuit option only At start up the charging switch is closed After the DC voltage rises to operating level the supply control unit opens the charging circuit and the main supply voltage can be connected to the drive 4 The layout depends on t...

Page 39: ...e ACX AP x 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 can be used to connect a PC to the drive When a PC is connected to the control panel the control panel keypad is disabled Operation principle and hardware description 39 ...

Page 40: ...on of persons against access to hazardous parts with finger Marine construction option C121 The option includes the following accessories and features reinforced mechanics grab railings door flush bolt which allows the door to open 90 degrees and prevents it from slamming close self extinctive materials flat bars at base of the cabinet for fastening fastening braces at the top of the cabinet Addit...

Page 41: ...omer controls the heating elements in the motor windings on and off with the external supply The power and voltage of the motor heater depend on the motor See also sections Supplying power for the auxiliary circuits page 78 circuit diagrams delivered with drive for the actual wiring Halogen free wiring and materials option G330 The option provides halogen free cable ducts control wires and wire sl...

Page 42: ...re part of the wiring between power modules Plug type connector identifications are marked on labels near the connectors The label holders are attached around conductor bundles Main circuit con ductors are marked with white tape or printing Short obvious connections are not marked G340 class A3 9 7 7 Equipment designations and pin identifiers are marked with snap on markers or equivalent on conduc...

Page 43: ... width of the cubicle and the size of the terminals within depend on the power rating of the drive Common output terminal option H366 As standard each inverter module must be individually cabled to the motor This option adds bridging that connects the outputs of multiple in practice two or three inverter modules mounted in the same cubicle The bridging balances the motor current between the module...

Page 44: ...ped with fuses a manual motor starter switch with an adjustable current limit a contactor controlled by the drive and terminal block X601 for customer connections The number of connections must be specified when ordering The maximum number of connections available depends on the current requirement The lower current ratings allow up to four fan connections eg option 4M602 while the highest current...

Page 45: ...its from left express the basic drive type The optional selections are given thereafter separated by plus signs eg E202 Codes preceded by a minus sign eg J400 indicate the absence of the specified feature The main selections are described below Not all selections are available for all types For more information refer to the ordering instructions available separately on request Description Code Bas...

Page 46: ...ion Descriptions of options page 40 C164 Door hinges on left C176 Plinth height 200 mm See section Descriptions of options page 40 C179 Marine product certification issued by DNV GL C205 Marine product certification issued by the American Bureau of Shipping ABS C206 Marine product certification issued by Lloyd s Register LR C207 Marine product certification issued by Bureau Veritas C209 Cooling un...

Page 47: ...00 Fieldbus adapters diverse communication options Panel bus control of several units from one control panel K450 FDNA 01 DeviceNet adapter module K451 FPBA 01 PROFIBUS DP adapter module K454 FCAN 01 CANopen adapter module K457 FSCA 01 RS 485 Modbus RTU adapter module K458 FCNA 01 ControlNet adapter module K462 FECA 01 EtherCat adapter module K469 FEPL 02 EtherPOWERLINK adapter module K470 FENA 11...

Page 48: ...est bench control program N5300 ESP Electrical Submersible Pump control program N5600 Control program for synchronous reluctance motors SynRM N7502 IEC 61131 3 application programmability N8010 Specialties Special color P913 Safety functions Emergency stop category 0 with safety relays by opening the main breaker contactor Q951 Earth fault monitoring for IT ungrounded systems Q954 Emergency stop b...

Page 49: ...ressure relief if present 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 meters Level the installation site if necessary as the cabinet is not equipped with adjustable feet Necessary tool...

Page 50: ...ontrol unit s at the factory appropriate drive and optional module manuals delivery documents Check that there are no signs of damage Before attempting installation and operation check the information on the type designation labels of the drive to verify that the delivery is of the correct type 50 Mechanical installation ...

Page 51: ...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 Mechanical installation 51 ...

Page 52: ...Lifting the crate with a crane max 20 b a Lifting point a Optimal position for the lifting sling as close to the traverse board as possible b 52 Mechanical installation ...

Page 53: ...ackage Remove the transport package as follows 1 Undo the screws that attach the wooden parts of the transport crate to each other 2 Remove the wooden parts 3 Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws 4 Remove the plastic wrapping Mechanical installation 53 ...

Page 54: ...t attach the wooden parts of the transport crate together 2 Remove the wooden parts 3 Remove the clamps with which the drive cabinet 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...

Page 55: ...inet on the rollers and move it carefully until close to its final location Remove the rollers by lifting the unit with a crane forklift pallet truck or jack Moving the cabinet on its back Support the cabinet from below alongside the cubicle seams Cabinet back panel Support Mechanical installation 55 ...

Page 56: ...cement 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 56 Mechanical installation ...

Page 57: ...to allow the doors to open sufficiently The doors must open 120 to allow supply or inverter module replacement a b 120 w 250 mm 9 85 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 between the cabinet bottom and floor Note 2 If the cabinet is delivered with lifting bars remove them Lifting eyes need...

Page 58: ...allation clamp a the rear edges of the flat bars c to the floor See the figure below 3 Attach corner brackets d to the lifting eye holes Fasten the corner brackets to the rear wall and or roof with suitable hardware such as U brackets e Fastening to wall Fastening to floor with a clamp M16 3 e d a b c 2 3 Fastening the cabinet at the top 2 Clamping the cabinet to the floor at the back d Corner bra...

Page 59: ...cubicle The screws required for the joining are enclosed in a plastic bag inside the cabinet The threaded bushings are already mounted on the cabinet posts 1 Fasten the first section to the floor 2 Remove any plates covering the rear post of the joining cubicle 3 Slide Axilock connectors onto the coolant pipes at the joint 4 Align the two sections The coolant pipe ends must be aligned as shown 5 1...

Page 60: ...or screws to the torque indicated on the connector label 6 Fasten the front and rear posts of the joining cubicle to the posts of the other section with 14 screws 7 per post Tighten the screws to 5 N m 3 7 lbf ft 7 Fasten the second section to the floor 1 3 5 4 4 4 60 Mechanical installation ...

Page 61: ...e M10 bolts and nuts included Tighten to 35 40 N m 25 30 lbf ft b a c a 35 40 N m 25 30 lbf ft a Plain washer b Spring washer c Bolt and nut 9 Remove the shroud covering the DC busbars in the joining cubicle Mechanical installation 61 ...

Page 62: ... sprayed zinc coating d Nut WARNING Make sure you install the washers in the correct order as shown For example placing an unpassivated zinc coated spring washer directly against the joint piece will cause corrosion WARNING Do not use any joining parts other than those delivered with the unit The parts are carefully selected to match the material of the busbars Other parts or materials can form a ...

