ABB ACS880-31 Hardware Manual

ABB industrial drives

Hardware manual

ACS880-31 drives

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

ACS880-31 manuals

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 codes below open an online listing of the manuals applicable to the product.

Hardware manual

ACS880-31 drives

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation – IEC

7. Electrical installation – USA

3AXD50000045933 Rev C

EFFECTIVE: 2018-06-25

Update notice 1

Update notice

The notice concerns the ACS880-31 hardware manual given below.

Contents of the notice: New values for ratings, fuses and sine filters.

Code of this notice: 3AXD50000335350 Rev A. Valid: From 2018-10-15 until revision D of

the manual.

Manual code Revision Language

3AXD50000045933 C English EN

Ratings

Changed:

Typ e

Frame

ACS880

-31-

3-phase UN = 500 V

07A6-5 R3 5.8 9.5 6.6 7.6 4.0 7.2 4.0 5.2 2.2 11A 0-5 R3 7.8 13.8 9.5 11.0 5.5 10.4 5.5 7.6 4.0 014A-5 R3 10.6 18.7 12 14 7.5 13 7.5 11.0 5.5

021A-5 R3 15.6 26.3 18 21 11 .0 19 11 .0 14 7.5 027A-5* R6 21.3 35.7 23 27 15.0 26 15.0 21 11. 0 034A-5* R6 26.2 45.9 29 34 18.5 32 18.5 27 15.0 040A-5* R6 31.2 57.8 35 40 22.0 38 22.0 34 18.5 052A-5* R6 40.1 68.0 45 52 30.0 49 30.0 40 22.0 065A-5* R6 49.5 88.4 56 65 37.0 62 37.0 52 30.0 077A-5* R6 60.2 110.5 67 77 45.0 73 45.0 65 37.0

101A-5 R8 71 148 87 101 45.0 91 45 77 37.0

124A-5 R8 96 178 107 124 55.0 11 8 55 96 45.0

156A-5 R8 115 247 137 156 75.0

180A-5 R8 141 287 156 180 90.0 171 90 156 75.0

size

Input

rating

Max.

current

A A kVA A kW A kW A kW

max

App.

power

Output ratings

Nominal use Light-duty use Heavy-duty use

148 75 124 55.0

Fuses

Changed:

Input

current

Nominal

current

t Voltage

Typ e

ACS880

-31-

3-phase UN = 500 V

07A6-5 65 5.8 25 130 690 170M1561 000 11A 0-5 65 7.8 25 130 690 170M1561 000 014A-5 120 10.6 40 460 690 170M1563 000

Min.

short-

circuit

current

AAAA

rating

Bussmann

type

IEC 60269

size

2 Update notice

Typ e

ACS880

-31-

Input

current

Nominal

current

Min.

short-

circuit

current

AAAA

t Voltage

rating

Bussmann

type

IEC 60269

021A-5 120 15.6 40 460 690 170M1563 000 027A-5 170 21.3 63 1450 690 170M1565 000 034A-5 170 26.2 63 1450 690 170M1565 000 040A-5 280 31.2 80 2550 690 170M1566 000 052A-5 300 40.1 100 4650 690 170M1567 000 065A-5 480 49.5 125 8500 690 170M1568 000 077A-5 700 60.2 160 16000 690 170M1569 000 101A-5 1000 71 250 28500 690 170M3816 1 124A-5 1280 96 315 46500 690 170M3817 1 156A-5 1610 11 5 400 74000 690 170M5808 2 180A-5 2210 141 500 155000 690 170M5810 2

Minimum short-circuit current of the installation

Typ e

ACS880

-31-

Min.

short-

circuit

current

Input

current

Nominal

current

AAAA

gG (IEC 60269)

t Voltage

rating

ABB type IEC 60269

3-phase UN = 500 V

07A6-5 120 5.8 16 700 500 OFAF000H16 000 11A0-5 120 7.8 16 700 500 OFAF000H16 000 014A-5 200 10.6 25 2500 500 OFAF000H25 000 021A-5 250 15.6 32 4500 500 OFAF000H32 000 027A-5 350 21.3 40 7700 500 OFAF000H40 000 034A-5 400 26.2 50 15400 500 OFAF000H50 000 040A-5 500 31.2 63 21300 500 OFAF000H63 000 052A-5 800 40.1 80 37000 500 OFAF000H80 000 065A-5 1000 49.5 100 63600 500 OFAF000H100 000 077A-5 1000 60.2 100 63600 500 OFAF000H100 000

