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ABB ACS880-37 Hardware Manual
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ABB ACS880-37 Hardware Manual

160 to 3200 kw
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ACS880-37 drives (160 to 3200 kW)

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Summary of Contents for ABB ACS880-37

  • Page 1 ABB industrial drives Hardware manual ACS880-37 drives (160 to 3200 kW)
  • Page 2 You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative. ACS880-37 (160 to 3200 kW) manuals...

  • Page 3: Effective: 2017

    Hardware manual ACS880-37 drives (160 to 3200 kW) Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 9. Start-up  2017 ABB Oy. All Rights Reserved. 3AXD50000020437 Rev B EFFECTIVE: 2017-03-27...

  • Page 5: Table Of Contents

    Table of contents 1. Safety instructions Contents of this chapter ..........15 Use of warnings and notes .
  • Page 6 Definitions ............45 IP22 (standard) .
  • Page 7 Additional requirements for braking applications ......79 Additional requirements for ABB high-output and IP23 motors ....79 Additional requirements for non-ABB high-output and IP23 motors .
  • Page 8 Signals in separate cables ..........86 Signals allowed to be run in the same cable .
  • Page 9 Wiring the Pt100 relays (option +nL514) ....... 106 Powering the heating and lighting equipment (options +G300, +G301 and +G313) . Wiring ground fault monitoring for IT ungrounded systems (option +Q954) .
  • Page 10 9. Start-up Contents of this chapter ..........145 Start-up procedure .
  • Page 11 Control panel ............176 Replacing the battery .
  • Page 12 3×R8i + 3×R8i ........... . . 204 ACS880-37-1210A-3, -1430A-3, -1700A-3, -1530A-5 ..... . 204 4×R8i + 4×R8i .
  • Page 13 Units with main breaker (600 mm), top cable entry ......226 Location and size of output terminals (units without common motor terminal cubicle) . 227 Frame 1×R8i + 1×R8i (without sine output filter) .
  • Page 14 Product training ............257 Providing feedback on ABB Drives manuals ....... . 257...

  • Page 15: Safety Instructions

    Safety instructions 15 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 Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 16: General Safety In Installation, Start-Up And Maintenance

    Do not use the module extraction/installation ramp with plinth heights over 50 mm (2”). The ramp supplied with the drive system is designed for a plinth height of 50 mm (2”) (the standard plinth height of ABB cabinets). • Secure the module extraction/installation ramp carefully.
  • Page 17 Safety instructions 17 Support the top and Do not tilt! Do not leave the module bottom of the module unattended on a sloping floor! when extracting it from the cubicle! 50 mm (2”) max. Lift the module by the upper part Mind your fingers! Keep fingers Support the top and bottom only using the lifting eyes at the...
  • Page 18 18 Safety instructions • Keep the cabinet doors closed when the drive is powered. With the doors open, a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists. If you cannot avoid working on a powered drive, obey the local laws and regulations on live working (including –...

  • Page 19: Electrical Safety In Installation, Start-Up And Maintenance

    Safety instructions 19 Electrical safety in installation, start-up and maintenance Electrical safety precautions  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.

  • Page 20: Additional Instructions And Notes

    20 Safety instructions Additional instructions and notes  WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you are not a qualified electrician, do not do electrical installation or maintenance work.

  • Page 21: Grounding

    Safety instructions 21 Grounding  These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase. •...

  • Page 22: Additional Instructions For Permanent Magnet Motor Drives

    22 Safety instructions Additional instructions for permanent magnet motor drives Safety in installation, start-up and maintenance  These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death and damage to the equipment can occur.

  • Page 23: Introduction To The Manual

    Introduction to the manual 23 Introduction to the manual Contents of this chapter This chapter describes the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals.

  • Page 24: Related Documents

    24 Introduction to the manual Electrical installation gives instructions on wiring the drive. Control units of the drive contains the default I/O connection diagrams, descriptions of the terminals and technical data for the control units of both the supply and inverter units. Installation checklist contains a list for checking the mechanical and electrical installation of the drive.

  • Page 25: Quick Installation, Commissioning And Operation Flowchart

    Introduction to the manual 25 Quick installation, commissioning and operation flowchart Task Plan the electrical installation and acquire the accessories needed Guidelines for planning the (cables, fuses, etc.). electrical installation (page 75) Check the ratings, required cooling air flow, input power connection, Technical data (page 179) compatibility of the motor, motor connection, and other technical...

  • Page 26: Terms And Abbreviations

    (aka line-side converter) and the inverter unit (aka motor-side converter) connected together by the DC link. In this manual, the term refers to the ACS880-37 as a whole. Electromagnetic compatibility Electromagnetic interference Electrical metallic tubing FAIO-01 Optional analog I/O extension module...

  • Page 27: Safety Data (Sil, Pl)

    Introduction to the manual 27 Term/ Explanation Abbreviation Inverter unit The part of the drive that converts DC to AC for the motor. Consists of one or more inverter modules and their auxiliary components. The inverter unit is also capable of feeding energy from a decelerating motor into the DC link.
  • Page 28 28 Introduction to the manual...

  • Page 29: Operation Principle And Hardware Description

    This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACS880-37 is a low-harmonic, air-cooled, cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance (SynRM) motors.

  • Page 30: Ac Voltage And Current Waveforms

    ACS880-37 supply module only. For example, a module with +N8201 cannot be used as an inverter module. On the other hand, it is possible to use a module without +N8201 as a spare part for an ACS880-37 supply module as long as the types of the modules are otherwise the same.

  • Page 31: Overview Circuit Diagram Of The Drive

    *Main contactor [Q2] *With drive types ACS880-37-1210A-3, -1430A-3, -1530A-5, -1450-7 and -1680-7, these items can be replaced by an air circuit breaker [Q1] by selecting option +F255. Larger drive types have an air circuit breaker as standard equipment. Drives with an air circuit breaker have AC fuses only at the input of each LCL filter.

