ABB ACS880-01 Hardware Manual

ABB industrial drives

Hardware manual

ACS880-01 drives (0.55 to 250 kW, 0.75 to 350 hp)

List of related manuals

Drive hardware manuals and guides Code (English)

ACS880-01 hardware manual 3AUA0000078093 ACS880-01 quick installation guide for frames R1 to R3 3AUA0000085966 ACS880-01 quick installation guide for frames R4 and R5 3AUA0000099663 ACS880-01 quick installation guide for frames R6 to R9 3AUA0000099689 ACS880-01 +P940/+P944 drives for cabinet installation supplement 3AUA0000145446 ACS880-01 assembly drawings for cable entry boxes of IP21 frames

R5 to R9 ACS880-01 +H358 gland plate installation guide 3AD50000034735 ACS-AP-x assistant control panels user’s manual 3AUA0000085685 Vibration dampers for ACS880-01 drives (frames R4 and R5, option

+C131) installation guide Vibration dampers for ACS880-01 drives (frames R6 to R9, option

+C131) installation guide ACS880-01/04 +C132 marine type-approved drives supplement 3AXD50000010521 ACS880-01 +N7502 drives for SYnRM motors (0.8 to 200 kW)

supplement Flange mounting kit installation supplement 3AXD50000019100 Flange mounting kit quick installation guide for ACS880-01 frames R1

to R3 Flange mounting kit quick installation guide for ACS880-01 frames R4

to R5 Flange mounting kit quick installation guide for ACS880-01 and

ACS580-01 frames R6 to R9 Common mode filter kit for ACS880-01 drives (frame R6, option

+E208) installation guide Common mode filter kit for ACS880-01 drives (frame R7, option

+E208) installation guide Common mode filter kit for ACS880-01 drives (frame R8, option

+E208) installation guide Common mode filter kit for ACS880-01 drives (frame R9, option

+E208) installation guide ACS880-01 drives and ACS880-04 drive modules common DC

systems application guide

Drive firmware manuals and guides

ACS880 primary control program firmware manual 3AUA0000085967 Quick start-up guide for ACS880 drives with primary control program 3AUA0000098062

Option manuals and guides

Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.

You can find manuals and other product documents in PDF format on the Internet. See section Document library

on the Internet on the inside of the back cover. For manuals not available in the Do cument library, contact your local

ABB representative. The code below opens an online listing of the manuals applicable to this product.

3AUA0000119627

3AXD50000010497

3AXD50000013389

3AXD50000029482

3AXD50000026158

3AXD50000026159

3AXD50000019099

3AXD50000015178

3AXD50000015179

3AXD50000015180

3AXD50000015201

3AUA0000127818

ACS880-01 manuals

Hardware manual

ACS880-01 drives (0.55 to 250 kW, 0.75 to 350 hp)

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation

8. Start-up

3AUA0000078093 Rev M

EFFECTIVE: 20

17-08-08

List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. Safety instructions

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Introduction to the manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Quick installation, start-up and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3. Operation principle and hardware description

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Layout (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Layout (IP55, option +B056) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Layout (UL Type 12, option +B056) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Layout (IP20 – UL Open Type, options +P940 and +P944) . . . . . . . . . . . . . . . . . . . . . . . 31

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

External control connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Control panel mounting platform cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Control panel door mounting kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. Mechanical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Moving the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Unpacking and examining the delivery (frames R1 to R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Frame R5 cable entry box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Unpacking and examining the delivery (frames R6 to R9) . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Frame R6 cable entry box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Frame R7 cable entry box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Frame R8 cable entry box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Frame R9 cable entry box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Installing vibration dampers (option +C131) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Frames R1 to R4 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Frames R5 to R9 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Frames R1 to R9 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Flange mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Grounding inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Installing drives above one another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5. Planning the electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Selecting and dimensioning the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Additional requirements for ABB motors of types other than M2_, M3_, M4_,

HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . . . 65

Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . . . 66

Additional data for calculating the rise time and the peak line-to-line voltage . . . . . . 67

Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . . . 78

Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 78

Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Protecting the drive and the input power and motor cables against thermal overload . . . 82

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Connecting drives to a common DC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Implementing the safety functions with the FSO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . . . . . 84

Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Switching the motor power supply from drive to direct-on-line . . . . . . . . . . . . . . . . . . 87

Switching the motor power supply from direct-on-line to drive . . . . . . . . . . . . . . . . . . 87

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Drive I/O, I/O extension and encoder interface modules . . . . . . . . . . . . . . . . . . . . . . . . . 89

6. Electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Checking the compatibility with IT (ungrounded) and corner-grounded TN systems . . . . . . . 93

EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

690 V drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Connection procedure for frames R1 to R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Connection procedure for frames R4 and R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Connection procedure for frames R6 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . 113

AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . . . 113

Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Controlling several drives through panel bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Mechanical installation of I/O extension, fieldbus adapter and pulse encoder

interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Wiring I/O extension, fieldbus adapter and pulse encoder interface modules . . . . . . . . 122

Installation of safety functions modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Installation procedure into Slot 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Installation next to the control unit on frames R7 to R9 . . . . . . . . . . . . . . . . . . . . . . 125

7. Installation checklist

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

8. Start-up

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Startup procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

9. Fault tracing

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

10. Maintenance

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Descriptions of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . . 134

Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Replacing the main cooling fan of frames R1 to R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Replacing the auxiliary cooling fan of IP55 frames R1 to R3 . . . . . . . . . . . . . . . . . . . . . 137

Replacing the main cooling fan of frames R4 and R5 . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Replacing the auxiliary cooling fan of frames R4 and R5 (IP55 and option +C135)

and IP21 frame R5 types ACS880-01-xxxx-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Replacing the main cooling fan of frames R6 to R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Replacing the auxiliary cooling fan of frames R6 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . 141

Replacing the IP55 auxiliary cooling fan of frames R8 and R9 . . . . . . . . . . . . . . . . . . . . 142

Replacing the main cooling fans of frame R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Replacing the drive (IP21, UL Type 1, frames R1 to R9) . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Replacing the control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Replacing safety functions modules (FSO-12, option +Q973 and FSO-21, option +Q972) . 148

11. Technical data

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Marine type-approved drives (option +C132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Drives for SynRM motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

IP21 (UL Type 1) drive types and other IP55 (UL Type 12) types than listed in

the following subheadings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

IP55 (UL Type 12) drive types -274A-2, 293A-3, -260A-5, -302A-5 and -174A-7 . . 158

IP55 (UL Type 12) drive type -240A-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

IP55 (UL Type 12) drive types -363A-3 and -361A-5 . . . . . . . . . . . . . . . . . . . . . . . . 160

IP55 (UL Type 12) drive type -210A-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

IP55 (UL Type 12) types -0430A-3, -0414A-5 and -0271A-7 . . . . . . . . . . . . . . . . . . 161

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . . . . . . . 162

Ex motor, sine filter, low noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

aR fuses (frames R1 to R9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

gG fuses (frames R1 to R9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Quick guide for selecting between gG and aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Calculating the short-circuit current of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Cooling air flow and heat dissipation for flange mounting (option +C135) . . . . . . . . . . . 191

Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

UL listed cable lugs and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Control unit (ZCU-12) connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 205

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Compliance with the European RoHS Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Compliance with the EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

WEEE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

12. Dimension drawings

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Frame R1 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Frame R1 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Frame R2 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Frame R2 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Frame R3 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Frame R3 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Frame R4 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Frame R4 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Frame R5 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Frame R5 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Frame R6 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Frame R6 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Frame R7 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Frame R7 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Frame R8 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Frame R8 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Frame R9 (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Frame R9 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

13. Safe Torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Dual-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Single-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Multiple drives (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Multiple drives (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Safety data (SIL, PL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

14. Resistor braking

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Selecting the brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Selecting a custom resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Selecting and routing the brake resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Frames R1 to R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Frames R5 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Degree of protection and thermal constant of the resistors . . . . . . . . . . . . . . . . . . . . . . 257

Terminals and cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Dimensions and weights of external resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

JBR-03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

SACE08RE44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

SACE15RE13 and SACE15RE22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

SAFUR80F500 and SAFUR90F575 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

SAFUR125F500 and SAFUR200F500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

15. Common mode, du/dt and sine filters

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

When is a common mode filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

When is a du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

du/dt filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . . . . 264

Description, installation and technical data of the NOCH filters . . . . . . . . . . . . . . . . . . . 264

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Selecting a sine filter for a drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Description, installation and technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Safety instructions 13

Safety instructions

What this chapter contains

This chapter contains the safety instructions which you must obey when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, motor or driven equipment. Read the safety instructions before you work on the unit.

