ABB ACS880-M04 Hardware Manual
ABB machinery drives
Hardware manual
ACS880-M04 drive
List of related manuals
Drive manuals and guides Code (English)
ACS880-M04 firmware manual
ACS880-M04 hardware manual
ACS880-M04 quick installation guide
Option manuals and guides
ACX-AP-X Assistant control panels user’s manual 3AUA0000085685
ACS-BP-S Basic control panel user’s manual 3AXD50000032527
ACS880-01 drives and ACS880-04 drive modules
Common DC systems Application guide
Drive (IEC 61131-3) application programming manual 3AUA0000127808
FDPI-02 diagnostics and panel interface user’s manual 3AUA0000113618
FSO-12 safety functions module user’s manual 3AXD50000015612
Technical Guide No. 3 – EMC Compliant Installation and
Configuration for a Power Drive System
Converter module capacitor reforming instructions 3BFE64059629
Manuals and quick guides for I/O extension modules,
fieldbus adapters, safety options, etc.
Tool and maintenance manuals and guides
Drive composer PC tool user's manual 3AUA0000094606
You can find manuals and other product documents in PDF format on the Internet. See section Document
library on the Internet
contact your local ABB representative.
on the inside of the back cover. For manuals not available in the Document library,
3AXD50000030629
3AXD50000028613
3AXD50000032345
3AUA0000127818
3AFE61348280
Hardware manual
ACS880-M04 machinery drive
Table of contents
1. Safety instructions
5. Mechanical installation
7. Electrical installation
9. Start-up
2016 ABB Oy. All Rights Reserved.
3AXD50000028613 Rev A
EN
EFFECTIVE: 2016-04-11
Table of contents 5
Table of contents
List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use of warning and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. About the manual
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Categorization according to frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Quick installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Safety
3. Operation principle and hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ACS880-M04 drive overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Module layout – Frame R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Module layout – Frame R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4. Planning the cabinet installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cabinet frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Disposition of devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6 Table of contents
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Vertically alone or side by side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Horizontally alone or side by side back installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Horizontally alone side installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Preventing recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cabinets with multiple modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Delivery check and drive module identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Before installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Required tools for installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installing the drive with screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installing drive to a DIN installation rail – Frames R1 and R2 only . . . . . . . . . . . . . . . . . 53
Installing mains choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installing EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installing brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6. Planning the electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Requirements in European Union (EU) countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Requirements in non-EU countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Signals run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Drive composer PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
FPBA-01 PROFIBUS DP adapter module connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Cable routing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . . 65
Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table of contents 7
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 66
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Protecting the drive and the input power and motor cables against thermal overload . . . 66
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Example of a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Changing the motor power supply from the drive to direct-on-line . . . . . . . . . . . . . . . . . . 70
Changing the motor power supply from direct-on-line to the drive . . . . . . . . . . . . . . . . . . 70
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Removing the cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Motor and motor cable insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Break resistor assembly insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Checking the compatibility with IT (ungrounded) and corner-grounded TN systems . . . . . . . 76
Disconnecting the internal EMC filter – all frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Installing the power cable clamp plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Power cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Installing the optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connecting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
ZCU-14 layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Control connections to the ZCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
DI6 as a PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
AI1 or AI2 as a Pt100 or KTY84 sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DIIL input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Drive-to-drive link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Safe torque off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Safety functions (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Control unit connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Ground isolation diagram (ZCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connecting the control cables – all frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8 Table of contents
8. Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9. Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Replacing fan (Frames R1 and R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Replacing fan (Frames R3 and R4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
11. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Nominal ratings with 230 V AC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Nominal ratings with 400 V AC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Nominal ratings with 460 V AC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Nominal ratings with 500 V AC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Low motor noise derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Terminal and lead-through data for power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Screwdrivers for the terminals of main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Supply cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
gR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
AC input (supply) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
ZCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Ground isolation diagram (ZCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Table of contents 9
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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
Compliance with the EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
12. The Safe torque off function
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Compliance of STO function with the European Machinery Directive . . . . . . . . . . . . . . . . . . 142
Connecting the STO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
STO wiring – single drive unit (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . 144
STO wiring – multiple drive units (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . 145
STO wiring – multiple drive units (external power supply) . . . . . . . . . . . . . . . . . . . . . . . 146