  • Page 32: Cabinet Line-Up And Layout Examples

    32 Operation principle and hardware description Cabinet line-up and layout examples Frame 1×R8i + 1×R8i  Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See page 38. Supply and inverter module cubicle. Contains the supply module, LCL filter, inverter module and switchgear, as well as the power cable terminals.
  • Page 33 Operation principle and hardware description 33 Cabinet layout example Auxiliary control cubicle (ACU). See page 38. Input cable lead-throughs, PE busbar LCL filter module Input terminals (behind LCL filter module) Main switch/disconnector [Q1.1] (behind mounting plate) AC fuses (behind mounting plate) Fuse disconnectors for auxiliary voltage [F20.x] Main contactor [Q2.1] Charging fuse switch [Q3]...

  • Page 34: Frame 2×R8I + 2×R8I

    34 Operation principle and hardware description Frame 2×R8i + 2×R8i  Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See page 38. Incoming cubicle. Contains the input terminals, switchgear and charging equipment. Supply module cubicle. Contains two R8i supply modules together with an LCL filter module. Inverter module cubicle.
  • Page 35 Operation principle and hardware description 35 Cabinet layout example Auxiliary control cubicle (ACU). See page 38. Input cable lead-throughs, PE busbar Input terminals Main switch-disconnector [Q1.1] Grounding/earthing switch [Q9.1] (option +F259) AC fuses Charging resistors and contactor Main contactor (behind charging equipment) Auxiliary voltage switch [Q21] Charging switch [Q3] Incoming cubicle cooling fan...

  • Page 36: Frame 3×R8I + 3×R8I (With Main Breaker)

    36 Operation principle and hardware description Frame 3×R8i + 3×R8i (with main breaker)  Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See page 38. Incoming cubicle. Contains the input terminals, switchgear and charging equipment. Supply module cubicle (1).
  • Page 37 Operation principle and hardware description 37 Cabinet layout example Auxiliary control cubicle (ACU). See page 38. Input cable lead-throughs, PE busbar Input terminals Charging resistors Incoming cubicle cooling fans (behind the charging resistor mounting plate) Main breaker [Q1] Charging switch [Q3] Auxiliary voltage switch [Q21] Grounding/earthing switch [Q9.1] (option +F259) Charging contactor (behind auxiliary equipment)

  • Page 38: Auxiliary Control Cubicle (Acu) Layout

    38 Operation principle and hardware description Auxiliary control cubicle (ACU) layout  A layout example of the auxiliary control cubicle (ACU) is shown below. Swing-out frame closed, Swing-out frame open, detachable mounting plates in place without detachable mounting plates 17 18 Fuse-disconnectors F101.
  • Page 39 Operation principle and hardware description 39 Switch F90 for ground fault monitoring (item 12) 24 Motor fan starters and contactors (options +M602…610) FSO-xx safety functions module (option +Q973 25 Terminal blocks X601 for motor fan connections and other options requiring FSO-xx) (options +M602…610) Temperature monitoring relays (options +L505 26 24 V DC power supply for cabinet lighting...

  • Page 40: Overview Of Power And Control Connections

    40 Operation principle and hardware description Overview of power and control connections The diagram shows the power connections and control interfaces of the drive. ACS880-37 Supply control unit [A51] Inverter control unit [A41] Slots 1, 2 and 3 Slot 4 X205 V1T/R…...
  • Page 41 Operation principle and hardware description 41 Terminal blocks for customer connections installed in the drive cabinet. For the locations, see Auxiliary control cubicle (ACU) layout (page 38). Wiring details are given starting on page 103. Supply unit (consisting of one or more supply modules and LCL filters) DC link Inverter unit (consisting of one or more inverter modules) Optional brake chopper (+D150) and resistors (+D151)

  • Page 42: Door Switches And Lights

    42 Operation principle and hardware description Door switches and lights Label in English Label in local Description language READY Ready light (option +G327) Run light (option +G328) FAULT Fault light (option +G329) RUN/ENBL Run enable signal switch for the supply unit OFF Run enable signal off (starting the supply unit not allowed) Run enable signal on...

  • Page 43: Main Disconnecting Device [Q1.1]

    Operation principle and hardware description 43 Main disconnecting device [Q1.1] Depending on the configuration of the drive, the main disconnecting device of the drive is either a switch-disconnector or a main circuit breaker. Units with a switch-disconnector also have a main contactor. The main disconnecting device switches the main supply to the drive on and off.

  • Page 44: Control Panel

    44 Operation principle and hardware description Control panel  The ACS-AP-W is the user interface of the drive. It provides the essential controls such as Start/Stop/Direction/Reset/Reference, and the parameter settings for the inverter control program. The control panel can be removed by pulling it forward by the top edge and reinstalled in reverse order.

  • Page 45: Descriptions Of Options

    Operation principle and hardware description 45 Descriptions of options Note: All options are not available for all drive types, do not coexist with certain other options, or may require additional engineering. Check actual availability with ABB. Degree of protection ...

  • Page 46: Marine Construction (Option +C121)

    46 Operation principle and hardware description Marine construction (option +C121)  The option includes the following accessories and features: • reinforced mechanics • grab railings • door flush bolt which allows the door to open 90 degrees and prevents it from slamming close •...

  • Page 47: Resistor Braking (Options +D150 And +D151)

    Operation principle and hardware description 47 Resistor braking (options +D150 and +D151)  See chapter Resistor braking on page 249. EMC filters (option + E202)  See section Type designation key on page and sections Compliance with the European EMC Directive on page Compliance with EN 61800-3:2004 on page 196.

  • Page 48: Output For Motor Space Heater (Option +G313)

    48 Operation principle and hardware description Output for motor space heater (option +G313)  The option contains: • load switch for providing electrical isolation during service • miniature circuit breaker for overcurrent protection • terminal block for external supply and heating element(s) connection The heater is off when the drive is running.

  • Page 49: Additional Wire Markings

    Operation principle and hardware description 49 Additional wire markings The following additional wire markings are available. Option Additional markings +G340 Equipment pin numbers are marked with snap-on markers on wires between modules and on wires connected to equipment, terminal blocks and detachable screw terminals. Plug-in connector identifications are marked on labels near the connectors.

