ABB ACS880-04F Hardware Manual

ABB industrial drives

Hardware manual

ACS880-04F drive modules

List of related manuals

ACS880-04 manuals

Drive hardware manuals and guides Code (English)

Drive/Converter/Inverter safety instructions Multilingual code:

3AXD50000037978

ACS880-04F drive modules hardware manual 3AXD50000034664 ACS880-04F drive modules quick installation guide 3AXD50000044913 ACS-AP-x Assistant control panels user’s manual 3AUA0000085685 ACS880-01/04 +C132 marine type-approved drives

supplement

Drive firmware manuals and guides

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

control program

Option manuals and guides

DPMP-01 mounting platform for ACS-AP control panel installation guide

DPMP-02/03 mounting platform for ACS-AP-X control panels installation guide

FSO-12 safety functions module user’s manual 3AXD50000015612 ACS880 ATEX-certified Safe disconnection function

application guide ACS880-01 drives and ACS880-04 drive modules

common DC systems application guide FOCH du/dt filters hardware manual 3AFE68577519 Sine filters hardware manual 3AXD50000016814 Manuals and quick guides for I/O extension modules,

fieldbus adapters, etc.

3AXD50000010521

3AUA0000098062

3AUA0000100140

3AUA0000136205

3AUA0000132231

3AUA0000127818

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

Document library on the Internet on the inside of the back cover. For manuals not available in the

Document library, contact your local ABB representative. The code below opens an on-line listing of the manuals applicable to this product.

Hardware manual

ACS880-04F drive modules

Table of contents

1. Safety instructions

5. Mechanical installation

7. Electrical installation

9. Start-up

3AXD50000034664 Rev A

EFFECTIVE: 2016-12-28

Table of contents

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

1. Safety instructions

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . 15

Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . 18

Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Quick installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . 21

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Standard drive module configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Drive module without full-size output cable connection terminals (option +0H371)

and IP20 shrouds (option +0B051), with common mode filter (+E208) . . . . . . . . . . . 29

Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

External control connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

External control unit connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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

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

4. Guidelines for planning the mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installation alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Channel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Basic requirements for the channel wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Installation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Basic requirements for the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Planning the layout of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Layout example, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Layout example, door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Arranging the grounding inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Selecting the busbar material and preparation of the joints . . . . . . . . . . . . . . . . . . . 41

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Planning the fastening of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Planning the cabinet placement on a cable channel . . . . . . . . . . . . . . . . . . . . . . . . . 41

Planning the electromagnetic compatibility (EMC) of the cabinet . . . . . . . . . . . . . . . 42

Planning the cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Required free space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Other installation positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Drive module on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Planning the placement of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Planning the use of cubicle heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5. Mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Package drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Attaching alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Attaching the drive module by the flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Attaching the drive module by the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Attaching the metallic shroud (standard and with ground bar [option +H370]) . . . . . . . 54

Attaching the external control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Attaching the external control unit to a mounting plate or wall . . . . . . . . . . . . . . . . . 55

Attaching the external control unit vertically on a DIN rail . . . . . . . . . . . . . . . . . . . . . 56

Attaching the control unit horizontally on a DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . 56

6. Guidelines for planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Selecting the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Additional requirements for explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . 60

Additional requirements for ABB motors of types other than

M2_, M3_, M4_, HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Additional requirements for the braking applications . . . . . . . . . . . . . . . . . . . . . . 60

Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . 60

Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . 60

Additional data for calculating the rise time and the peak line-to-line voltage . . . 61

Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Additional note for common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Power cable types for restricted use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Continuous motor cable shield or enclosure for equipment in the motor cable . . . . . 67

Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . 67

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . 67

Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . 68

Protecting the drive and the input power and motor cables against thermal

overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Connecting drive modules to a common DC system . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . 70 Implementing safety functions provided by the FSO safety functions module (options

+Q972 and +Q973) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Implementing the Power loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . 71