Page 63: ...C compliance 500 19 68 50 1 97 500 19 68 50 1 97 Arc welding ABB does not recommend attaching the cabinet by arc welding However if arc welding is the only option connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0 5 meters 1 6 of the welding point Note The thickness of the zinc plating of the cabinet frame is 100 to 200 micrometers 4 to 8 mil WARNING ...

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Page 65: ...ns given by ABB are not followed the drive may experience problems that the warranty does not cover Selecting the supply transformer The drive does not have input chokes For this reason the following requirements for the supply transformer apply Transformer impedance must suit the supply rectifier of the drive transformer reactance Xk must be at least 4 and nominal apparent power of the transforme...

Page 66: ...nous motors AC induction servomotors or ABB synchronous reluctance motors SynRM motors with the drive Select the motor size and drive type from the rating tables on basis of the AC line voltage and motor load Use the DriveSize PC tool if you need to tune the selection more in detail Make sure that the motor withstands the maximum peak voltage in the motor terminals See section Requirements table p...

Page 67: ...y voltage Motor type ABB du dt and common mode filters insulated N end motor bearings Motor insula tion system PN 350 kW or frame size IEC 400 100 kW PN 350 kW or IEC 315 frame size IEC 400 PN 100 kW and frame size IEC 315 PN 469 hp or frame size NEMA 580 134 hp PN 469 hp or NEMA 500 frame size NEMA 580 PN 134 hp and frame size NEMA 500 N CMF N Standard UN 500 V Random wound M2_ M3_ and M4_ N du d...

Page 68: ...CMF du dt N or CMF du dt Reinforced ÛLL 1600 V 500 V UN 600 V or N CMF N or CMF Reinforced ÛLL 1800 V N du dt CMF du dt N du dt Reinforced ÛLL 1800 V 600 V UN 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 micro second rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if addit...

Page 69: ...h 480 V Additional requirements for ABB high output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 2001 This table shows the requirements for protecting the motor insulation and bearings in drive systems for ABB random wound motor series for example M3AA M3AP and M3BP Requirement for Nominal AC supply voltage ABB...

Page 70: ...ced ÛLL 2000 V 0 3 microsecond rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed in the applied drive operation range Additional data for calculating the rise time and the peak line to line voltage If you need to calculate the actual ...

Page 71: ... permissible touch voltage appearing under fault conditions so that the fault point voltage will not rise excessively when a ground fault occurs 600 V AC cable is accepted for up to 500 V AC 750 V AC cable is accepted for up to 600 V AC For 690 V AC rated equipment the rated voltage between the conductors of the cable should be at least 1 kV With US installations consider the additional US require...

Page 72: ...or can either be selected from the table below or calculated according to 543 1 of IEC 60364 5 54 This table shows the minimum cross sectional area related to the phase conductor size according to IEC 61800 5 1 when the phase conductor and the protective conductor are made of the same metal If this is not so the cross sectional area of the protective earthing conductor shall be determined in a man...

Page 73: ...10 mm2 Cu or 16 mm2 Al you need two PE conductors typically for example the shield and a separ ate conductor cable This is due to the safety regulations related to the leakage current See IEC EN 61800 5 1 or the drive safety instructions for more information PE Symmetrical shielded cable with three phase conductors and a shield and a separate PE conduct or cable Not allowed power cable types Use a...

Page 74: ...g the control cables Shielding All control cables must be shielded Use a double shielded twisted pair cable for analog signals This type of cable is recommended for the pulse encoder signals also Employ one individually shielded pair for each signal Do not use common return for different analog signals A double shielded cable figure a below is the best alternative for low voltage digital signals b...

Page 75: ...e installed on separate trays Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive The cable trays must have good electrical bo...

Page 76: ...hort circuit situations install fuses or a suitable circuit breaker at the supply side of the cabling The drive is equipped with internal AC fuses as standard In case of a short circuit inside the drive the AC fuses protect the drive restrict drive damage and prevent damage to adjoining equipment Protecting the motor and motor cable in short circuits The drive protects the motor cable and motor in...

Page 77: ...rameter refer to the firmware manual An optional ground fault monitoring device Q954 is available for IT ungrounded systems The option includes a ground fault indicator on the drive cabinet door Residual current device compatibility The drive is suitable to be used with residual current devices of Type B Note The drive contains capacitors connected between the main circuit and the frame These capa...

Page 78: ...n the motor and the power line Make sure with interlocking that the contactors cannot be closed simultaneously The installation must be clearly marked as defined in IEC EN 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY Bypass connection is available as a factory installed option for certain cabinet built drive types Consult ABB for more information WARNING Never connect th...

Page 79: ...ally be equipped with a blocking reactor or harmonic filter Using 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 switch is needed to isolate the motor during any maintenance work on the drive Protecting the contacts of relay outputs Inductive loads relays contactors motors cause voltage...

Page 80: ... s of the drive 2 If there is basic insulation between the sensor and the live parts of the motor you can connect the sensor to the analog digital input s of the drive if all other circuits connected to the digital and analog inputs typically extra low voltage circuits are protected against contact and insulated with basic insulation from other low voltage circuits The insulation must be rated for...

Page 81: ...ed insulation between the motor live parts and the drive control unit Temperature sensor insulation requirement Temperature sensor type Extension module Pt100 Pt1000 KTY PTC Insulation Isolation Type Reinforced insulation x x Galvanic isolation between sensor connector and other connectors in cluding drive control unit connector FIO 11 Reinforced insulation x x Galvanic isolation between sensor co...

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Page 83: ...is manual Ignoring the safety instructions can cause injury or death Checking the insulation of the drive WARNING Do not make any voltage withstand 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 c...

Page 84: ...un the control cables into the cabinet as described in section Grounding the outer shields of the control cables at the cabinet entry below 3 Route the control cables as described in section Routing the control cables inside the cabinet page 86 4 Connect the control cables as described in section Connecting control cabling page 86 Grounding the outer shields of the control cables at the cabinet en...

Page 85: ...e of the shield is non conductive Cut the shield at the midpoint of the bare part Be careful not to cut the conductors the grounding wire if present Turn the shield inside out to expose its conductive surface Cover the turned shield and the stripped cable with copper foil to keep the shieldin continuous Note for top entry of cables When each cable has its own rubber grommet sufficien and EMC prote...