STO operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
STO start-up and acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Competency for testing STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
STO acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
STO acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Using the STO function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
STO function maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Competency for STO operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
STO fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Relevant failure modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
STO data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Temperature profile for safety value calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
STO indication data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
STO abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
13. Mains chokes
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
When is a mains choke required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10 Table of contents
Selecting a mains choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Guidelines for installing the mains choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Connecting the mains choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
14. EMC filters
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
EMC standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
EMC filter emission limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
EMC filtering option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Selecting EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Installing EMC filters – JFI-A1/JFI-B1 (Frame R1/R2, category C3) . . . . . . . . . . . . . . . . . . 162
JFI-x1 filter installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
JFI-x1 filter connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Installing the JFI-A1 filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Installing the JFI-B1 filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Installing EMC filter – JFI-0x (Frames R1…R4, category C2) . . . . . . . . . . . . . . . . . . . . . . . 167
JFI-0x filter installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
JFI-0x filter connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
15. du/dt and common mode filtering
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
When is du/dt or common mode filtering required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Selecting the du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_
171
Additional requirements for the braking applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Installing du/dt and common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
du/dt filters data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
du/dt filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Common mode filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
du/dt filters dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
du/dt filters degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
16. Resistor braking
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Selecting brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Brake choppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Brake choppers data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Brake resistors data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Brake resistors degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Brake resistors dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Installing and wiring brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Contactor protection of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Commissioning the braking circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
17. Dimension drawings
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Table of contents 11
Frame size R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Frame size R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Frame size R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Frame size R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Mains chokes (type CHK-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Mains choke – CHK-xx dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
EMC filters (type JFI-x1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
JFI-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
JFI-B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
EMC filters (type JFI-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
EMC filter – JFI-xx dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Brake resistors (type JBR-xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Brake resistor - JBR-xx dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
12 Table of contents
Safety instructions 13
1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must follow 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 warning 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.
Hot surface warning warns you of component surfaces that may become hot
enough to cause burns if touched.
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.
WAR N ING! Follow these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
• Handle the drive carefully.
• Use safety shoes with a metal toe cap to avoid foot injury.
• Keep the drive in its package or protect it otherwise from dust and burr from
drilling and grinding until you install it.
• Protect also the installed drive against dust and burr. Electrically conductive
debris inside the drive may 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. For more information, see sections
Checking the installation site on page 51 and Losses, cooling data and noise on
page 117.
• 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 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.
• 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. The maximum
number of times the circuit can charge is: 100000 (frames R1-R2) and 50000
(frames R3-R4).
If you have connected safety circuits to the drive (for example, emergency stop and
Safe torque off), validate them at the start up.
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.
• When the control location is not set to Local, the stop key on the control panel will
not stop the drive.
Drives can be repaired only by an authorized person.
Safety instructions 15
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! Follow 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 the 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.
• Open the main disconnector at the power supply of the drive.
• Make sure that reconnection is not possible. Lock the disconnector to open
position and attach a warning notice to it.
• Disconnect any external power sources from the control circuits before you do
work on the control cables.
CAUTION - Risk of electric shock. After disconnecting the input power, always
wait for 5 minutes to let the intermediate circuit capacitors discharge before you
start working on the drive, motor or motor cable.
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.
16 Safety instructions
Additional instructions and notes
WAR N ING! Follow these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
• If you install the drive on an IT system (an ungrounded power system or a highresistance-grounded [over 30 ohms] power system), disconnect the internal EMC
filter; otherwise the system will be connected to ground potential through the EMC
filter capacitors. This can cause danger or damage the drive. See page 76.
Note: Disconnecting the internal EMC filter increases the conducted emission
and reduces the drive EMC compatibility considerably. See section Compliance
with the European EMC Directive on page 134.
• If you install the drive on a corner-grounded TN system, disconnect the internal
EMC filter; otherwise the system will be connected to ground potential through the
EMC filter capacitors. This will damage the drive. See page 159.
Note: Disconnecting the internal EMC filter increases the conducted emission
and reduces the drive EMC compatibility considerably. See section Compliance
with the European EMC Directive on page 134.