Minimum short-circuit current of the installation

size

Typ e

ACS880

-31-

Input current UL (one fuse per phase)

Nominal current Voltage rating Bussmann type UL class

AAV

3-phase UN = 480 V

07A6-5 5.8 15 600 JJS-15 T 11A 0-5 7.8 20 600 JJS-20 T 014A-5 10.6 25 600 JJS-25 T 021A-5 15.6 35 600 JJS-35 T 027A-5 21.3 40 600 JJS-40 T 034A-5 26.2 50 600 JJS-50 T 040A-5 31.2 60 600 JJS-60 T 052A-5 40.1 80 600 JJS-80 T 065A-5 49.5 90 600 JJS-90 T

Update notice 3

Typ e

ACS880

-31-

Input current UL (one fuse per phase)

Nominal current Voltage rating Bussmann type UL class

AAV 077A-5 60.2 110 600 JJS-110 T 101A-5 74 150 600 JJS-150 T 124A-5 100 200 600 JJS-200 T 156A-5 120 225 600 JJS-225 T 180A-5 147 300 600 JJS-300 T

Sine filter

Changed:

Type ACS880

Sine filter type I

cont.

max

-31-

UN = 400 V

09A4-3 B84143V0011R229 10,0 4,0 226 90 316 72 12A6-3 B84143V0016R229 12,9 5,5 329 80 409 72 017A-3 B84143V0025R229 17 7,5 395 140 535 75 025A-3 B84143V0025R229 25 11,0 579 140 719 75 032A-3 B84143V0033R229 32 15,0 625 160 785 75 038A-3 B84143V0050R229 38 18,5 751 220 971 78 045A-3 B84143V0050R229 45 22,0 912 220 1132 78 061A-3 B84143V0066R229 61 30,0 1088 250 1338 78 072A-3 B84143V0075R229 72 37,0 1502 310 1812 79 087A-3 B84143V0095R229 87 45,0 1904 400 2304 79 105A-3 B84143V0130S230 105 55,0 1877 600 2477 80 145A-3 B84143V0162S229 145 75,0 2963 550 3513 80 169A-3 B84143V0162S229 169 90,0 3168 550 3718 80 206A-3 B84143V0230S229 206 110,0 3990 900 4890 80

UN = 500 V

07A6-5 B84143V0011R229 7,6 4,0 219 90 309 72,0 11A0-5 B84143V0011R229 11,0 5,5 278 90 368 72,0 014A-5 B84143V0016R229 14 7,5 321 80 401 70 021A-5 B84143V0025R229 21 11,0 473 140 613 75 027A-5 B84143V0033R229 27 15,0 625 160 785 75 034A-5 B84143V0050R229 34 18,5 711 220 931 78 040A-5 B84143V0050R229 40 22,0 807 220 1027 78 052A-5 B84143V0066R229 52 30,0 960 250 1210 78 065A-5 B84143V0066R229 65 37,0 1223 250 1473 78 077A-5 B84143V0075R229 77 37,0 1560 310 1870 78 101A-5 B84143V0130S230 96 55,0 1995 630 2625 80 124A-5 B84143V0130S230 124 55,0 2800 630 3430 80 158A-5 B84143V0162S229 156 90,0 3168 550 3718 80 180A-5 B84143V0162S229 180 110,0 3872 550 4422 80

cont.

max

Heat dissipation Noise

Drive Filter Total

AkWWWWdB(A)

4 Update notice

Table of contents 5

Table of contents

1. Safety instructions

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

Use of warnings and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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

Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Additional instruction for DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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

Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Categorization by frame (size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Quick installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4. Mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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

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

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Moving the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Unpacking and examining delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Flange mounting (option +C135) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6 Table of contents

Cabinet installation (option +P940) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5. Guidelines for planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

North American Market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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

AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . . . 56

Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . . . 56

Additional data for calculating the rise time and peak line-to-line voltage . . . . . . . . . 57

Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Drive composer PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . . 66

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

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

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Protecting the drive and the input power and motor cables against thermal overload . . . 67

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Implementing the safety functions provided with the FSO safety functions module (options +Q972

and +Q973) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Table of contents 7

Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . . . . . 69

Implementing the undervoltage control (power-loss ride-through) . . . . . . . . . . . . . . . . . . . . . 69

Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Connection of motor temperature sensor to the drive via an option module . . . . . . . . . . . 73

Connection of motor temperature sensor to the drive via a relay . . . . . . . . . . . . . . . . . . . 74