Page 86: ...t the conductors to the appropriate terminals see page 127 of the contr terminal block X504 option L504 Connect the inner twisted pair shields and all separate grounding wires to the gr clamps below the control unit The drawing below represents a drive with additional I O terminal block option Without the block the grounding is made the same way Notes Do not ground the outer shield of the cable he...

Page 87: ...ith 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 At the other end of the cable leave the shields unconnected or ground them indirectly via a high frequency capacitor with a few nanofarads eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they ...

Page 88: ...drive is equipped with a common motor terminal cubicle option H359 follow the instructions in section Connecting the motor cables units with common motor terminal cubicle page 92 Motor 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 U2 V2 W2 PE U2 V2 W2 M 3 U1 W1 V1 PE Inverter...

Page 89: ...cts to the output busbars at one module only use the module in the middle Note The H366 option only interconnects the outputs of inverter modules within the same cubicle not modules installed in different cubicles Therefore when the drive has multiple inverter cubicles ie two cubicles of two modules each make sure that the motor cabling is identical for both cubicles Procedure Refer to the drawing...

Page 90: ...cable ties 14 Seal the gap between the cable and mineral wool sheet if used with sealing compound eg CSD F ABB brand name DXXT 11 code 35080082 15 Connect the twisted shields of the cables to the PE busbar of the cabinet 16 Connect the phase conductors of the cables to the appropriate terminals Tighten the screws to the torque given under Tightening torques page 171 17 Refit the inner shroud 18 Wi...

Page 91: ...PE PE 10 13 12 22 Electrical installation 91 ...

Page 92: ...he equipment can occur 1 Do the steps in section Electrical safety precautions page 16 before you start the work 2 Open the door of the cubicle and remove the shrouding 3 Lead the cables into the cubicle Make the 360 earthing arrangement at the cable entry as shown 118 Electrical installation 3 Lead the cables into the cubicle Make the 360 earthing arrangement at the cable entry as shown 4 Cut the...

Page 93: ...ding 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 resistor assembly See section Electrical installation ...

Page 94: ...link 6 Medium voltage low voltage switchboard 1 Supply modules 7 Supply transformer 2 Charging circuit option F272 8 Charging switchgear including 3 Disconnecting device AC fuses 9 Supply switchgear including 4 Disconnecting device Breaker contactor 360 degrees grounding 10 Overcurrent and short circuit protection of input cabling 5 Note Use symmetrical supply cabling to ensure equal current shari...

Page 95: ...ecting device AC fuses 8 Interlocked dedicated supply unit switchgear in cluding 4 360 degrees grounding 9 Disconnecting device Breaker contactor Overcurrent and short circuit protection of input cabling Note Use symmetrical supply cabling to ensure equal current sharing between parallel diode bridges Required minimum length of the cables is 5 meters For cable and component selection information s...

Page 96: ...r AC fuses 8 Combined transformer pre magnetizing circuit and drive charging circuit 3 360 degrees grounding 9 Supply transformer 4 Overcurrent and short circuit protection of input cabling 5 Note Use symmetrical supply cabling to ensure equal current sharing between parallel diode bridges Required minimum length of the cables is 5 meters For cable and component selection information see chapter G...

Page 97: ... between parallel diode bridges Required minimum length of the cables is 5 meters For cable and component selection information see chapter Guidelines for planning the electrical installation Layout of the input cable connection terminals and cable entries The location and dimensions of the busbars are visible in the dimensional drawings delivered with the drive Alternatively see the example dimen...

Page 98: ...Obey the grease manufacturer s instructions Aluminum aluminum contact can cause oxidation in the contact surfaces PE PE 6 If fire insulation is used make an opening in the mineral wool sheet according to the diameter of the cable 7 Remove rubber grommets from the cable entries for the cables to be connected Cut adequate holes into the rubber grommets Slide the grommets onto the cables Slide the ca...

Page 99: ...80082 10 Connect the twisted shields of the cables to the PE busbar of the cabinet 11 Connect the phase conductors of the input cable to the L1 L2 and L3 terminals With 12 pulse connection the terminals are 1L1 1L2 and 1L3 for one 6 pulse supply line 2L1 2L2 and 2L3 for the other Tighten the screws to the torque given under Tightening torques page 171 12 Reinstall the shrouding removed earlier 13 ...

Page 100: ...holder if present 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 activ...

Page 101: ...odule move termination switch S2 into the TERMINATED position Make sure that bus termination is off on all other drives 4 On the control panel switch on the panel bus functionality Options Select drive Panel bus The drive to be controlled can now be selected from the list under Options Select drive If a PC is connected to the control panel the drives on the panel bus are automatically displayed in...

Page 102: ...ly into its position on the control unit 6 Fasten the mounting screw Note The screw tightens the connections and grounds the module It is essential for fulfilling the EMC requirements and for proper operation of the module Wiring of optional modules See the appropriate optional module manual for specific installation and wiring instructions 102 Electrical installation ...

Page 103: ...CU 14 unit consists of a ZCON control board contained in a plastic housing The inverter unit of the drive is controlled by a dedicated BCU x2 control unit component designation A41 The BCU x2 consists of a BCON control board and a BIOC I O connector board and power supply board built in a metal housing In this manual the name BCU x2 represents the control unit types BCU 02 and BCU 12 These have a ...

Page 104: ...nections The layout and connections of the ZCU 14 are shown below SLOT 1 SLOT 2 SLOT 3 X12 SAFETY OPTION X208 FAN2 X210 FAN1 X209 AIR IN TEMP X13 CONTROL PANEL X205 MEMORY UNIT CLOSE X R O 2 X R O 3 X P O W J1J2 X A I X A O X D 2 D X S T O X D I X D I O J6 X D 2 4 X R O 1 J3 Description XPOW External power input XAI Analog inputs XAO Analog outputs XD2D Drive to drive link XRO1 Relay output RO1 XR...

Page 105: ...I O bus J3 XD2D Termination ON on units at end of link ON OFF Distributed I O bus for cooling fan monitoring Shield 4 BGND 3 A 2 B 1 XSTO connector XSTO For the supply unit to start both IN1 and IN2 must be connected to OUT Note De energizing this input will stop the supply unit but will not constitute a true Safe torque off STO function IN2 4 IN1 3 SGND 2 OUT 1 Digital inputs XDI Fault reset 0ĺ1 ...

Page 106: ...p The cabinet builder must ar control unit External 24 V block XPOW DICOM and DIOGND separate applicable to them all For example some units have the DC link c parameter settings and IO connections are valid for the version wit 1 Use of the signal in the control program When parameter 120 30 control program reserves this I O terminal for external charging circ 110 24 RO1 source and 110 30 RO3 sourc...