Implementing a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . 71

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Switching the motor power supply from drive to direct-on-line . . . . . . . . . . . . . . . 73

Switching the motor power supply from direct-on-line to drive . . . . . . . . . . . . . . . 74

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Drive I/O, I/O extension and encoder interface modules . . . . . . . . . . . . . . . . . . . . . . 75

Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

7. Electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Installing the motor cable at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Brake resistor and resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . 79

Grounding the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Overview of control cable connection process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Removing the control panel holder from the external control unit . . . . . . . . . . . . . . . . . 84

Attaching the control cable clamp plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Connecting the external control unit to the drive module . . . . . . . . . . . . . . . . . . . . . . . . 86

Routing the control unit cables into the drive module . . . . . . . . . . . . . . . . . . . . . . . . 86

Connections to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Connections to the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Connecting the control cables to the terminals of the control unit . . . . . . . . . . . . . . . . . 88

Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

External power supply for the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . . 91

DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Safety functions (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Installing the control panel holder back onto the external control unit . . . . . . . . . . . 93

Connecting a control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Controlling several drives from one control panel through panel bus . . . . . . . . . . . . . . 94

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Installing the FSO safety functions module (options +Q972 and +Q973) . . . . . . . . . 95

Installing I/O extension, fieldbus adapter and pulse encoder interface modules . . . 97

Wiring the optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Connecting the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

8. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

9. Start-up

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

10. Fault tracing

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

LEDs with options +J410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

11. Maintenance

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Descriptions of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . 108

Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . . 108

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Cleaning the interior of the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Replacing the circuit board compartment cooling fans . . . . . . . . . . . . . . . . . . . . . . . 111

Replacing the main cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Replacing the standard drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Replacing the control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

12. Ordering information

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Output (du/dt) filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

FSO accessories kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Retrofit accessory kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

13. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

When is derating needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . . . . 122

Ex motor, sine filter, low noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Ultrarapid (aR) fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Units without full-size output cable connection terminals (+0H371) and with a

common mode filter (+E208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Brake resistor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

DC connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Control unit connection data (ZCU-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Control panel type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . 134

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Compliance with the European RoHS Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Compliance with EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

EAC (Eurasian Conformity) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

EIP (Electronic Information Products) marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

14. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Standard configuration – IP20 (UL Open Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Drive module with options +E208 and +H370 – IP20 (UL Open Type) . . . . . . . . . . . . 143

Drive module with options +0B051+E208+0H371 – IP00 (UL Open Type) . . . . . . . . . 144

Drive module with options +0B051+E208+0H371+C217 – IP00 (UL Open Type) . . . 145

Drive module with options +0B051+0H371 – IP00 (UL Open Type) . . . . . . . . . . . . . . 146

Mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

External control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

15. Example circuit diagram

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

16. Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 154

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Dual-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Single-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Multiple drives (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Multiple drives (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

17. Resistor braking

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Selecting the default brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Selecting a custom resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Selecting and routing the external brake resistor cables . . . . . . . . . . . . . . . . . . . . . 166

Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Mechanical installation of external brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

SAFUR resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Ordering codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Terminals and cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

18. du/dt and sine filters

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

When is a du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Ordering codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . 172

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

When is a sine filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Ordering codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Description, installation and technical data of the sine filters . . . . . . . . . . . . . . . . . . 172

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Safety instructions

Safety instructions 13

Contents of this chapter

This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur.

Use of warnings and notes

Warnings tell you about conditions which can cause injury or death, or damage to the equipment. They also tell you how to prevent the danger. Notes draw attention to a particular condition or fact, or give information on a subject.

The manual uses these warning symbols:

Electricity warning tells about hazards from electricity which can cause injury or death, or damage to the equipment.

General warning tells about conditions, other than those caused by electricity, which can cause injury or death, or damage to the equipment.

Electrostatic sensitive devices warning tells you about the risk of electrostatic discharge which can cause damage to the equipment.