  • Page 50: Common Output Terminal (Option +H366)

    50 Operation principle and hardware description Note that this option is not available with option +E206 (sine filters) – in this case, the motor cables are connected to the sine filter cubicle. Common output terminal (option +H366)  As standard, each inverter module must be individually cabled to the motor. This option adds bridging that connects the outputs of multiple (in practice, two or three) inverter modules mounted in the same cubicle.

  • Page 51: L505, +2L505, +L513, +2L513

    Operation principle and hardware description 51 +L505, +2L505, +L513, +2L513 Option +L505 provides a thermistor relay and a terminal block. The terminal block has connections for the measuring circuit (one to three PTC sensors in series), the output indication of the relay, and an optional external reset button. The relay can be reset either locally or externally, or the reset circuit can be jumpered for automatic reset.

  • Page 52: Thermal Protection With Pt100 Relays (Options +Nl506 And +Nl514)

    52 Operation principle and hardware description Thermal protection with Pt100 relays (options +nL506 and +nL514)  Pt100 temperature monitoring relays are used for overtemperature supervision of motors equipped with Pt100 sensors. For example, there can be three sensors to measure the temperature of the motor windings and two sensors for the bearings.

  • Page 53: Starter For Auxiliary Motor Fan (Options +M602

    Operation principle and hardware description 53 Starter for auxiliary motor fan (options +M602…+M610)  What the option contains The option provides switched and protected connections for 3-phase auxiliary motor fans. Each fan connection is equipped with • fuses • a manual motor starter switch with an adjustable current limit •...

  • Page 54: Type Designation Label

    54 Operation principle and hardware description Type designation label The type designation label includes ratings, appropriate markings, a type designation and a serial number, which allow the identification of each unit. A sample label is shown below. Quote the complete type designation and serial number when contacting technical support.

  • Page 55: Type Designation Key

    Type designation key The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (eg, ACS880-37-1210A-3). The optional selections are given thereafter, separated by plus signs, eg, +E202. The main selections are described below.
  • Page 56 56 Operation principle and hardware description CODE DESCRIPTION Line options F255 Main (air circuit) breaker (instead of line contactor) F259 Grounding (earthing) switch Cabinet equipment G300 Cabinet and module heating elements (external supply) (page 47) G301 Cabinet lighting (page 47) G307 Terminals for connecting external control voltage (230 V AC or 115 V AC, eg.
  • Page 57 Operation principle and hardware description 57 CODE DESCRIPTION L514 ATEX-certified thermal protection with Pt100 relays (3, 5 or 8 pcs) (page 52) L515 FEA-03 I/O extension adapter L516 FEN-21 resolver interface module L517 FEN-01 TTL incremental encoder interface module L518 FEN-11 TTL absolute encoder interface module L521 FSE-31 pulse encoder interface module...
  • Page 58 58 Operation principle and hardware description CODE DESCRIPTION Q978 Emergency stop (configurable for category 0 or 1) with FSO-xx safety functions module, by opening the main breaker/contactor Q979 Emergency stop (configurable for category 0 or 1) with FSO-xx safety functions module, by activating the Safe torque off function Q982 PROFIsafe with FSO-xx safety functions module and FENA-21 Ethernet adapter module...

  • Page 59: Mechanical Installation

    Mechanical installation 59 Mechanical installation Contents of this chapter This chapter describes the mechanical installation procedure of the drive. Examining the installation site Examine the installation site: • The installation site is sufficiently ventilated or cooled to transfer away the drive losses.

  • Page 60: Necessary Tools

    60 Mechanical installation Necessary tools The tools required for moving the unit to its final position, fastening it to the floor and wall and tightening the connections are listed below: • crane, fork-lift or pallet truck (check load capacity!), slate/spud bar, jack and rollers •...

  • Page 61: Moving And Unpacking The Drive

    Mechanical installation 61 Moving and unpacking the drive Move the drive in its original packaging to the installation site as shown below to avoid damaging the cabinet surfaces and door devices. When you are using a pallet truck, check its load capacity before you move the drive. The drive cabinet is to be moved in the upright position.

  • Page 62: Lifting The Crate With A Crane

    62 Mechanical installation Lifting the crate with a crane Position each sling as close to a transverse board as possible. We recommend the use of transverse spreader bars. Lifting point...

  • Page 63: Moving The Crate With A Forklift

    Mechanical installation 63 Moving the crate with a forklift Free width for fork tines: 750 mm (29.5”)

  • Page 64: Removing The Transport Package

    64 Mechanical installation Removing the transport package  Remove the transport package as follows: 1. Undo the screws that attach the wooden parts of the transport crate together. 2. Remove the wooden parts. 3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws.

  • Page 65: Moving The Cabinet On Rollers

    Mechanical installation 65 Moving the cabinet on rollers WARNING: Do not move marine versions (option +C121) on rollers. Lay the cabinet on the rollers and move it carefully until close to its final location. Remove the rollers by lifting the unit with a crane, forklift, pallet truck or jack. Moving the cabinet on its back WARNING: Transportation of the cabinet on its back is only allowed with the BLCL (LCL filter) modules and sine filters (option +E206) removed from the...

  • Page 66: Final Placement Of The Cabinet

    66 Mechanical installation Final placement of the cabinet Move the cabinet into its final position with a slate bar (spud bar). Place a piece of wood between the edge of the cabinet and the bar to protect the cabinet frame.

  • Page 67: Fastening The Cabinet To The Floor And Wall Or Roof (Non-Marine Units)

    Mechanical installation 67 Fastening the cabinet to the floor and wall or roof (non-marine units) General rules  • The drive must be installed in an upright vertical position. • The cabinet can be installed with its back against a wall (a), or back-to-back with another unit (b).

  • Page 68: Fastening Methods

    68 Mechanical installation Fastening methods  Fasten the cabinet to the floor by using the clamps included along the edge of the cabinet bottom, or by bolting the cabinet to the floor through the holes inside (if they are accessible). Alternative 1 –...