Page 107: ...t AI2 I current U voltage AI2 Termination switch for drive to drive link D2D D2D TERM Ground selection Determines whether DICOM is separated from DIOGND ie the common reference for the digital inputs floats See the ground isolation diagram DICOM DIOGND 7 segment display Multicharacter indications are displayed as repeated se quences of characters U is indicated briefly before o Control program run...

Page 108: ...mitter VxR receiver V1T V1R V2T V2R Fiber optic connection to modules 3 7 BCU 12 22 only VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to modules 8 12 BCU 22 only VxT transmitter VxR receiver V8T V8R V12T V12R Data logger memory card for inverter module communication SD CARD Real time clock battery voltage is higher than 2 8 V If the LED is off when the control unit is powere...

Page 109: ... 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 voltage output AI 10 V DC RL 1 10...

Page 110: ...ed 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 A PTC sensor can be connected to this input for motor temperature measurement as follows The sensor can alte...

Page 111: ... 12 Standard AI 2 Select the excitation mode in parameter group 13 Standard AO of inverter unit control program WARNING As the inputs pictured above are not insulated according to IEC EN 60664 the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfill the requirement the I O board terminals must b...

Page 112: ...e terminal block has jumpers to close the circuit Remove the jumpers before connecting an external Safe torque off circuit to the drive For information on the implementation of a Safe torque off function see chapter The Safe torque off function page 189 Note The XSTO input only acts as a true Safe torque off input on the inverter control unit A41 De energizing the IN1 and or IN2 terminals on the s...

Page 113: ...4 4 Connector pitch 5 mm wire size 2 5 mm2 Total load capacity of these outputs is 4 8 W 200 mA 24 V m the power taken by DIO1 and DIO2 Digital inputs DI1 DI6 XDI 1 XDI 6 Connector pitch 5 mm wire size 2 5 mm2 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Input type NPN PNP DI1 DI5 NPN DI6 Hardware filtering 0 04 ms digital filtering up to 8 ms DI6 XDI 6 can alternatively be used as an input for a P...

Page 114: ...ctor pitch 5 mm wire size 2 5 mm2 RS 485 connection X485 Physical layer RS 485 Connector pitch 5 mm wire size 2 5 mm2 Safe torque off connection XSTO Input voltage range 3 30 V DC Logic levels 0 5 V 1 17 V For the unit to start both connec tions must be 1 Current consumption 66 mA continuous per STO channel per R8i inverter module EMC immunity according to IEC 61326 3 1 Connector pitch 5 mm wire s...

Page 115: ...OGND 8 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 OUT 1 SGND 2 IN1 3 IN2 4 XSTO OUT IN1 5 SGND 6 IN2 7 SGND 8 Common mode voltage between each AI input and AGND is 30 V Ground Ground selector DICOM DIOGND settings DICOM DIOGND ON All digital inputs share a common ground DICOM connected to DIOGND This is the default setting DICOM DIOGND OFF Ground of di...

Page 116: ... ZCU 12 ZCU 14 All digital inputs share a common ground DICOM connected to DIOGND This is the default setting ZCU 12 ZCU 14 Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO signal ground DIOGND Isolation voltage 50 V All digital inputs share a common ground DICOM connected to DIOGND This is the default setting ZCU 14 152 Supply control unit Notes Wire sizes and tightening torqu...

Page 117: ... will be connected to an IT ungrounded or a corner grounded TN network The EMC filter of the drive has been disconnected Contact your local ABB representative for instructions There is an adequately sized protective earth ground conductor between the drive and the switchboard and the conductor has been connected to appropriate terminal and the terminal have been tightened Pull the conductor to che...

Page 118: ... The brake resistor cable has been routed away from other cables The control cables have been connected to the appropriate terminals and the terminals have been tightened Pull on the conductors to check The supply voltage matches the nominal input voltage of the drive Check the type designation label The voltage setting of the auxiliary voltage transformers if any is correct See the electrical ins...

Page 119: ...ot 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 options Q950 Q951 Q952 Q957 Q963 Q964 Q978 Q979 additional start up instructions are given in their s...

Page 120: ... diagrams of the delivery and IRDH275B Ground Fault Monitor Operating Manual by Bender code TGH1386en Powering up the auxiliary circuit of the drive Make sure that it is safe to connect voltage Ensure that nobody is working on the drive or circuits that have been wired from outside into the drive cabinet the cover of the motor terminal box is in place Close the circuit breakers and or fuse disconn...

Page 121: ...ction and the air flows upwards Check that the motor starts stops and follows the speed reference in the correct direction when controlled with the control panel Check that the motor starts stops and follows the speed reference in the correct direction when controlled through the customer specific I O or fieldbus Drives in which the Safe torque off control circuit is in use Test and validate the o...

Page 122: ...122 ...

Page 123: ...ounting platform Drive in fault state Red FAULT Battery voltage of the real time clock is OK higher than 2 8 V When the LED is not lit Green BATT OK Control unit battery voltage is below 2 8 V the battery is missing or the control unit is not powered Internal voltage OK Green PWR OK The control program indicates that the equipment is faulty See the appropriate firmware manual Red FAULT Writing to ...

Page 124: ...124 ...

Page 125: ...ion consult your local ABB Service representative www abb com searchchannels Years from start up Maintenance task object 12 11 10 9 8 7 6 5 4 3 2 1 0 Coolant R R Coolant draining and replacement P P P P P P Checking coolant quality P P P P P P P P P P P P P Checking coolant antifreeze concentration Cooling fans R Supply module cubicle fan 230 V R R Supply module cubicle fan 115 V R Inverter module...

Page 126: ...lacement R Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions ABB recommends annual drive inspections to ensure the highest reliability and optimum performance Note Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for cert...

Page 127: ...id cooled multidrive cabinets and modules 3AXD50000048633 English If you ignore them injury or death or damage to the equipment can occur WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges Refer to the drawing below 1 Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work 2 O...

Page 128: ...rp edges 1 Repeat the steps described in section Electrical safety precautions page 16 2 Remove any shrouding in front of the cooling fan 3 Disconnect the fan wiring 4 Undo the two retaining screws a 5 Pull the fan outwards to separate it from the heat exchanger housing 6 Install new fan in reverse order Align the guide pins b at the rear of the fan cowling with the slots c in the module bottom gu...