14 Safety instructions

General safety in installation, start-up and maintenance

These instructions are for all personnel that install the drive module and do maintenance work on it.

WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

• Use protective gloves when working on the drive module.

• Handle the drive module carefully:

• Use safety shoes with a metal toe cap to prevent foot injury.

• Lift the drive module only by the lifting lugs.

Note: Before you lift the module horizontally, remove the bottom grille in order to

prevent distorting. Reinstall it after lifting.

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

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

• Make sure that debris from borings and grindings does not enter the drive during the

installation. Electrically conductive debris inside the drive may cause damage or malfunction.

• Make sure that there is sufficient cooling.

• Before you connect voltage to the drive, make sure that the cabinet doors are closed.

Keep the doors closed during the operation. Obey the panel builder’s instructions.

• Before you adjust the drive operation limits, make sure that the motor and all driven

equipment can operate throughout the set operation limits.

• 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”.

Safety instructions 15

• 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 fault reset unless you configure the drive for pulse start. See the firmware manual.

• When the control location is not set to Local, the stop key on the control panel will not

stop the drive.

Electrical safety in installation, start-up and maintenance

 Precautions before electrical work

These warnings are for all personnel that do work on the drive, motor cable or motor.

WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, do not do installation or maintenance work. Go through these steps before you begin any

installation or maintenance work.

1. Clearly identify the work location.

2. Disconnect all possible voltage sources.

• Open the main disconnector of the drive.

• Open the disconnector of the supply transformer as the main disconnector of the

drive does not remove the voltage from the input busbars of the drive.

• Make sure that reconnection is not possible. Lock the disconnectors to open

position and attach a warning notice to them.

• Disconnect any external power sources from the control circuits before you do

work on the control cables.

• After you disconnect the drive, always wait for 5 minutes to let the intermediate

circuit capacitors discharge before you continue.

3. Protect any other energized parts in the work location against contact.

4. Take special precautions when close to bare conductors.

5. Measure that the installation is de-energized.

• Use a multimeter with an impedance of at least 1 Mohm.

• Make sure that the voltage between the drive module input power terminals

(L1/U1, L2/V1, L3/W1) and the grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the drive module UDC+ and UDC- terminals

and the grounding (PE) busbar is close to 0 V.

6. Install temporary grounding as required by the local regulations.

7. Ask for a permit to work from the person in control of the electrical installation work.

16 Safety instructions

 Additional instructions and notes

WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

• If you are not a qualified electrician, do not do installation or maintenance work.

• Do not install a drive with EMC filter option +E200 on an ungrounded power system or

a high resistance-grounded (over 30 ohms) power system.

• Do not connect the drive to a voltage higher than what is on the type designation label.

If you do, the brake chopper starts to operate which causes the overheating of the brake resistor (if present). Overvoltage can also cause the motor to rush to its maximum speed.

• We do not recommend that you secure the cabinet by arc welding.

• Do not do insulation or voltage withstand tests on the drive or drive modules.

Note:

• The motor cable terminals of the drive are at a dangerous voltage when the input

power is on, regardless of whether the motor is running or not.

• The DC bus and brake resistor terminals (UDC+, UDC-, R+ and R-) are at a

dangerous voltage.

• External wiring can supply dangerous voltages to 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 not effective against deliberate sabotage or misuse.

WARNING! Use a grounding wrist band when you handle the printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge.

Safety instructions 17

WARNING! Obey these instructions. If you ignore them, equipment malfunction and damage to the fiber optic cables can occur.

• Handle the fiber optic cables with care.

• When you unplug the cables, always hold the connector, not the cable itself.

• Do not touch the ends of the fibers with bare hands as the ends are extremely

sensitive to dirt.

• Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is

35 mm (1.4 in).

 Grounding

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

WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase.

• If you are not a qualified electrician, do not do grounding work.