  • Page 69: Fastening The Cabinet To The Floor And Roof/Wall (Marine Units, +C121)

    Mechanical installation 69 Fastening the cabinet to the floor and roof/wall (marine units, +C121) Follow the general rules given in section General rules on page 67. See the dimension drawing delivered with the drive for the locations of the fastening holes in the flat bars below the cabinet and for fastening points at the top of the cabinet.

  • Page 70: Joining Shipping Splits Together

    70 Mechanical installation Joining shipping splits together Wide cabinet line-ups are delivered in multiple parts called “shipping splits”. The connection is made using a 200 mm wide joining cubicle at the end of one shipping split (a common motor terminal cubicle can also act as a joining cubicle). The screws required for the joining are enclosed in a plastic bag inside the cabinet.
  • Page 71 Mechanical installation 71 7. Remove the shroud covering the DC busbars in the joining cubicle. 8. Use the joint pieces to connect the DC busbars. Tighten the bolts to 55…70 N·m (40…50 lbf·ft). Units with single DC busbars 55…70 N·m (40…50 lbf·ft) Units with double DC busbars Joint piece...

  • Page 72: Miscellaneous

    72 Mechanical installation Miscellaneous Cable duct in the floor below the cabinet  A cable duct can be constructed below the 500 mm wide middle part of the cabinet. The cabinet weight lies on the two 50 mm wide transverse sections which the floor must carry. Prevent the cooling air flow from the cable duct to the cabinet by bottom plates.

  • Page 73: Air Outlet Duct On The Cabinet Roof (Option +C130)

    = 0.5 • • v = 0.5 • 1.1 • 5.5 = 17 Pa The required pressure in the exit air duct is then, 1.5…2 • 17 Pa = 26…34 Pa, below the pressure in the room. For more information: Contact ABB.

  • Page 74: Arc Welding

    74 Mechanical installation Arc welding  Fastening the cabinet by arc welding is not recommended. However, if arc welding is the only mounting option, connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1’6”) of the welding point. Note: The thickness of the zinc coating of the cabinet frame is 100 to 200 micrometers (4 to 8 mil).

  • Page 75: Guidelines For Planning The Electrical Installation

    ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 76: Examining The Compatibility Of The Motor And Drive

    76 Guidelines for planning the electrical installation Examining the compatibility of the motor and drive Use an asynchronous AC induction motor, permanent magnet synchronous motor or AC induction servomotor with the drive. Several induction motors can be connected to the drive at a time.

  • Page 77: Requirements Table

    Motor Nominal AC Requirement for type supply voltage Motor ABB du/dt and common mode filters, insulated N-end insulation motor bearings system < 100 kW 100 kW < P < 350 kW > 350 kW and frame size <...

  • Page 78: Additional Requirements For Explosion-Safe (Ex) Motors

    78 Guidelines for planning the electrical installation Motor Nominal AC Requirement for type supply voltage Motor ABB du/dt and common mode filters, insulated N-end insulation motor bearings system < 100 kW 100 kW < P < 350 kW > 350 kW and frame size <...

  • Page 79: Additional Requirements For Abb Motors Of Types Other Than M2_, M3_, M4_, Hx_ And

    Additional requirements for non-ABB high-output and IP23 motors The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consult the motor manufacturer.

  • Page 80: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    80 Guidelines for planning the electrical installation Additional data for calculating the rise time and the peak line-to-line voltage If you need to calculate the actual peak voltage and voltage rise time considering the actual cable length, proceed as follows: •...

  • Page 81: Selecting The Power Cables

    Guidelines for planning the electrical installation 81 Selecting the power cables General rules  Select the input power and motor cables according to local regulations: • Select a cable capable of carrying the drive nominal current. See section Ratings (page 179) for the rated currents, and section Typical cable sizes (page 82).

  • Page 82: Typical Cable Sizes

    Dimensions (page 201). Drive type Al cable size Cu cable size Cu cable size Ground cable size ACS880-37-… AWG/kcmil AWG/kcmil = 400 V 0450A-3 2 × (3 × 240 + 72 Cu) 2 × (3 × 150 + 70) 2 × 400 0620A-3 3 ×...

  • Page 83: Output (Motor) Cable Sizes

    Common output terminal (option +H366) (page 50). Drive type Al cable size Cu cable size Cu cable size ACS880-37-… AWG/kcmil = 400 V 0450A-3 2 × (3 × 240 + 72 Cu) 2 × (3 × 185 + 95) 2 × 400 0620A-3 4 ×...

  • Page 84: Alternative Power Cable Types

    84 Guidelines for planning the electrical installation on top of the other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (IEC/EN 60204- 1 and IEC 60364-5-52/2001). For other conditions, size the cables according to local safety regulations, appropriate input voltage and the load current of the drive. 2.

  • Page 85: Motor Cable Shield

    Guidelines for planning the electrical installation 85 Motor cable shield  If the motor cable shield is used as the sole protective earth conductor of the motor, make sure that the conductivity of the shield is sufficient. See subsection General rules above, or IEC 61800-5-1.

  • Page 86: Planning The Braking System

    Relay cable type  The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel cable length and type  In remote use, the cable connecting the control panel to the drive must not be longer than three meters (10 ft).

  • Page 87: Separate Control Cable Ducts

    Guidelines for planning the electrical installation 87 A diagram of the cable routing is shown below. Motor cable Drive min 300 mm (12 in.) Power cable Input power cable Motor cable 90 ° min 200 mm (8 in.) min 500 mm (20 in.) Control cables Separate control cable ducts ...

  • Page 88: Implementing Thermal Overload And Short-Circuit Protection

    88 Guidelines for planning the electrical installation Implementing thermal overload and short-circuit protection Protecting the drive and input power cable in short-circuits  The drive is equipped with internal AC fuses as standard. Protect the input cable with fuses or a suitable circuit breaker. Size the input cable fuses according to the instructions given in chapter Technical data.