Page 129: ...wer part of the cubicle 4 Slacken the nuts of the fuses until you can slide the fuse blocks out Make note of the order of the washers 5 Move the screws nuts and washers from the old fuse blocks to the new fuse blocks Make sure to keep the washers in the original order 6 Slide the new fuse blocks into place Tighten the nuts to 50 N m 37 lbf ft Bussmann fuses or 46 N m 34 lbf ft Ferraz Shawmut fuses...

Page 130: ... the door of the module cubicle 3 Remove the shrouding in front of the fuses if any 4 Check the condition of the fuses In case of a blown fuse replace all fuses with similar fuses slacken the nuts of the fuses and pull the fuses out Do not unscrew the nuts completely not to drop them inside the module s below Tighten the nuts first by hand or applying maximum 5 N m force Tightening torques for M12...

Page 131: ...Remove the shroud above the supply modules Note that two of the screws are fastened from below 6 Close the inlet and outlet valves of the supply cubicle 7 Lead the drain hoses into a suitable container 8 Open the drain valves located behind the inlet and outlet valves Make sure the ends of the hoses are not immersed at any point of the draining so that air can displace the coolant in the system Wa...

Page 132: ...5 4 11 7 6 8 132 Maintenance ...

Page 133: ...14 15 16 12 13 17 Maintenance 133 ...

Page 134: ...urized and drained WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges Removing the module 1 Repeat the steps described in section Electrical safety precautions page 16 2 Remove the shrouding in front of the module 3 Undo the locking screws of the swing out frame if present and open it 4 Unplug the wiring from the module and mo...

Page 135: ... on both sides of the cubicle into a suitable container Open the drain valves c on both sides of the cubicle This will drain all modules in the cubicle a b c 7 After the module has drained disconnect the piping from the module 8 Remove the module retaining screws at the top and the bottom of the module Maintenance 135 ...

Page 136: ...ion is available for inverter units consisting of parallel connected inverter modules The function makes it possible to continue operation with limited current even if one or more module is out of service for example because of maintenance work In principle reduced run is possible with only one module but the physical requirements of operating the motor still apply for example the modules remainin...

Page 137: ...is powered from the faulty module connect the power supply wiring to another module using the extension wire set included 8 If the Safe torque off STO function is in use install the jumper wire set included in the STO wiring in place of the missing module This is not needed if the module was the last on the STO wire chain X51 X52 X51 X52 X51 X52 R8i R8i R8i BCU Jumper wire set Removed module 8 9 O...

Page 138: ...bf ft DC busbar assembly to lower insulators 2 M10 18 N m 13 3 lbf ft Fuses to DC busbars 50 N m 37 lbf ft Bussmann 46 N m 34 lbf ft Mersen Ferraz Shawmut Module to cabinet frame 4 M8 22 N m 16 lbf ft DC busbar assembly to module DC input 2 M12 70 N m 52 lbf ft 2 Remove the plugs from the coolant pipes and reconnect the pipes to the module See the Replacing an inverter module page 134 3 Restore th...

Page 139: ...attery 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 172 Maintenance Control panel Replacing the battery 1 Turn the lid on the back of the panel counter clockwise until the lid open 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 o...

Page 140: ...ew control unit WARNING Do not remove or insert the memory unit when the control unit is powered 1 Stop the drive and do the steps in section Electrical safety precautions page 16 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 unit in reverse order Replacing the BCU control unit battery Replace t...

Page 141: ...5 Set the real time clock Maintenance 141 ...

Page 142: ...142 ...

Page 143: ...applicable to cabinet built ACS880 liquid cooled multidrive Except where otherwise indicated the information is also applicable to drives built out of ACS880 liquid cooled multidrive modules Internal cooling system Note This section describes cabinet built liquid cooled ACS880 drives The information in this section can be used as guidelines for building a drive system out of ACS880 liquid cooled m...

Page 144: ...alve b Outlet valve c Outlet side drain valve d The coolant used with ACS880 liquid cooled drive systems is Antifrogen L by Clariant International Ltd www clariant com mixed with water See Coolant specification page 147 Connection to a cooling unit Connection to an ACS880 1007LC cooling unit Refer to ACS880 1007LC cooling unit user s manual 3AXD50000129607 English 144 Internal cooling circuit ...

Page 145: ...When necessary regulate the pressure to appropriate level by draining excess coolant out of the system WARNING Bleeding of the cooling circuit is very important and has to be done with great care Air bubbles in the cooling circuit may reduce or completely block coolant flow and lead to overheating Let the air out of the cooling system while filling in coolant and eg after any power module replacem...

Page 146: ...w with a valve 15 Re check the pressure and add coolant if necessary 16 Repeat steps 13 to 15 a few times until all air is let out of the cooling circuit Listen for a humming sound and or feel the piping for vibration to find out if there is still air left in the circuit Draining the internal cooling circuit The modules in each cubicle can be drained through the drain valves without draining the w...

Page 147: ...he higher the concentration of heat transfer fluid the higher the viscosity of the coolant This results in a higher pressure loss in the system An operating pressure of more than 150 kPa is required for sufficient flow The nominal current ratings of drive system modules apply to an Antifrogen L water solution of 25 75 volume For derating with other ratios contact your local ABB representative Inco...

Page 148: ...t temperature 4 C is required Example At an air temperature of 45 C and relative humidity of 65 the coolant temperature may not be below 36 8 C T 1 00 0 90 40 C 104 F k 0 80 0 70 0 60 45 C 113 F 50 C 122 F a b c ACS880LC_coolant temp derating curve pdf Condensation is not allowed The minimum coolant temperature to avoid condensation at an atmospheric pressure of 1 bar is shown below as a function ...

Page 149: ... use with antifreeze rubber gasketing NBR nitrile rubber WARNING If connecting external piping to the internal cooling circuit use only materials that are specified above Copper brass or bronze must not be used under any circumstances Even minor dissolution of copper can cause copper precipitation on aluminum and subsequent galvanic corrosion The liquid cooling system must not contain any zinc eg ...

Page 150: ...150 ...

Page 151: ...A kVA hp kW A A A UN 690 V 6 pulse connection 300 250 292 350 355 374 466 400 355 585 390 357 0390A 7 300 250 322 450 355 413 514 450 400 645 430 394 0430A 7 350 315 359 450 400 461 574 500 450 720 480 439 0480A 7 400 355 396 500 450 509 633 550 500 795 530 485 0530A 7 450 400 449 600 560 576 717 600 560 900 600 549 0600A 7 500 450 501 700 630 643 801 700 630 1005 670 613 0670A 7 600 500 561 700 7...