6. Electrical installation – IEC

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Checking the compatibility with IT (ungrounded), corner-grounded delta, midpoint-grounded del-

ta, and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

EMC filter option +E200 or +E202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

When to disconnect EMC filter (options E200 and +E202) or ground-to-phase varistor: TN-S,

IT, corner-grounded delta, and midpoint-grounded delta systems . . . . . . . . . . . . . . . . . . 79

Guidelines for installing the drive to a TT system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Identifying different types of electrical power systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Disconnecting internal EMC filter (option +E200 or +E202) and ground-to-phase varistor –

frame R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Disconnecting internal EMC filter (option +E200 or +E202) and ground-to-phase varistor –

frame R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Disconnecting internal EMC filter and ground-to-phase varistor –frame R8 . . . . . . . . . . . 84

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

R8 power cable connection if you detach the motor cable connectors . . . . . . . . . . . . 95

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Default I/O connection digram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . . . . . 99

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Control cable connection procedure (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8 Table of contents

Mechanical installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Wiring option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Installation of safety functions modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Installation procedure into Slot 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Installation next to the control unit on frames R6 and R8 . . . . . . . . . . . . . . . . . . . . 110

Reinstalling cover(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Controlling several drives through the panel bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7. Electrical installation – USA

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

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Checking the compatibility with IT (ungrounded), corner-grounded and midpoint-grounded delta

systems, and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

R8 motor cable connection if you detach the connectors . . . . . . . . . . . . . . . . . . . . 130

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Default I/O connection digram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . . . 134

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . 134

Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Reinstalling cover(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Controlling several drives through the panel bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

8. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

9. Start-up

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Table of contents 9

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

10. Maintenance and hardware diagnostics

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Description of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . . . 148

Recommended maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Replacing the main cooling fan, frame R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Replacing the main cooling fan, frame R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Replacing the main cooling fan, frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R3 . . . . . . . . . . . . . . . . . 153

Replacing the auxiliary cooling fan, frame R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Replacing the auxiliary cooling fan, frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Replacing the second auxiliary cooling fan IP55 (UL Type 12), frame R8 . . . . . . . . . . . 156

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Replacing the control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Replacing the battery in the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Drive LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Control panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

11. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

UL (NEC) ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Ambient temperature derating, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Ambient temperature derating, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Ambient temperature derating in table format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . . . . . . . 169

High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Quick guide for selecting between gG and aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Calculating the short-circuit current of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

10 Table of contents

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Terminal and entry data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

UL listed cable lugs and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Terminal and entry data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Voltage (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Control unit (ZCU-12) connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 193

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Compliance with the European ROHS II Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Compliance with the European WEEE Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Compliance with the EN 61800-3:2004 + A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

General disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

12. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

R3, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

R3 – Option +B056 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

R6, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

R6 – Option +B054 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

R6 – Option +B056 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

R8 – Option +B056 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Table of contents 11

13. The Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Multiple drives (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Multiple drives (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Safety data (SIL, PL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

14. Resistor braking

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Selecting the brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Selecting a custom resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Selecting and routing the brake resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Protecting the system in fault situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Terminals and cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

12 Table of contents

15. Common mode, du/dt and sine filters

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

When is a common mode filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

When is a du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

du/dt filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Description, installation and technical data of the NOCH filters . . . . . . . . . . . . . . . . . . . 232

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Selecting a sine filter for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Description, installation and technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Safety instructions 13

Safety instructions

Contents of this chapter

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

Use of warnings and notes in this manual

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

• Handle the drive carefully.

• Lift the drive with a lifting device. Use the lifting eyes of the drive.

• Do not tilt the drive. The drive is heavy and its center of gravity is high. It will

overturn easily.

• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors, remain hot for a while after disconnection of the electrical supply.

• Keep the drive in its package or protect it from dust and metal shavings from drilling and grinding until you install it. Protect the installed drive against dust and metal shavings. Electrically conductive debris inside the drive can cause damage or malfunction.

• Vacuum clean the area below the drive before the start-up to prevent the drive cooling fan from drawing the dust inside the drive.

• Do not cover the air inlet and outlet when the drive runs.

• Make sure that there is sufficient cooling. See sections Examining the installation

site on page 40 and Losses, cooling data and noise on page 180 for more

information.

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

• 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

Safety instructions 15

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 at start-up. For the Safe torque off, see chapter The Safe torque

off function page 213. For other safety functions, see their separate instructions..