  • Page 89: Residual Current Device Compatibility

    Guidelines for planning the electrical installation 89 Residual current device compatibility  The drive is suitable to be used with residual current devices of Type B. Note: The EMC filter of the drive includes capacitors connected between the main circuit and the frame.

  • Page 90: Implementing The Functions Provided By The Fso-Xx Safety Functions Module (Option +Q972 Or +Q973)

    90 Guidelines for planning the electrical installation Implementing the functions provided by the FSO-xx safety functions module (option +Q972 or +Q973) The drive can be equipped with an FSO-xx safety functions module (option +Q972 or +Q973) which enables the implementation of functions such as Safe brake control (SBC), Safe stop 1 (SS1), Safe stop emergency (SSE), Safely limited speed (SLS) and Safe maximum speed (SMS).

  • Page 91: Using Power Factor Compensation Capacitors With The Drive

    Guidelines for planning the electrical installation 91 Using power factor compensation capacitors with the drive Power factor compensation is not needed with AC drives. However, if a drive is to be connected in a system with compensation capacitors installed, note the following restrictions.

  • Page 92: Connecting A Motor Temperature Sensor To The Drive I/O

    92 Guidelines for planning the electrical installation 230 V AC 230 V AC + 24 V DC 1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode Connecting a motor temperature sensor to the drive I/O WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non-conductive or conductive but not connected to the protective earth.

  • Page 93: Drive I/O, I/O Extension And Encoder Interface Modules

    Guidelines for planning the electrical installation 93 connectors of the module. See the table below for the sensor insulation requirement. For sensor connection to the extension module, see its manual. 4. You can connect a sensor to an external thermistor relay the insulation of which is rated for the same voltage level as the main circuit of the drive.
  • Page 94 94 Guidelines for planning the electrical installation...

  • Page 95: Electrical Installation

    Electrical installation 95 Electrical installation Contents of this chapter This chapter gives instructions on the wiring of the drive. Warnings WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.

  • Page 96: Motor And Motor Cable

    Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, consult the manufacturer’s instructions. Note: Moisture inside the motor casing will reduce the insulation resistance.

  • Page 97: T21 And T101 Tap Settings (400

    Electrical installation 97 T21 and T101 tap settings (400…500 V units)  T21_X2 or T101_X2 T21_X1 or T101_X1 500 V 230 V 480 V 460 V 440 V 415 V Θ 400 V 380 V T21 and T101 tap settings (690 V units) ...

  • Page 98: T111 Tap Settings

    98 Electrical installation T111 tap settings  3~ input 3~ output 3~ input 3~ output Tap settings Terminals Supply Terminals 400 V 320/340 V voltage A1– B1– C1– (50 Hz) (60 Hz) 690 V A1, B1, C1 a1, b1, c1 a2, b2, c2 660 V A1, B1, C1...

  • Page 99: Connecting The Control Cables

    Electrical installation 99 Connecting the control cables See chapter Control units of the drive (page 131) for the default I/O connections of the inverter unit (with the ACS880 primary control program). The default I/O connections can be different with some hardware options, see the circuit diagrams delivered with the drive for the actual wiring.
  • Page 100 100 Electrical installation Note 1: Keep the shields continuous as close to the connection terminals as possible. Secure the cables mechanically at the lead-through strain relief. Note 2: If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the bare part. Be careful not to cut the conductors or the grounding wire (if present).

  • Page 101: Routing The Control Cables Inside The Cabinet

    Electrical installation 101 5. Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions. 6. If more than one cable go through a grommet, seal the grommet by applying Loctite 5221 (catalogue number 25551) inside the grommet. Routing the control cables inside the cabinet Use the existing trunking in the cabinet wherever possible.
  • Page 102 102 Electrical installation At the other end of the cable, leave the shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg. 3.3 nF / 630 V. The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points.

  • Page 103: Connecting A 230/115 V Ac Auxiliary Voltage Supply (Ups, Option +G307)

    Electrical installation 103 Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) Wire the external control voltage to terminal block X307 at the back side of the mounting plate as shown below. X307 Internal wiring of UPS supervision: circuit breaker or fuse off/fault = contact open. Connecting emergency stop push buttons (options +Q951, +Q952, +Q963, +Q964, +Q978, +Q979) Connect external emergency stop push buttons according to the circuit diagrams delivered...

  • Page 104: Wiring The Ptc Thermistor Relay(S) (Options +L505, +2L505, +L513, +2L513)

    104 Electrical installation Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513, +2L513) The external wiring of option +2L505 and +2L513 (two thermistor relays) is shown below. For example, one relay can be used to monitor the motor windings, the other to monitor the bearings.

  • Page 105: Wiring The Pt100 Relays (Option +Nl506)

    Electrical installation 105 Wiring the Pt100 relays (option +nL506) External wiring of eight Pt100 sensors is shown below. The maximum contact load capacity is 250 V AC 10 A. For the actual wiring, see the circuit diagram delivered with the drive.

  • Page 106: Wiring The Pt100 Relays (Option +Nl514)

    106 Electrical installation Wiring the Pt100 relays (option +nL514) External wiring of three Pt100 sensors is shown below. The maximum contact load capacity is 250 V AC 10 A. For the actual wiring, see the circuit diagram delivered with the drive.

  • Page 107: Powering The Heating And Lighting Equipment (Options +G300, +G301 And +G313)

    Electrical installation 107 Powering the heating and lighting equipment (options +G300, +G301 and +G313) See the circuit diagrams delivered with drive. Connect the external power supply wires for the cabinet heater and lighting to terminal block X300. X300 Internal wiring of the cabinet heater: heater off/fault = contact open.

  • Page 108: Wiring Ground Fault Monitoring For It Ungrounded Systems (Option +Q954)

    108 Electrical installation Wiring ground fault monitoring for IT ungrounded systems (option +Q954) We recommend to connect Alarm 1 for drive tripping and Alarm 2 for alarm signals in order to avoid unnecessary trippings due to the ground fault monitor self testing with Alarm 2. X954 Internal wiring: Ground fault alarm 1.