• Always ground the drive, the motor and adjoining equipment. This is necessary for the

personnel safety. Proper grounding also reduces electromagnetic emission and interference.

• Make sure that the conductivity of the grounding conductors is sufficient. See section

Selecting the power cables on page 62. Obey the local regulations.

• Connect the power cable shields to protective earth (PE) of the drive to make sure of

personnel safety.

• Make a 360° grounding of the power and control cable shields at the cable entries to

suppress electromagnetic disturbances.

• In a multiple-drive installation, connect each drive separately to the protective earth

(PE) busbar of the switch board or the transformer.

Note:

• You can use power cable shields as grounding conductors only when their conductivity

is sufficient.

• 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. See standard EN 61800-5-1, 4.3.5.5.2.

18 Safety instructions

Additional instructions for permanent magnet motor drives

 Safety in installation, start-up and maintenance

These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid.

WARNING! Obey these instructions. If you ignore them, injury or death and equipment malfunction can occur.

• Do not do work on the drive when the permanent magnet motor is rotating. A rotating

permanent magnet motor energizes the drive including its input power terminals.

Before installation, start-up and maintenance work on the drive:

• Stop the motor.

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

• If you cannot disconnect the motor, make sure that the motor cannot rotate during

work. Make sure that no other system, like hydraulic crawling drives, can rotate the motor directly or through any mechanical connection like felt, nip, rope, etc.

• Measure that the installation is de-energized.

• Use a multimeter with an impedance of at least 1 Mohm.

• Make sure that the voltage between the drive output terminals (T1/U2, T2/V2,

T3/W2) and the grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the drive input power terminals (L1/U1, L2/V1,

L3/W1) and the grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the drive module UDC+ and UDC- terminals

and the grounding (PE) busbar is close to 0 V.

• Install temporary grounding to the drive output terminals (T1/U2, T2/V2, T3/W2).

Connect the output terminals together as well as to the PE.

• Make sure that the operator cannot run the motor over the rated speed. Motor

overspeed causes overvoltage can damage or explode the capacitors in the intermediate circuit of the drive.

Introduction to the manual 19

Introduction to the manual

Contents of this chapter

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

Target audience

This manual is intended for persons who

• plan the cabinet assembly of the drive module and install the module into a user-

defined cabinet

• plan the electrical installation of the drive cabinet

• make instructions for the end user of the drive concerning the mechanical installation

of the drive cabinet, connection of power and control cables to the cabinet-installed drive and maintenance of 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.

20 Introduction to the manual

Contents of the manual

This manual contains the instructions and information for the basic drive module configuration. The chapters of the manual are briefly described below.

Safety instructions gives safety instructions for the installation, commissioning, operation

and maintenance of the drive module.

Introduction to the manual introduces the manual. Operation principle and hardware description describes the drive module. Guidelines for planning the mechanical installation guides in planning drive cabinets and

installing the drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirements around the module for cooling.

Mechanical installation describes how to install the drive module mechanically. Guidelines for planning the electrical installation instructs in the motor and cable selection,

protections and cable routing.

Electrical installation gives instructions on the wiring of the drive. Installation checklist contains lists for checking the mechanical and electrical installation of

the drive.

Start-up refers to the start-up instructions of the cabinet-installed drive. Fault tracing describes the LED indications and refers to the fault tracing instructions of the

drive.

Maintenance contains maintenance instructions. Ordering information gives ordering information on additional components available from

ABB for the drive module installation.

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

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

Dimension drawings contains dimension drawings of the drive module installed into a

Rittal TS 8 cabinet.

Example circuit diagram shows an example circuit diagram for a cabinet-installed drive

module.

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 optional brake choppers and

resistors. The chapter also contains technical data.

du/dt and sine filters describes how to select du/dt and sine filters for the drive.

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 (R10 or R11). 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, eg, +J410. 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 21

Quick installation, commissioning and operating flowchart

Task See

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

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

Unpack and check the units. Check that all necessary optional modules and equipment

are present and correct. Only intact units can be started up.