Use of warnings

Warnings caution you about conditions which can result in serious injury or death and/or damage to the equipment and advise on how to avoid the danger. The following warning symbols are used in this manual:

Electricity warning warns of hazards from electricity which can cause physical injury and/or damage to the equipment.

General warning warns about conditions, other than those caused by electricity, which can result in physical injury and/or damage to the

equipment.

Electrostatic sensitive devices warning warns of electrostatic discharge which can damage the equipment.

14 Safety instructions

Safety in installation and maintenance

 Electrical safety

These warnings are intended for all who work on the drive, motor cable or motor.

WAR N ING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:

• Only qualified electricians are allowed to install and maintain the drive.

• Never work on the drive, motor cable or motor when main power is applied. After disconnecting the input power, always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive, motor or motor cable.

Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:

• voltage between drive input phases L1, L2 and L3 and the frame is close to 0 V

• voltage between terminals UDC+ and UDC- and the frame is close to 0 V.

• Do not work on the control cables when power is applied to the drive or to the external control circuits. Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off.

• Do not make any insulation or voltage withstand tests on the drive.

• Do not connect the drive to a voltage higher than what is marked on the type designation label. Higher voltage can activate the brake chopper and lead to brake resistor overload, or activate the overvoltage controller what can lead to motor rushing to maximum speed.

Note:

• The motor cable terminals on the drive are at a dangerously high voltage when the input power is on, regardless of whether the motor is running or not.

• The DC terminals (UDC+, UDC-) carry a dangerous DC voltage (over 500 V) when internally connected to the intermediate DC circuit.

• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the terminals of relay outputs (XRO1, XRO2 and XRO3).

• The Safe torque off function does not remove the voltage from the main and auxiliary circuits. The function is ineffective against deliberate sabotage or misuse.

Safety instructions 15

Grounding

These instructions are intended for all who are responsible for the grounding of the drive.

WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction:

• Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and interference.

• Make sure that grounding conductors are adequately sized as required by safety regulations.

• In a multiple-drive installation, connect each drive separately to protective earth (PE).

• Where EMC emissions must be minimized, make a 360° high frequency grounding of cable entries in order to suppress electromagnetic disturbances. In addition, connect the cable shields to protective earth (PE) in order to meet safety regulations.

• Do not install a drive with EMC filter options +E200 or +E202 on an ungrounded power system or a high-resistance-grounded (over 30 ohms) power system. See page 93.

• Do not install 690 V drives on corner-grounded TN systems or cornergrounded IT systems.

Note:

• Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations.

• Standard EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed protective earth connection and

• a cross-section of the protective earthing conductor of at least 10 mm or 16 mm

Al,

• automatic disconnection of the supply in case of discontinuity of the protective earthing conductor,

• a second protective earthing conductor of the same cross-sectional area as the original protective earthing conductor.

16 Safety instructions

Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives.

WAR N ING! Ignoring the instructions can cause physical injury or death, or damage to the equipment:

• Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.

Before installation and maintenance work on the drive:

• Stop the motor.

• Ensure that there is no voltage on the drive power terminals according to step 1 or 2, or if possible, according to the both steps.

1. Disconnect the motor from the drive with a safety switch or by other

means. Check by measuring that there is no voltage present on the drive input or output terminals (L1, L2, L3, T1/U, T2/V, T3/W, UDC+, UDC-).

2. Ensure that the motor cannot rotate during work. Make sure that no other

system, like hydraulic crawling drives, is able to rotate the motor directly or through any mechanical connection like felt, nip, rope, etc. Check by measuring that there is no voltage present on the drive input or output terminals (L1, L2, L3, T1/U, T2/V, T3/W, UDC+, UDC-). Ground the drive output terminals temporarily by connecting them together as well as to the PE.

Safety instructions 17

General safety

These instructions are intended for all who install and service the drive.

WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:

• Use safety shoes with a metal toe cap to avoid foot injury. Wear protective gloves and long sleeves. Some parts have sharp edges.

• Handle the unit carefully.

•For fr

• Beware of hot surfaces. Some parts, such as heatsinks of power

• Ensure that debris from borings and grindings does not enter the drive when

• Ensure sufficient cooling.

ame sizes R6 to R9: Lift the drive using the lifting eyes of the unit. Do not

tilt the drive. The drive is heavy and its center of gravity is high. An

overturning unit can cause physical injury.

semiconductors, remain hot for a while after disconnection of the electrical supply.

installing. Electrically conductive debris inside the unit may cause damage or malfunction.

• Do not attach the drive by riveting or welding.

18 Safety instructions

 Printed circuit boards

WARNING! Ignoring the following instructions can cause damage to the printed circuit boards:

• Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily. The printed circuit boards contain components sensitive to electrostatic discharge.

Safe start-up and operation

 General safety

These warnings are intended for all who plan the operation of the drive or operate the drive.

WAR N ING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:

• Before you connect voltage to the drive, make sure that the drive covers are on. Keep the covers on during the operation.

• Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line.

• Before you activate the automatic fault reset or automatic restart functions of the drive control program, make sure that no dangerous situations can occur. These functions reset the drive automatically and continue operation after a fault or supply break. If these functions are activated, the installation must be clearly marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”.

• The maximum number of drive power-ups is five in ten 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 in start-up. See chapter Start-up for reference of the validation instructions.

Note:

• If you select an external source for start command and it is ON, the drive will start immediately after an input voltage break or fault reset unless the drive is configured for 3-wire (a pulse) start/stop.

Safety instructions 19

• When the control location is not set to local, the stop key on the control panel will not stop the drive.

Permanent magnet motor drives

WARNING! Do not run the motor over the rated speed. Motor overspeed

leads to overvoltage which may damage or explode the capacitors in the

intermediate circuit of the drive.

20 Safety instructions

Introduction to the manual 21

Introduction to the manual

What this chapter contains

This chapter describes the manual. It contains a flowchart of steps for checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals.

Target audience

This manual is intended for people who plan the installation, install, start-up, use and service the drive. Read the manual before working on the drive. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic 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 manual introduces the manual.

Operation principle and hardware description describes the drive.

Mechanical installation describes how to install the basic drive mechanically.

Planning the electrical installation contains instructions for the motor and cable

selection, protections and cable routing.

22 Introduction to the manual

Electrical installation gives instructions on wiring the drive.

Installation checklist contains a list for checking the mechanical and electrical

installation of the drive.

Start-up describes the start-up procedure of the drive.

Fault tracing describes the fault tracing of the drive.

Maintenance contains preventive maintenance instructions.

Technical data contains the technical specifications of the drive, eg, the ratings, sizes

and technical requirements, provisions for fulfilling the requirements for CE and other markings.

Dimension drawings contains dimension drawings of the drives and auxiliary

components.

Safe Torque off function describes the Safe torque off function of the drive and gives

instructions on its implementing.

Resistor braking describes selection, protection and wiring of brake choppers and

resistors. The chapter also contains technical data.

Common mode, du/dt and sine filters describes selection external filters for the drive.

Related manuals

See List of related manuals on the inside of the front cover.

Categorization by frame size and option code

The instructions, technical data and dimension drawings which concern only certain drive frame sizes are marked with the symbol of the frame size (R1, R2, etc.). The frame size is marked on the type designation label.

The instructions and technical data which concern only certain optional selections are marked with option codes (such as +E200). The options included in the drive can be identified from the option codes visible on the type designation label. The option selections are listed in section Type designation key on page 35.

Introduction to the manual 23

Quick installation, start-up and operating flowchart

Ta sk S ee

Plan the electrical installation and acquire the accessories needed (cables, fuses, etc.).

Check the ratings, required cooling air flow, input power connection, compatibility of the motor, motor connection, and other technical data.

Check the installation site. Ambient conditions (page 202)

Unpack and examine the units (only intact units may be started up).

Examine that all necessary optional modules and equipment are present and correct.

Mount the drive.

Route the cables. Routing the cables (page 77)

Check the insulation of the supply cable, the motor and the motor cable.