  • Page 109: Connecting The Motor Cables

    Electrical installation 109 Connecting the motor cables (units without common motor terminal cubicle or sine output filter) On units without a common motor terminal cubicle or a sine output filter, the motor cables connect to busbars located behind the inverter module(s). The location and dimensions of the busbars are visible in the dimension drawings delivered with the drive, as well as the example drawings presented in this manual (starting on page 227).

  • Page 110: Connection Diagram (With Option +H366)

    110 Electrical installation WARNING! The cabling from all inverter modules to the motor must be physically identical considering cable type, cross-sectional area, and length. Inverter unit cubicle(s) Connection diagram (with option +H366)  With option +H366, the output busbars of the inverter modules within the same cubicle are connected by bridging busbars.

  • Page 111: Procedure

    Electrical installation 111 multiple inverter cubicles (ie. two cubicles of two modules each), make sure that the motor cabling is identical for both cubicles. Procedure  Removing the inverter module(s) To allow more room for cabling work, the inverter module can be removed completely instead of only the fan carriage.
  • Page 112 112 Electrical installation...
  • Page 113 Electrical installation 113...
  • Page 114 114 Electrical installation...

  • Page 115: Removing And Reinstalling The Fan Carriage Of An Inverter Module

    Electrical installation 115 Removing and reinstalling the fan carriage of an inverter module Refer to the drawings below. WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1.
  • Page 116 116 Electrical installation...

  • Page 117: Connecting The Motor Cables

    Electrical installation 117 Connecting the motor cables Refer to the drawings below. WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Do the steps in section Electrical safety precautions (page 19) before you start the work.
  • Page 118 118 Electrical installation 360° grounding detail...

  • Page 119: Re-Installing The Fan Carriage Of An Inverter Module

    Electrical installation 119 Re-installing the fan carriage of an inverter module (If the inverter module was removed completely instead of only the fan carriage, proceed to section Re-inserting the inverter module into the cubicle below.) The re-installation of the fan carriage is the removal procedure in reverse. See section Removing and reinstalling the fan carriage of an inverter module (page 115).

  • Page 120: Connecting The Motor Cables (Units With Common Motor Terminal Cubicle Or Sine Filter)

    120 Electrical installation Connecting the motor cables (units with common motor terminal cubicle or sine filter) Output busbars  If the drive is equipped with option +H359, the motor cables connect to a common motor terminal cubicle. Similarly, if the drive is equipped with option +E206 (sine output filter), the motor cables connect to the output busbars in the sine filter cubicle.

  • Page 121: Connecting An External Brake Resistor Assembly

    Electrical installation 121 3. Lead the cables into the cubicle. Make the 360° earthing arrangement at the cable entry as shown. Grommet 4. Cut the cables to suitable length. Strip the cables and conductors. 5. Twist the cable screens into bundles and connect the bundles to the PE busbar in the cubicle.

  • Page 122: Connecting The Input Power Cables

    122 Electrical installation Connecting the input power cables Connection diagram  LCL filter IGBT supply modules Components for charging circuit ICU cubicle ISU cubicle Notes: Fuses or other protection means. Use a separate PE conductor in addition if the conductivity of the shield does not meet the requirement for the PE conductor.
  • Page 123 8. Fasten the conductive sleeves to the cable shields with cable ties. 9. Seal the slot between the cable and mineral wool sheet (if used) with sealing compound (eg, CSD-F, ABB brand name DXXT-11, code 35080082). 10. Tie up the unused conductive sleeves with cable ties.
  • Page 124 124 Electrical installation...

  • Page 125: Connecting A Pc

    Electrical installation 125 Connecting a PC A PC (with eg. the Drive composer PC tool) can be connected to the inverter unit as follows: 1. Connect an ACS-AP-x control panel to the inverter control unit either by using an Ethernet (eg. CAT5E) networking cable, or by inserting the panel into the panel holder (if present).

  • Page 126: Panel Bus (Control Of Several Drives From One Control Panel)

    This is done by daisy-chaining the panel connections of the drives. Some drives have the necessary panel connectors in the control panel holder. Others, including the ACS880-37, require the installation of an FDPI-02 module (available separately). For further information, see FDPI-02 diagnostics and panel interface user’s manual (3AUA0000113618 [English]).

  • Page 127: Installing Option Modules

    Electrical installation 127 Installing option modules Mechanical installation of I/O extension, fieldbus adapter and pulse  encoder interface modules See page for the available slots for each module. Install the option modules as follows: WARNING! Obey the instructions in chapter Safety instructions.

  • Page 128: Mechanical Installation Of An Fso-Xx Safety Functions Module

    128 Electrical installation Mechanical installation of an FSO-xx safety functions module  This procedure describes the mechanical installation of an FSO-xx safety functions module onto the inverter control unit. (The FSO-xx can alternatively be installed beside the control unit, which is the standard with factory-installed FSO-xx modules. For instructions, see the FSO-xx manual.) 1.

  • Page 129: Wiring Of Option Modules

    Electrical installation 129 2. Tighten the FSO-xx electronics grounding screw. 3. Connect the FSO-xx data cable between FSO-xx connector X110 and to BCU-x2 connector X12. Wiring of option modules  See the appropriate option module manual for specific installation and wiring instructions.
  • Page 130 130 Electrical installation...

  • Page 131: Control Units Of The Drive

    (and a BIOC-01 I/O connector board and power supply board) built in a metal housing. The supply and inverter units of the ACS880-37 are each controlled by a dedicated BCU-x2 control unit. The designation of the supply control unit is A51; the inverter control unit is A41.

  • Page 132: Control Unit Layout And Connections

    132 Control units of the drive Control unit layout and connections  Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection...
  • Page 133 Control units of the drive 133 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XDIO Digital input/outputs XD24 XPOW XD2D Drive-to-drive link XD24 +24 V output (for digital inputs) XRO2 XETH Ethernet port (eg. for PC communication) XDIO XPOW External power input...
  • Page 134 134 Control units of the drive Default I/O diagram of the supply control unit [A51] The diagram below shows the default I/O connections on the supply control unit [A51], and describes the use of the signals/connections in the supply unit. Under normal circumstances, the factory-made wiring should not be changed.