Check the installation site. Fasten the base of the cabinet to the floor.

Guidelines for planning the mechanical installation (page 37)

Guidelines for planning the electrical installation

(page 57)

Technical data (page 119) Resistor braking (page 165)

Option manual (if optional equipment is included)

Moving and unpacking the unit (page 48) Installing the motor cable at the motor end

(page 77) If the drive module has been non-operational

for more than one year, the converter DC link capacitors need to be reformed. (Reforming the

capacitors, page 114)

Examining the installation site (page 47) Ambient conditions (page 132) Guidelines for planning the mechanical

installation (page 37)

Route the cables. Routing the cables (page 66)

Check the insulation of the supply cable, the motor and the motor cable and the resistor cable (if present).

Installing the drive module

• Install the drive module into the cabinet.

• Install the additional components into the cabinet: for example, main disconnector, main contactor, main AC fuses, etc.

• Connect the motor cables to the drive module terminals.

• Connect the brake resistor and DC connection cables (if any) to the drive module terminals.

• If the main disconnector is installed into the cabinet, connect it to the drive module terminals and the input power cabling to the disconnector.

• Connect the cables from the drive module to the external control unit and install the control unit into the cabinet.

Checking the insulation of the assembly (page

78)

Mechanical installation (page 47) Connecting the power cables (page 80) Connecting the external control unit to the drive

module (page 86) Attaching the external control unit (page 54) Overview of control cable connection process

(page 83) Manuals for any optional equipment

22 Introduction to the manual

Task See

Connect the external control cables to the drive control unit. Connecting the control cables to the terminals

of the control unit (page 88)

Check the installation. Installation checklist (page 99)

Commission the drive. Start-up (page 103)

Commission the brake chopper (if used). Resistor braking (page 165)

Operate the drive: start, stop, speed control etc. Appropriate firmware manual

Terms and abbreviations

Term/Abbreviation Explanation

AIBP Input bridge protection board

BPOW Power supply board

BFPS Fan power supply board

BGDR Gate driver board

CMF Common mode filtering

DDCS Distributed drives communication system; a protocol used in optical fiber

communication

DTC Direct torque control

EMC Electromagnetic compatibility

EMI Electromagnetic interference

FAIO-01 Optional analog I/O extension module

FCAN-01 Optional CANopen adapter module

FCNA-01 Optional ControlNet fieldbus adapter module

FDCO-0x Optional optical DDCS communication module

FDIO-01 Optional digital I/O extension module

FDNA-01 Optional DeviceNet™ fieldbus adapter module

FECA-01 Optional EtherCAT adapter module

FEN-01 Optional TTL encoder interface module

FEN-11 Optional absolute encoder interface module

FEN-21 Optional resolver interface module

FEN-31 Optional HTL encoder interface module

FENA-11 Optional high performance Ethernet/IP™, Modbus/TCP and PROFINET IO

adapter module

Introduction to the manual 23

Term/Abbreviation Explanation

FENA-21 Optional high performance Ethernet/IP™, Modbus/TCP and PROFINET IO

adapter module, 2-port

FEPL-01 Optional Ethernet POWERLINK

FIO-01 Optional digital I/O extension module

FIO-11 Optional analog I/O extension module

FPBA-01 Optional PROFIBUS DP adapter module

Frame (size) Size of the drive module. The drive modules described in this manual are of frame

size R10 and R11.

FSCA-01 Optional Modbus RTU adapter module

FSE-31 Pulse encoder interface module

FSO Optional safety functions module

HTL High-threshold logic

IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type widely

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

fieldbus adapter module

I/O Input/Output

IT system Type of supply network that has no (low-impedance) connection to ground/earth.

PLC Programmable logic controller

RFI Radio-frequency interference

SAFUR Series of optional brake resistors

STO Safe torque off

SOIA Optical interface adapter board

TN system Type of supply network that provides a direct connection to ground (earth).