Note:

• If you select an external source for the start command and it is on, the drive will start immediately after fault reset unless you configure the drive for pulse start. See the firmware manual.

• Depending on the wiring and parametrization of the drive, the stop key on the control panel may not stop the drive.

• Only authorized persons are allowed to repair a malfunctioning drive.

16 Safety instructions

Electrical safety in installation, start-up and maintenance

 Precautions before electrical work

These warnings are for all personnel who 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 electrical professional, do not do electrical 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. Lock and tag.

• Open the main disconnector at the power supply of the drive.

• Make sure that reconnection is not possible.

• Disconnect any external power sources from the control circuits.

• 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 input power terminals (L1, L2, L3) and the grounding terminal (PE) is close to 0 V.

• Make sure that the voltage between the drive DC terminals (UDC+ and UDC-) and the grounding terminal (PE) 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.

Safety instructions 17

 Additional instructions and notes

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

• A drive with EMC filter options +E200 and +E202 connected can be installed to a symmetrically grounded TN-S system. If you install the drive to another system, check if you must disconnect the EMC filter. See sections When to disconnect

EMC filter (options E200 and +E202) or ground-to-phase varistor: TN-S, IT, corner-grounded delta, and midpoint-grounded delta systems on page 79 and Guidelines for installing the drive to a TT system on page 80.

WARNING! Do not install the drive with EMC filter options +E200 and +E202 connected to a system that the filter is not suitable for. This can

cause danger, or damage the drive. Note: When EMC filter +E200 and +E202 is disconnected, the drive EMC

compatibility is considerably reduced.

• A drive with the ground-to-phase varistor connected can be installed to a symmetrically grounded TN-S system. If you install the drive to another system, check if you must disconnect the varistor.. See sections When to disconnect EMC

filter (options E200 and +E202) or ground-to-phase varistor: TN-S, IT, cornergrounded delta, and midpoint-grounded delta systems on page 79 and Guidelines for installing the drive to a TT system on page 80.

WARNING! Do not install the drive with the ground-to-phase varistor connected to a system that the varistor is not suitable for. If you do, the

varistor circuit can be damaged.

• 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 terminals (UDC+, UDC-) 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.

18 Safety instructions

 Grounding

These instructions are for all personnel who are responsible for the electrical installation, including 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 electrical professional, do not do grounding work.

• Always ground the drive, the motor and adjoining equipment to the protective earth (PE) bus of the power supply. This is necessary for the personnel safety. Proper grounding also reduces electromagnetic emission and interference.

• In a multiple-drive installation, connect each drive separately to the protective earth (PE) bus of the power supply.

• Make sure that the conductivity of the protective earth (PE) conductors is sufficient. See section Selecting the power cables on page 59. Obey the local regulations.

• Connect the power cable shields to the protective earth (PE) terminals of the drive.

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

Note:

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

• Standard IEC/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 (PE) connection. In addition,

• install a second protective earth conductor of the same cross-sectional area

as the original protective earthing conductor,

• install a protective earth conductor with a cross-section of at least 10 mm

or 16 mm

Al,

• install a device which automatically disconnects the supply if the protective

earth conductor breaks.

Safety instructions 19

Additional instructions for permanent magnet motor drives

 Safety in installation, start-up and maintenance

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

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

• Do not work on a drive when a rotating permanent magnet motor is connected to it. 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/U, T2/V,

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

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

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

• Make sure that the voltage between the drive DC terminals (UDC+, UDC-) and

the grounding (PE) terminal is close to 0 V.

• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W). Connect the output terminals together as well as to the PE.

Start-up and operation:

• Make sure that the operator cannot run the motor over the rated speed. Motor overspeed causes overvoltage that can damage or destroy the capacitors in the intermediate circuit of the drive.

20 Safety instructions

General safety in operation

These instructions are for all personnel that operate the drive.

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

• Do not control the motor with the disconnector at the drive power supply; instead, use the control panel start and stop keys or commands through the I/O terminals of the drive.

• Give a stop command to the drive before you reset a fault. If you have an external source for the start command and the start is on, the drive will start immediately after the fault reset, unless you configure the drive for pulse start. See the firmware manual.

• Before you activate automatic fault reset 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.

Note: When the control location is not set to Local, the stop key on the control panel will not stop the drive.

Additional instruction for DC connection

WARNING! Do not connect the drive DC link to a common DC system. The

drive will get damaged.