Connect the power cables. Connect the control cables.

Planning the electrical installation

(page 59)

Technical data (page 149)

Mechanical installation (page 42 or 45)

If the drive has been non-operational for more than one year, the converter DC link capacitors need to be reformed (page 146)

Checking the insulation of the assembly (page 91)

Connecting the power cables (page

94), Connecting the control cables

(page 110)

Check the installation. Installation checklist (page 127)

Start the drive up. Start-up (page 129)

Operate the drive: start, stop, speed control etc. ACS880 quick start-up guide, firmware

manual

24 Introduction to the manual

Terms and abbreviations

Term/

Abbreviation

EMC Electromagnetic compatibility EMI Electromagnetic interference EMT Electrical metallic tubing FAIO-01 Optional analog I/O extension module FDIO-01 Optional digital /O extension module FIO-01 Optional digital I/O extension module FIO-11 Optional analog I/O extension module FCAN-01 Optional FCAN-01 CANopen adapter module FCNA-01 Optional ControlNet™ adapter module FDNA-01 Optional DeviceNet™ adapter module FECA-01 Optional EtherCAT adapter module FEPL-01 Optional Ethernet POWERLINK adapter module FENA-01 Optional Ethernet/IP™ and Modbus/TCP and PROFINET adapter module FENA-11 Optional dual port Ethernet/IP™ and Modbus/TCP and PROFINET adapter

FLON-01 Optional LonWorks® adapter module FPBA-01 Optional PROFIBUS DP adapter module FEN-01 Optional TTL incremental encoder interface module FEN-11 Optional TTL absolute encoder interface module FEN-21 Optional resolver interface module FEN-31 Optional HTL incremental encoder interface module FDCO-01 Optional optical DDCS communication adapter module FPTC-01 Optional thermistor protection module for ACS880 drives FPTC-02 Optional ATEX-certified thermistor protection module for ACS880 drives FSE-31 Optional pulse encoder interface module FSO-12 Optional functional safety module FSO-21 Optional functional safety module Frame (size) Physical size of the drive IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type

I/O Input/Output ZCON Control board in which the control program runs. ZCU Control board built in a housing. The external I/O control signals are

ZGAB Brake chopper adapter board in frames R8 to R9

Explanation

module

widely used in inverters due to their easy controllability and high switching frequency.

connected to the control unit, or optional I/O extensions mounted on it.

Introduction to the manual 25

Ter m/

Abbreviation

ZGAD Gate driver adapter board in frames R6 to R9 ZINT Main circuit board ZMU The memory unit attached to the control unit of the drive R1…R9 Frame size designation of the drive

Explanation

26 Introduction to the manual

Operation principle and hardware description 27

Operation principle and hardware description

What this chapter contains

This chapter briefly describes the operation principle and construction of the drive.

Product overview

The ACS880-01 is a drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors). The main cooling air fan of the drive is speed controlled and the auxiliary cooling fan on/off controlled.

28 Operation principle and hardware description

L1 L2

T1/U

T2/V T3/W

ACS880-01

R- UDC+ UDC-

R+

1 2 3

 Main circuit

The main circuit of the drive is shown below.

1 Rectifier. Converts alternating current and voltage to direct current and voltage. 2 DC link. DC circuit between rectifier and inverter. 3 Inverter. Converts direct current and voltage to alternating current and voltage. 4 Brake chopper. Conducts the surplus energy from the intermediate DC circuit of the

drive to the brake resistor when necessary. The chopper operates when the DC link voltage exceeds a certain maximum limit. The voltage rise is typically caused by deceleration (braking) of a high inertia motor. User obtains and installs the brake resistor when needed.

Operation principle and hardware description 29

1 Control panel 2 Front cover 3 Cable entry box 4 Four fastening points at the back of

the unit 5 Heatsink 6 Lifting holes

 Layout (IP21, UL Type 1)

The components of the standard IP21 drive are shown below (view of frame R5).

30 Operation principle and hardware description

1 Control panel behind the

control panel cover 2 Front cover 3 Four fastening points at the

back of the unit 4 Heatsink 5 Lifting holes

 Layout (IP55, option +B056)

The components of the IP55 drive (option +B056) are shown below (view of frame R4).

+ 240 hidden pages