• Use all ELV (extra low voltage) circuits connected to the drive only within a zone
of equipotential bonding, that is, within a zone where all simultaneously
accessible conductive parts are electrically connected to prevent hazardous
voltages appearing between them. You can accomplish this by a proper factory
grounding, that is, make sure that all simultaneously accessible conductive parts
are grounded to the protective earth (PE) bus of the building.
• 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 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.
• 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 components on the boards
are sensitive to electrostatic discharge.
Safety instructions 17
Grounding
These instructions are for all personnel who are responsible for the electrical
installation, including the grounding of the drive.
WARNING! Follow 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 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 57. 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,
or
• install a protective earth conductor with a cross-section of at least 10 mm
or 16 mm
2
Al,
2
Cu
or
• install a device which automatically disconnects the supply if the protective
earth conductor breaks.
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! Follow 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 explode the capacitors in the
intermediate circuit of the drive.
Safety instructions 19
General safety in operation
These instructions are for all personnel that operate the drive.
WARNING! Follow 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.
20 Safety instructions
About the manual 21
2
About the manual
Contents of this chapter
This chapter describes the intended audience and contents of this 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.
Applicability
This manual applies to the ACS880-M04 drive module of frame sizes R1 to R4.
Intended audience
This manual is intended for people who plan the installation, install, commission, use
and service the drive. Read the manual before working on the drive. The reader is
expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
This manual is written for readers worldwide. Both SI and imperial units are shown
wherever appropriate.
Categorization according to frame size
The ACS880-M04 drive is manufactured in frame sizes R1 to R4. Some instructions,
technical data and dimensional drawings which concern only certain frame sizes are
marked with the symbol of the frame size (R1, R2, R3, R4). The frame size is marked
on the drive designation label. See also the frame size of each drive type in the
ratings tables in chapter Technical data.
22 About the manual
Categorization according to the + code
The instructions, technical data and dimensional drawings which concern only certain
optional selections are marked with + codes, e.g. +L500. The options included in the
drive can be identified from the + codes visible on the type designation label of the
drive. See the + code selections listed in Type designation label on page 35.
Contents of the manual
This manual consists of the following chapters:
Safety instructions give safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About the manual describes the applicability and intended audience of this manual. It
also includes a flow chart of steps to check the delivery of the drive for installing and
commissioning.
Operation principle and hardware description describes the drive module.
Planning the cabinet installation guides in planning the installation of the drive module
into a user-defined cabinet.
Mechanical installation instructs how to place and mount the drive.
Planning the electrical installation instructs on the motor and cable selection, the
protections and the cable routing.
Electrical installation instructs on how to wire the drive.
Installation checklist contains a list for checking the mechanical and electrical
installation of the drive.
Start-up refers to the start-up instructions of the drive.
Maintenance lists periodic maintenance actions along with work instructions.
Technical data contains technical specifications of the drive, for example, ratings,
sizes, technical requirements and provisions for fulfilling the requirements for valid
markings.
The Safe torque off function briefs the Safe torque off (STO) function of the drive
modules and gives instructions for its use.
Mains chokes briefs the optional mains chokes available for the drive.
EMC filters briefs the EMC filtering options available for the drive.
About the manual 23
du/dt and common mode filtering lists the du/dt and common mode filtering options
available for the drive.
Resistor braking describes how to select, protect and wire brake resistors.
Dimension drawings contains the dimensional drawings of the drive and connected
equipment.
24 About the manual
Quick installation and commissioning flowchart
Task Re f er t o
Identify the frame size of your drive:
R1, R2, R3, R4.
Plan the installation. Select the cables, 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 drive.
Check that all necessary optional modules
and equipment are present and correct.
Only intact units may be started up.
Check the installation site. Checking the installation site on page 51.
Install the drive in a cabinet. Installing the drive on page 52.
Type designation label on page 51.
Planning the cabinet installation on page 39.
Planning the electrical installation on page 55.
Technical data on page 110.
Option manual (if optional equipment is
included)
Contents of the package on page 49.
Delivery check and drive module identification
on page 50.
If the converter was non-operational for more
than one year, reform the converter DC link
capacitors. For more information, contact your
ABB representative.
Route the cables. Routing the cables on page 64.
Check the insulation of the supply cable, the
motor and the motor cable, and the resistor
cable (if present).
Checking the insulation of the assembly on
page 75.