Page 152: ...80 1250 1200 1258 1566 1250 1200 1965 1310 1199 1310A 7 A004 1000 1000 1100 1500 1200 1411 1757 1500 1400 2205 1470 1345 1470A 7 A004 1250 1200 1242 1750 1400 1594 1984 1750 1600 2490 1660 1519 1660A 7 A004 1500 1400 1451 2000 1800 1862 2319 2000 1800 2910 1940 1775 1940A 7 A004 1750 1400 1631 TBA 2000 2093 2605 TBA 2000 3270 2180 1995 2180A 7 A004 2000 1800 1848 TBA 2300 2371 2952 TBA 2300 3705 2...

Page 153: ... factor k UN 690 V 0820A 7 A019 820 1000 1400 980 1143 932 960 895 800 745 1540A 7 A019 1540 1880 2632 1840 2149 1752 1805 1682 1504 1401 2290A 7 A019 2290 2805 3927 2737 3206 2614 2693 2509 2244 2091 3040A 7 A019 3040 3720 5208 3633 4252 3466 3571 3328 2976 2773 3AXD00000601909 XLS Nominal ratings UN Nominal input voltage For U1 see Electrical power network specification on page 139 For U2 see DC...

Page 154: ...Output frequency derating Motor operation above 150 Hz can require type specific output current derating Contact ABB for more information 154 Technical data ...

Page 155: ...CS880 104LC 0600A 7 2 ACS880 304LC 0820A 7 A019 2 2 D8D 2 R8i 1170A 7 ACS880 104LC 0670A 7 2 ACS880 304LC 0820A 7 A019 2 2 D8D 2 R8i 1310A 7 ACS880 104LC 0750A 7 2 ACS880 304LC 0820A 7 A019 2 2 D8D 2 R8i 1470A 7 ACS880 104LC 0850A 7 2 ACS880 304LC 0820A 7 A019 2 2 D8D 2 R8i 1660A 7 ACS880 104LC 0670A 7 3 ACS880 304LC 0820A 7 A019 3 3 D8D 3 R8i 1940A 7 ACS880 104LC 0750A 7 3 ACS880 304LC 0820A 7 A0...

Page 156: ...A004 ACS880 104LC 0750A 7 4 ACS880 304LC 0820A 7 A019 4 4 D8D 4 R8i 2880A 7 A004 ACS880 104LC 0850A 7 4 ACS880 304LC 0820A 7 A019 4 4 D8D 4 R8i 3260A 7 A004 ACS880 104LC 0750A 7 5 ACS880 304LC 0820A 7 A019 6 6 D8D 5 R8i 3580A 7 A004 ACS880 104LC 0850A 7 5 ACS880 304LC 0820A 7 A019 6 6 D8D 5 R8i 4050A 7 A004 ACS880 104LC 0850A 7 6 ACS880 304LC 0820A 7 A019 6 6 D8D 6 R8i 4840A 7 A004 ACS880 104LC 08...

Page 157: ...8 3580A 4840A 7 A004 24 5650A 6460A 7 A004 UN 690 V 24 pulse connection 170M6467 Bussmann 690 2450000 1400 12 2470A 3260A 7 A006 24 4840A 6460A 7 A006 DC fuses The drive has DC fuses at the input of each inverter module Notes Fuses with higher current rating than the recommended ones must not be used Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the f...

Page 158: ...nn 1000 1100 2 0600A 7 A004 170M6500 Bussmann 1100 1250 2 0670A 7 A004 170M6501 Bussmann 1100 1400 2 0750A 7 A004 0850A 7 A004 170M6548 Bussmann 1100 1000 4 1030A 7 A004 170M6549 Bussmann 1000 1100 4 1170A 7 A004 170M6500 Bussmann 1100 1250 4 1310A 7 A004 170M6501 Bussmann 1100 1400 4 1470A 7 A004 1660A 7 A004 170M6500 Bussmann 1100 1250 6 1940A 7 A004 170M6501 Bussmann 1100 1400 6 2180A 7 A004 6 ...

Page 159: ...ise Noise Heat dissipation Coolant flow ACS880 07CLC dB A kW US gal min l min UN 690 V 6 pulse connection 66 8 6 7 4 28 0390A 7 66 9 3 7 4 28 0430A 7 66 10 7 4 28 0480A 7 66 11 7 4 28 0530A 7 66 13 7 4 28 0600A 7 66 14 7 4 28 0670A 7 66 16 7 4 28 0750A 7 66 18 7 4 28 0850A 7 68 22 14 3 54 1030A 7 68 25 14 3 54 1170A 7 68 27 14 3 54 1310A 7 68 31 14 3 54 1470A 7 68 35 14 3 54 1660A 7 69 41 19 72 19...

Page 160: ... 69 41 22 82 1940A 7 A004 69 46 22 82 2180A 7 A004 69 53 22 82 2470A 7 A004 70 61 26 98 2880A 7 A004 70 69 26 98 3260A 7 A004 72 76 33 126 3580A 7 A004 72 87 33 126 4050A 7 A004 72 104 38 142 4840A 7 A004 73 121 45 170 5650A 7 A004 73 138 49 186 6460A 7 A004 UN 690 V 24 pulse connection 69 53 22 82 2470A 7 A006 70 69 26 98 3260A 7 A006 72 103 41 154 4840A 7 A006 73 121 45 170 5650A 7 A006 73 138 4...

Page 161: ... Cu 2 3 240 72 Cu 4 3 95 0600A 7 3 3 150 70 3 3 240 72 Cu 3 3 150 41 Cu 4 3 95 0670A 7 3 3 185 95 3 3 240 72 Cu 3 3 185 57 Cu 5 3 95 0750A 7 4 3 150 70 4 3 185 57 Cu 3 3 240 72 Cu 5 3 95 0850A 7 2 2 3 185 95 2 3 3 150 41 Cu 2 2 3 185 57 Cu 2 3 3 95 1030A 7 2 2 3 240 120 2 3 3 185 57 Cu 2 2 3 240 72 Cu 2 4 3 95 1170A 7 2 2 3 240 120 2 3 3 240 72 Cu 2 3 3 150 41 Cu 2 4 3 95 1310A 7 2 3 3 185 95 2 3 ...

Page 162: ...3 185 57 Cu 4 2 3 240 72 Cu 4 3 3 120 2180A 7 A004 4 2 3 240 120 4 3 3 185 57 Cu 4 2 3 240 72 Cu 4 3 3 120 2470A 7 A004 4 3 3 150 70 4 3 3 240 72 Cu 4 3 3 185 57 Cu 4 3 3 150 2880A 7 A004 4 3 3 185 95 4 3 3 240 72 Cu 4 4 3 150 3260A 7 A004 6 2 3 240 120 6 3 3 185 57 Cu 6 2 3 240 72 Cu 6 4 3 95 3580A 7 A004 6 3 3 150 70 6 3 3 240 72 Cu 6 3 3 150 41 Cu 6 4 3 95 4050A 7 A004 6 3 3 185 95 6 4 3 185 57...