Introduction to the manual 21

Introduction to the manual

Contents of this chapter

The chapter describes applicability, target audience and purpose of this manual. It describes the contents of this manual and refers to a list of related manuals for more information. The chapter also contains a flowchart of steps for checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual.

Applicability

The manual applies to the ACS880-31 drives.

Target audience

The reader is 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. Special US instructions for installations in the United States are given.

Purpose of the manual

This manual provides information needed for planning the installation, installing, and servicing the drive.

Categorization by frame (size)

The drive is manufactured in frames. Some instructions and other information which only concern certain frames are marked with the symbol of the frame, for example R3. The frame is marked on the type designation label attached to the drive, see section Type designation label on page 35.

22 Introduction to the manual

Quick installation and commissioning flowchart

Task See

Identify the frame of your drive: R3, R6 or R8. See the type designation label of the drive.

Plan the installation: select the cables, etc. Check the ambient conditions, ratings and

required cooling air flow.

Unpack and check the drive. Unpacking and examining delivery on page

If the drive will be connected to an IT (ungrounded) system or corner-grounded delta system, check that the internal EMC filter and ground-to-phase varistor are not connected.

Install the drive on a wall. Mechanical installation on page 39

Route the cables. Routing the cables on page 65

Check the insulation of the input cable and the motor and the motor cable.

Connect the power cables. Connecting the power cables on page 85

Connect the control cables. Connecting the control cables on page 96

Guidelines for planning the electrical installation on page 51

Technical data on page 163

44,

Checking the compatibility with IT (ungrounded), corner-grounded delta, midpoint-grounded delta, and TT systems on

page 78

Checking the insulation of the assembly on

page 76

Check the installation. Installation checklist on page 143

Commission the drive. Firmware manual

Quick start-up guide for the drive

Terms and abbreviations

Term/abbreviation Explanation

ACX-AP-x Assistant control panel, advanced operator keypad for communication

with the drive.

Introduction to the manual 23

Term/abbreviation Explanation

Brake chopper An external brake chopper conducts the surplus energy from the

Brake resistor Dissipates the drive surplus braking energy conducted by the brake

Control board Circuit board in which the control program runs. Capacitor bank See DC link capacitors. DC link DC circuit between rectifier and inverter DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage DPMP-01 Control panel mounting platform (flush) DPMP-02 Control panel mounting platform (surface) Drive Frequency converter for controlling AC motors EMC Electromagnetic compatibility EFB Embedded fieldbus FAIO-01 Optional analog I/O extension module FCAN-01 Optional CANopen adapter module FCNA-01 ControlNet adapter module FDIO-01 Optional digital /O extension module FECA-01 Optional EtherCAT adapter module FENA-21 Optional Ethernet adapter module for EtherNet/IP, Modbus TCP and

FEPL-02 Optional Ethernet POWERLINK adapter module FIO-01 Optional digital I/O extension module FIO-11 Optional analog I/O extension module FPBA-01 Optional PROFIBUS DP adapter module FSO-12 Optional functional safety module FSO-21 Optional functional safety module Frame (size) Refers to drive physical size, for example R3. The type designation

I/O Input/Output IGBT Insulated gate bipolar transistor Intermediate circuit See DC link. Inverter Converts direct current and voltage to alternating current and voltage. NETA-21 Remote monitoring tool

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.

chopper to heat. Essential part of the brake circuit. See Brake chopper.

PROFINET IO protocols

label attached to the drive shows the frame of the drive, see section

Type designation key on page 36.

24 Introduction to the manual

Term/abbreviation Explanation

Network control With fieldbus protocols based on the Common Industrial Protocol

Parameter User-adjustable operation instruction to the drive, or signal measured or

PLC Programmable logic controller PROFIBUS,

PROFIBUS DP, PROFINET IO

PTC Positive temperature coefficient (PTC) refers to materials that

R3, R6, R8 Frame (size) Rectifier Converts alternating current and voltage to direct current and voltage. STO Safe torque off. See chapter The Safe torque off function on page 213.

(CIP

), such as DeviceNet and Ethernet/IP, denotes the control of the drive using the Net Ctrl and Net Ref objects of the ODVA AC/DC Drive Profile. For more information, see www.odva.org manuals:

• FDNA-01 DeviceNet adapter module user’s manual (3AFE68573360

[English]), and

• FENA-01/-11/-21 Ethernet adapter module user’s manual

(3AUA0000093568 [English]).

calculated by the drive

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experience an increase in electrical resistance when their temperature is raised.

, and the following