  • Page 135: Default I/O Diagram Of The Inverter Control Unit [A41]

    Control units of the drive 135 Default I/O diagram of the inverter control unit [A41]  Drive-to-drive link XD2D Drive-to-drive link BGND Shield RS485 connection X485 Not in use BGND Shield Relay outputs XRO1…XRO3 Ready 250 V AC / 30 V DC Running 250 V AC / 30 V DC Fault...

  • Page 136: External Power Supply For The Control Unit (Xpow)

    136 Control units of the drive Notes: The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (24…12 AWG). The torque is 0.5 N·m (5 lbf·in). See section Drive-to-drive link (XD2D) (page 137).

  • Page 137: Ai1 Or Ai2 As A Pt100, Pt1000, Ptc Or Kty84 Sensor Input

    Control units of the drive 137 WARNING! As the inputs pictured above are not insulated according to IEC 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. If the assembly does not fulfill the requirement, the I/O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I/O terminals.

  • Page 138: Safe Torque Off (Xsto, Xsto Out)

    The BCU-x2 has an on-board data logger that collects real-time data from the power modules to help fault tracing and analysis. The data is stored onto the SDHC memory card inserted into the SD CARD slot and can be analyzed by ABB service personnel.

  • Page 139: Control Unit Connector Data

    Control units of the drive 139 Control unit connector data Power supply Connector pitch 5 mm, wire size 2.5 mm (XPOW) 24 V (±10%) DC, 2 A External power input. Two supplies can be connected for redundancy. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3) 250 V AC / 30 V DC, 2 A...
  • Page 140 140 Control units of the drive Analog outputs AO1 and AO2 Connector pitch 5 mm, wire size 2.5 mm (XAO) 0…20 mA, R < 500 ohm load Frequency range: 0…500 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm (XD2D)
  • Page 141 Control units of the drive 141 Ground isolation diagram XPOW +24VI +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- each AI input and AGND is AI2+ AI2- +30 V AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD...
  • Page 142 142 Control units of the drive...

  • Page 143: Installation Checklist

    Installation checklist 143 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before you start up the drive. Warnings WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Checklist Do the steps in section Electrical safety precautions...
  • Page 144 144 Installation checklist Check that … There is an adequately sized protective earth (ground) conductor between the drive and the switchboard, and the conductor has been connected to appropriate terminal. Proper grounding has also been measured according to the regulations. There is an adequately sized protective earth (ground) conductor between the motor and the drive, and the conductor has been connected to appropriate terminal.

  • Page 145: Start-Up

    Start-up 145 Start-up Contents of this chapter This chapter contains the start-up procedure of the drive. Start-up procedure The tasks which are needed in certain cases only are marked with underlining, and option codes are given in brackets. Default device designations (if any) are given in brackets after the name, for example “main switch-disconnector [Q1]”.

  • Page 146: Checks/Settings With No Voltage Connected

    146 Start-up Action Safety WARNING! Obey the safety instructions during the start-up procedure. See chapter Safety instructions on page Checks/Settings with no voltage connected Ensure that the disconnector of the supply transformer is locked to the off (0) position, ie. no voltage is, and cannot be connected to the drive inadvertently.

  • Page 147: Setting Up The Supply Unit Parameters

    Start-up 147 Action Switch on the auxiliary voltage [Q21]. Drives of frame size 1×R8i + 1×R8i: Close the main switch-disconnector [Q1.1]. This will power up the main circuit of the drive as well as the auxiliary voltage circuit. Setting up the supply unit parameters Check the voltage range setting in parameter 195.01 Supply voltage.
  • Page 148 148 Start-up Action Check that the motor starts, stops and follows the speed reference in the correct direction when controlled through the customer-specific I/O or fieldbus. Drives in which the Safe torque off control circuit is in use: Test and validate the operation of the Safe torque off function.

  • Page 149: Fault Tracing

    Fault tracing 149 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs Where Color Indication Control POWER Green Control unit is powered and +15 V is supplied to the control panel panel. mounting FAULT Drive in fault state.
  • Page 150 150 Fault tracing...

  • Page 151: Maintenance

    Maintenance 151 Maintenance Contents of this chapter This chapter contains preventive maintenance instructions.

  • Page 152: Maintenance Intervals

    Control panel battery Control unit battery Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance.

  • Page 153: Cabinet

    Maintenance 153 Cabinet Cleaning the interior of the cabinet  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use a vacuum cleaner with an antistatic hose and nozzle, and wear a grounding wristband.

  • Page 154: Cleaning The Door Air Inlets (Ip54)

    154 Maintenance Cleaning the door air inlets (IP54)  1. Remove the fasteners at the top of the grating. 2. Lift the grating and pull it away from the door. 3. Remove the air filter mat. 4. Place the new filter mat in the grating the metal wire side facing the door. 5.

  • Page 155: Power Connections And Quick Connectors

    Maintenance 155 WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use a vacuum cleaner with antistatic hose and nozzle. Using a normal vacuum cleaner creates static discharges which can damage circuit boards.

  • Page 156: Fans

    Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the cooling fan in the auxiliary control cubicle ...

  • Page 157: Replacing The Fan(S) In The Incoming Cubicle

    Maintenance 157 Replacing the fan(s) in the incoming cubicle  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work.

  • Page 158: Replacing A Roof Fan (Ip54/Ul Type 12)

    158 Maintenance Replacing a roof fan (IP54/UL type 12)  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work.

  • Page 159: Replacing A Supply Or Inverter Module Cooling Fan

    Maintenance 159 Replacing a supply or inverter module cooling fan  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 19) before you start the work.