TTL

Transistor-transistor logic

ZBIB Adapter board connected to the control board in the control unit (ZCU)

ZCU Drive control unit. As standard, the external I/O control signals are connected to

the control board, or optional I/O extensions installed on it.

ZINT Main circuit board

ZMU The memory unit attached to the control unit of the drive

24 Introduction to the manual

Operation principle and hardware description 25

Operation principle and hardware description

Contents of this chapter

This chapter describes the operating principle and construction of the drive module.

26 Operation principle and hardware description

L1/U1 L2/V1

L3/W1

T1/U2

T2/V2 T3/W2

ACS880-04F

R-

R+

421

UDC-

UDC+

Product overview

The ACS880-04F is a drive module for controlling asynchronous AC induction motors, permanent magnet motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors).

The main circuit of the drive module is shown below.

1 AC choke 2 Rectifier. Converts alternating current and voltage to direct current and voltage. 3 DC link. DC circuit between rectifier and inverter 4 Inverter. Converts direct current and voltage to alternating current and voltage. 5 Brake chopper (option +D150). Conducts the surplus energy from the intermediate 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.

Operation principle and hardware description 27

A B

Layout

 Standard drive module configuration

The assembled standard drive module configuration is shown below.

A Front view 5 Heatsink cleaning hole cover B Back view 6 Flange 1 Drive module 7 Hood 2 Upper front cover 8 External control unit with control panel holder 3 Lower front cover 9 Control panel 4 Clear plastic shrouds attached - -

See the part descriptions below.

28 Operation principle and hardware description

+H370

1 Clear plastic shroud to be attached onto the

drive module input power cabling (a). Leadthrough shroud for side cabling (b).

2 Clear plastic shrouds to be attached onto the

drive module output power cabling

3 Clear plastic shroud to be attached on top of

the drive module (lead-through for top cabling)

4 Upper back clear plastic shroud 14 External control unit. The control unit can also

5 Lower back clear plastic shroud 15 Control panel 6 Front clear plastic shroud 16 Control cable clamp plate 7 Input power cable connection terminals

(option +H370) 8 Output power cable connection terminals 18 Fiber optic cables 9 Grounding terminal for output power cable

shields

10 Metallic shroud. With option +H370, the

shroud includes a ground bar.

11 Fiber optic cables

12 PE (ground) terminal

13 Main cooling fans

be inside the drive module (option +P905)

17 Cables for connecting the control unit to the

drive module

19 Support brackets

20 Lifting lugs

Operation principle and hardware description 29

 Drive module without full-size output cable connection terminals

(option +0H371) and IP20 shrouds (option +0B051), with common mode filter (+E208)

1 Lifting lugs 2 Input cable connection busbars (L1/U1, L2/V1, L3/W1) and DC+ and DC- busbars (UDC+, UCD-

with option +H356) 3 Circuit board compartment 4 Output cable connection busbars (T1/U2, T2/V2, T3/W2) and brake resistor connection busbars (R+

and R- with option +D150) 5 Common mode filter (option +E208) 6 Auxiliary cooling fans 7 Heatsink 8 PE busbar 9 Cover on heatsink cleaning hole

10 Main cooling fans

30 Operation principle and hardware description

1 2 3

 Control unit

See section Standard drive module configuration on page 27.

 Control panel

1 ACS-AP-W bluetooth control panel 2 DPMP-01 door mounting kit (option +J410) 3 DPMP-02 door mounting kit for surface mounting (option +J413)

In the standard drive module configuration, the control panel is located in the control panel holder of the external control unit.

The control panel can be mounted on the cabinet door using a DPMP-01 mounting platform (option +J410) or a DPMP-02 mounting platform (option +J413).

For the use of the control panel, see the firmware manual or ACS-AP-X assistant control

panels user’s manual (3AUA0000085685 [English]).

+ 142 hidden pages