Task Refer to
About the manual 25
If the drive is about to be connected to an IT
(ungrounded) system, disconnect the internal
varistors and EMC filters. Also note that using
an EMC filter is not allowed in an IT
(ungrounded) system.
Connect the power cables. Connecting the power cables on page 77.
Connect the control and the auxiliary control
cables.
Check the installation. Installation checklist on page 99.
Commission the drive. Start-up on page 101.
Electrical safety in installation, start-up and
maintenance on page 15.
Checking the compatibility with IT
(ungrounded) and corner-grounded TN
systems on page 76.
Connecting the control unit on page 85.
For optional equipment:
Mains chokes on page 155.
EMC filters on page 159.
Resistor braking on page 173.
Manuals for any optional equipment
Firmware manual [3AXD50000030629
(English)]
Commission the brake chopper if required. Resistor braking on page 173.
Operate the drive: start, stop, speed control
etc.
Firmware manual [3AXD50000030629
(English)]
26 About the manual
Terms and abbreviations
Term/Abbreviation Explanation
Brake chopper Conducts the surplus energy from the intermediate circuit of the
Brake resistor Dissipates the drive surplus braking energy conducted by the
Control board Circuit board in which the control program runs.
Capacitor bank Refer to DC link capacitors.
DC link DC circuit between rectifier and drive
DC link capacitors Energy storage which stabilizes the intermediate circuit DC
Drive Frequency converter for controlling AC motors
EFB Embedded fieldbus
EMC Electromagnetic compatibility
FBA Fieldbus adapter
FCAN-01/-01-M Optional CANopen adapter module
FCNA-01 ControlNet adapter module
FDNA-01 Optional DeviceNet adapter module
FECA-01/-01-M Optional EtherCAT adapter module
FENA-01/-11/-21/-21-M Optional Ethernet adapter module for EtherNet/IP, Modbus TCP
FEPL-02 Ethernet POWERLINK adapter module
FPBA-01/-01-M Optional PROFIBUS DP adapter module
Frame (size) Refers to drive physical size, for example R1 and R2. The type
FSCA-0x Optional Modbus/RTU adapter module
IGBT Insulated Gate Bipolar Transistor; a voltage-controlled
I/O Input/Output
JBR-xx Series of optional brake resistors
JFI-xx Series of optional EMC filters
JPU/RPU Power unit; see the definition below.
Power unit Contains the power electronics and connections of the drive
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.
brake chopper to heat. Essential part of the brake circuit. Refer
to Brake chopper.
voltage
and PROFINET IO protocols
designation label attached to the drive shows the frame of the
drive, refer to Type designation key on page 34.
semiconductor type widely used in drives due to their easy
controllability and high switching frequency.
module. The ZCU is connected to the power unit.
About the manual 27
Term/Abbreviation Explanation
RFI Radio-frequency interference
ZMU The memory unit attached to the control unit of the drive.
ZCU The control unit of the drive module. The ZCU is installed on top
of the power unit. The external I/O control signals are connected
to the ZCU, or optional I/O extensions mounted on it.
28 About the manual
Operation principle and hardware description 29
3
Operation principle and hardware description
Contents of this chapter
The chapter describes the operating principle and construction of the drive module.
ACS880-M04 drive overview
The ACS880-M04 is an air-cooled IP20 drive module for controlling asynchronous
induction motors, permanent magnet motors and ABB synchronous reluctance
motors. It is optimized for cabinet mounting.
The drive is available in several frame sizes depending on the output power. All frame
sizes use the same control unit of ZCU type.
30 Operation principle and hardware description
Motor output
Brake chopper (see chapter
Resistor braking on page
173)
+–
UDC+ UDC– V1 W1U1
V2 W2U2 R– R+
AC supply
ACS880-M04
drive
Capacitor bank
Rectifier
CHK-xx mains choke (see
chapter Mains chokes on
page 155)
JFI-xx EMC filter (see chapter
EMC filters on page 159)
JBR-xx brake resistor (see
chapter Resistor braking on
page 173)
NOCHxxxx-xx du/dt filter
(see chapter du/dt and
common mode filtering
on page 169)
Operation principle
Main circuit
Motor control
The motor control is based on direct torque control. Two phase currents and DC link
voltage are measured and used for the control. The third phase current is measured
for earth fault protection.
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