Page 163: ... Cu 4 3 120 0850A 7 2 2 3 240 120 2 3 3 185 57 Cu 2 4 3 95 1030A 7 2 2 3 240 120 2 3 3 185 57 Cu 2 4 3 95 1170A 7 2 3 3 150 70 2 4 3 150 41 Cu 2 4 3 95 1310A 7 2 3 3 185 95 2 4 3 185 57 Cu 2 4 3 120 1470A 7 2 3 3 240 120 2 4 3 240 72 Cu 2 4 3 120 1660A 7 3 3 3 150 70 3 3 3 240 72 Cu 3 4 3 95 1940A 7 3 3 3 185 95 3 4 3 185 57 Cu 3 4 3 120 2180A 7 3 3 3 240 120 3 4 3 240 72 Cu 3 4 3 150 2470A 7 4 3 ...

Page 164: ...60A 7 A006 Terminal and lead through data for the power cables The locations and sizes of lead throughs are shown by the dimension drawings delivered with the drive and the dimension drawing examples in this manual Terminal data for the supply and inverter control units See chapter Control units of the drive page 103 Contact data for main contactor breaker control General The main contactor or bre...

Page 165: ...C NO 24 V 2 A Electrical power network specification 690 V units 525 690 V AC 3 phase 10 525 600 V AC 10 in corner grounded TN systems This is indicated in the type designation label as typical input voltage levels 3 525 600 690 V AC Voltage U1 TN grounded and IT ungrounded systems Network type 50 60 Hz variation 5 of nominal frequency Frequency Max 3 of nominal phase to phase input voltage Imbala...

Page 166: ... repres entative Operation above 150 Hz may require type specific derating For more information contact your local ABB representative See the rating tables Current 3 kHz typical The switching frequency can vary per frame and voltage For exact values please contact your local ABB representative Switching frequency 500 m 1640 ft Maximum recommended motor cable length Note With motor cables longer th...

Page 167: ...roups of environmental paramet ers and their severities Stationary use of weather protected locations Contamination Chemical gases Class 2C2 Solid particles Class 2S2 Chemical gases Class 1C2 Solid particles Class 1S3 packing must support this otherwise 1S2 Chemical gases Class 3C2 Solid particles Class 3S2 No conductive dust al lowed IEC EN 60721 3 2 1997 IEC EN 60721 3 1 1997 IEC EN 60721 3 3 20...

Page 168: ...fed and humidity controlled storage cannot be arranged Cabinets are fastened to the pallet with screws and braced from the top end to the package walls to prevent swaying inside the package Package elements are at tached to each other with screws The main parts of the drive can be recycled to preserve natural resources and en ergy Product parts and materials should be dismantled and separated Disp...

Page 169: ...efines 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 Compliance with EN 61800 3 2004 page 169 Compliance with the European Machinery Directive The drive includes the Safe torque off function and can be equipped with other safety functions for machinery which as sa...

Page 170: ... cables and control cables are selected as specified in the appropriate drive manual s 2 The drive is installed according to the instructions given in the appropriate drive manual s 3 Maximum motor cable length is 100 meters 328 ft WARNING A drive of category C3 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if t...

Page 171: ...network Tightening torques Unless a tightening torque is specified in the text the following torques can be used Electrical connections Note Torque Size Strength class 4 6 8 8 0 5 N m 4 4 lbf in M3 Strength class 4 6 8 8 1 N m 9 lbf in M4 Strength class 8 8 4 N m 35 lbf in M5 Strength class 8 8 9 N m 6 6 lbf ft M6 Strength class 8 8 22 N m 16 lbf ft M8 Strength class 8 8 42 N m 31 lbf ft M10 Stren...

Page 172: ...e information and data via a network interface It is Customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls application of authentication measures encryption of data in...

Page 173: ...y 25 4 The data given is preliminary ABB reserves the right to modify the design at any time without notice Consult ABB for up to date drive specific information Weight Width ACS880 07CLC lbs kg mm UN 690 V 6 pulse connection 1235 560 730 0390A 7 1235 560 730 0430A 7 1235 560 730 0480A 7 1235 560 730 0530A 7 1235 560 730 0600A 7 1235 560 730 0670A 7 1235 560 730 0750A 7 1235 560 730 0850A 7 1565 7...

Page 174: ...1565 710 930 1310A 7 A004 1565 710 930 1470A 7 A004 1565 710 930 1660A 7 A004 2270 1030 1230 1940A 7 A004 2270 1030 1230 2180A 7 A004 2270 1030 1230 2470A 7 A004 2845 1290 1530 2880A 7 A004 2845 1290 1530 3260A 7 A004 4165 1890 2230 3580A 7 A004 4165 1890 2230 4050A 7 A004 4540 2060 2430 4840A 7 A004 5115 2320 2730 5650A 7 A004 5490 2490 2930 6460A 7 A004 UN 690 V 24 pulse connection 2270 1030 123...

Page 175: ... Dimension drawing examples Cabinet height and depth Marine construction option C121 IP42 side view Non marine IP42 side view Dimensions 175 ...

Page 176: ...ACS880 07CLC 0390A 7 C121 marine construction 176 Dimensions ...

Page 177: ...ACS880 07CLC 1310A 7 Dimensions 177 ...

Page 178: ...ACS880 07CLC 2180A 7 C121 marine construction 178 Dimensions ...

Page 179: ...ACS880 07CLC 3260A 7 C121 marine construction Dimensions 179 ...

Page 180: ...als Drives with up to four supply modules have one supply module cubicle while drives with more modules have two For the quantity of supply modules in each drive type see Frame sizes and power module types page 155 1 D8D 180 Dimensions ...

Page 181: ... 2 D8D Dimensions 181 ...

Page 182: ... 3 D8D 182 Dimensions ...

Page 183: ... 4 D8D Dimensions 183 ...

Page 184: ...Location and size of output terminals Units without common motor terminal cubicle Inverter module cubicle with one R8i module bottom cable exit 184 Dimensions ...

Page 185: ...Inverter module cubicle with two R8i modules bottom cable exit Dimensions 185 ...

Page 186: ...Inverter module cubicle with three R8i modules bottom cable exit 186 Dimensions ...

Page 187: ...Brake chopper cubicle D150 Dimensions 187 ...

Page 188: ...188 ...

Page 189: ... A see diagram below thus preventing the drive 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 calculated for redundant use and does not apply ...

Page 190: ...of unexpected start up as specified by EN 1037 1995 A1 2008 and Uncontrolled stop stop category 0 as specified in EN IEC 60204 1 Compliance with the European Machinery Directive See Compliance with the European Machinery Directive page 169 Wiring The following diagrams present examples of Safe torque off wiring for a frame n R8i inverter unit page 192 multiple inverter units page 194 multiple inve...

Page 191: ...rame 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 units at one control unit only Do not ground the shield in the cabling between BCU and R8i module or between R8i modules The Safe torque o...

Page 192: ...circuit 234 The Safe torque off function Frame n R8i inverter unit internal power supply 24 V OUT1 SGND IN1 IN2 XSTO K IN1 SGND XSTO OUT IN2 SGND 24VDC CH1 GND CH1 STO IN X52 24VDC CH2 FE 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 Control unit Inverter module To next inverter module...

Page 193: ...ts IN1 IN2 must be connected to the activation switch Otherwise no SIL PL classification is given Pay special attention to avoiding any potential failure modes for the wiring For example use shielded cable For measures for fault exclusion of wiring see eg EN ISO 13849 2 2012 table D 4 The Safe torque off function 193 ...

Page 194: ...orque off function 235 Multiple inverter units internal power supply 24 V OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 K XSTO XSTO XSTO Inverter unit Control unit Inverter unit Control unit Inverter unit Control unit 194 The Safe torque off function ...

Page 195: ...orque off function Multiple inverter units external power supply OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 24 V 24 V DC K XSTO XSTO XSTO Inverter unit Control unit Inverter unit Control unit Inverter unit Control unit The Safe torque off function 195 ...

Page 196: ... the safety function Competence The acceptance test of the safety function must be carried 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 logb...

Page 197: ... testing the operation when the motor is stopped Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Test the operation of the failure detection of the drive The motor can be stopped or running Open the 1st channel of the STO circuit wire coming to IN1 If the motor was running it should coast to a stop The drive generates a FA81 Safe Torque Off 1 ...

Page 198: ...e inverter system can produce an alignment torque which maximally rotates the motor shaft by 180 p with permanent magnet motors or 180 2p 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 drive is stopped by using the Safe torque off function the drive will cut off the motor supply vol...

Page 199: ...eters are restored follow the test given in section Acceptance test procedure page 196 Use only ABB approved spare parts Record all maintenance and proof test activities in the machine logbook Competence The maintenance and proof test activities of the safety function must be carried out by a competent person with adequate expertise and knowledge of the safety function as well as functional safety...

Page 200: ...perature profile is used in safety value calculations 670 on off cycles per year with ΔT 71 66 C 1340 on off cycles per year with ΔT 61 66 C 30 on off cycles per year with ΔT 10 0 C 32 C board temperature at 2 0 of time 60 C board temperature at 1 5 of time 85 C board temperature at 2 3 of time The STO is a type B safety component as defined in IEC 61508 2 Relevant failure modes The STO trips spur...

Page 201: ...d safety function when a demand occurs IEC 61508 PFDavg Average frequency of dangerous failures per hour that is average frequency of a dangerous failure of a safety related system to perform the specified safety function over a given period of time IEC 61508 PFH Performance level Levels a e correspond to SIL EN ISO 13849 1 PL Systematic capability IEC 61508 SC Safe failure fraction IEC 61508 SFF ...

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Page 203: ...ated by a decelerating motor During the deceleration motor generates energy back to the drive and the voltage in the drive intermediate DC link starts to rise 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 b...

Page 204: ...9C 0400 7 722 808 534 596 238 214 828 2 72 807 2 NBRW 669C 0800 7 1083 1212 801 894 357 321 1242 2 72 1211 3 NBRW 669C 1200 7 1444 1616 1068 1192 476 428 1656 2 72 1615 4 NBRW 669C 1600 7 1805 2020 1335 1490 595 535 2070 2 72 2019 5 NBRW 669C 2000 7 2166 2424 1602 1788 714 642 2484 2 72 2422 6 NBRW 669C 2400 7 Ratings of standard chopper resistor combinations ER Duty cycle 10 60 s Duty cycle 1 5 m...

Page 205: ...um peak current Imax Maximum braking power for the specified duty cycle Pbr Rms current for the specified duty cycle Irms SAFUR resistor data The following SAFUR resistors are available separately IPxx PRcont ER R UN Type kW kJ ohm V IP00 9 0 3600 4 0 500 SAFUR125F500 IP00 10 5 4200 3 4 575 SAFUR210F575 IP00 13 5 5400 2 7 500 SAFUR200F500 IP00 15 0 6000 2 4 460 SAFUR180F460 Nominal voltage UN Resi...

Page 206: ...er than those available as option D151 can be used provided that the resistance is not lower than the value given in the ratings table WARNING Never use a brake resistor with a resistance below the value specified for the particular drive brake chopper resistor combination The drive and the chopper would not able to handle the overcurrent caused by the low resistance the resistance of the custom r...

Page 207: ...ing electromagnetic interference Follow these rules in order to minimize electromagnetic interference caused by the rapid current changes in the resistor cables Shield the braking power line completely either by using shielded cable or a metallic enclosure Unshielded single core cable can only be used if it is routed inside a cabinet that efficiently suppresses the radiated emissions Install the c...

Page 208: ...urrent of the drive By default a brake chopper fault is wired to stop the supply unit of the drive Thermal protection of the resistors The standard resistors available as option D151 are equipped with a thermal switch The switches of the resistors are wired in series and connected to the Enable input of the brake chopper The relay output of the chopper is wired to the supply control unit so that a...

Page 209: ... to the equipment c Do the steps in section Precautions before electrical work on page 19 be the work Connect the resistor cable at the resistor end only If a shielded three con is used cut off the third conductor Ground the twisted shield of the cable any separate PE conductor if present At the chopper end of the cable connect the R and R conductors of th cable together Measure the insulation res...

Page 210: ... if the isolation level and protection conditions for the thermal switches are not sufficient The thermal switches must always be properly insulated over 2 5 kV and shrouded against contact Brake system start up Check the settings of the following inverter control program parameters ACS880 primary control program 30 30 Overvoltage control Overvoltage control disabled For settings of other control ...

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Page 213: ...by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dri...

Page 214: ...Contact us www abb com drives 3AXD50000131457 Rev A EN EFFECTIVE 2018 03 09 3AXD50000131457A ...