  • Page 160: Replacing The Circuit Board Compartment Fan (Frame R8I)

    160 Maintenance Replacing the circuit board compartment fan (frame R8i)  The R8i module is equipped with a fan blowing air through the circuit board compartment. The fan is accessible from the front of the module. WARNING! Obey the instructions in chapter Safety instructions.
  • Page 161 Maintenance 161 8. Put the fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder. 9. Install and tighten the four nuts removed earlier. 10. Connect the fan cable. 11. Align and push the fan holder into the module. 12.

  • Page 162: Replacing The Fan Of The Lcl Filter (Blcl-1X-X)

    162 Maintenance Replacing the fan of the LCL filter (BLCL-1x-x)  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive (if running) and do the steps in section Electrical safety precautions (page 19) before you start the work.

  • Page 163: Replacing The Fan Of The Lcl Filter (Blcl-2X-X)

    Maintenance 163 Replacing the fan of the LCL filter (BLCL-2x-x)  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive (if running) and do the steps in section Electrical safety precautions (page 19) before you start the work.

  • Page 164: Supply And Inverter Modules

    164 Maintenance Supply and inverter modules Cleaning  The module heatsink fins pick up dust from the cooling air. The module runs into overtemperature warnings and faults if the heatsink is not clean. In a “normal” environment (neither especially dusty nor clean), the heatsink should be checked annually, in a dusty environment more often.

  • Page 165: Reduced Run

    Maintenance 165 Reduced run  A “reduced run” function is available for supply and inverter units consisting of parallel- connected modules. The function makes it possible to continue operation with limited current even if one (or more) module is out of service, for example, because of maintenance work.
  • Page 166 166 Maintenance 6. If the control unit (A41 or A51) is powered from the faulty module, connect the power supply wiring using the extension wire set included to another module. 7. If the Safe torque off (STO) function is in use, install the jumper wire set included in the STO wiring in place of the missing module.

  • Page 167: Returning The Module

    Maintenance 167 Returning the module 1. Remove the air baffle and install the module in reverse order. Use the following tightening torques: • DC busbar assembly to upper insulators (2 × M8): 9 N·m (6.6 lbf·ft) • DC busbar assembly to lower insulators (2 × M10): 18 N·m (13.3 lbf·ft) •...

  • Page 168: Lcl Filter

    Do not use the module extraction/installation ramp with plinth heights over 50 mm. The ramp supplied with the drive system is designed for a plinth height of 50 mm (the standard plinth height of ABB cabinets). WARNING! Obey the instructions in chapter Safety instructions.
  • Page 169 Maintenance 169 12. Replace the module: install the module in reverse order. Mind you fingers. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. Note: Be careful not to break the fastening screws: tighten the fastening screws of the module to 22 N·m (16.2 lbf.ft) and fastening bolts of the DC output busbars to 70 N·m (51.6 lbf.ft).
  • Page 170 170 Maintenance...

  • Page 171: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB-specified spare parts.

  • Page 172: Fuses

    172 Maintenance Fuses Replacing the AC fuses in the incoming cubicle  Units without a main breaker have AC fuses in the incoming cubicle (or, in the case of frame 1×R8i + 1×R8i, in the combined supply and inverter module cubicle). WARNING! Obey the instructions in chapter Safety instructions.
  • Page 173 Maintenance 173 Replacing the DC fuses in the supply module cubicle (frame  2×R8i + 2×R8i and up) There are DC fuses at the output of each supply module (labeled 4b in the drawing below). Note that there are also DC fuses at the input of each inverter module; see page 175. This procedure can also be used to replace the AC fuses located above the LCL filter modules (4a).
  • Page 174 174 Maintenance...

  • Page 175: Replacing The Dc Fuses In The Inverter Module Cubicle (Frame 2×R8I + 2×R8I And Up)

    Maintenance 175 Replacing the DC fuses in the inverter module cubicle (frame  2×R8i + 2×R8i and up) Parallel-connected inverter modules have DC fuses fitted above each module. WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 176: Control Panel

    176 Maintenance Control panel Replacing the battery  1. Turn the lid on the back of the panel counter-clockwise until the lid opens. 2. Replace the battery with a new CR2032 battery. 3. Put the lid back and tighten it by turning it clockwise. 4.

  • Page 177: Control Units

    Maintenance 177 Control units BCU control unit types  There are three variants of the BCU control unit used in ACS880 drives: BCU-02, BCU-12 and BCU-22. These have a different number of converter module connections (2, 7 and 12 respectively) but are otherwise identical. The three BCU types are interchangeable as long as the number of connections is sufficient.

  • Page 178: Control Unit Battery

    178 Maintenance Control unit battery  Replace the real-time clock battery if the BATT OK LED is not illuminated when the control unit is powered. For information on the LED, see Control unit layout and connections page 132. 1. Do the steps in section Electrical safety precautions (page 19) before you start the work.

  • Page 179: Technical Data

    The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table. Output ratings Input Drive type ratings No-overload use Light-overload use Heavy-duty use ACS880-37- … = 400 V 0450A-3 – – – 0620A-3 –...

  • Page 180: Definitions

    Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.

  • Page 181: Derating

    Technical data 181 Derating  Ambient temperature derating In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k): 1.00 0.90 0.80...

  • Page 182: Switching Frequency Derating

    Derating factor 0.90 Derating factor 0.85 Derating factor 0.80 Switching frequency derating Switching frequencies other than default can require output current derating. Contact ABB for more information. Output frequency derating Motor operation above 150 Hz can require type-specific output current derating. Contact...

  • Page 183: Frame Sizes And Power Module Types

    Technical data 183 Frame sizes and power module types Supply module(s) used LCL filter(s) used Inverter modules used Drive type Frame size Type Type ACS880-37-… Type ACS880-104-… ACS880-104-… = 400 V 0450A-3 1×R8i + 1×R8i 0470A-3+E205+N8201 BLCL-13-5 0470A-3+E205 0620A-3 1×R8i + 1×R8i...

  • Page 184: Fuses

    Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table. Ultrarapid (aR) AC fuses Drive type ACS880-37-… Manufacturer Type at 660 V...

  • Page 185: Dc Fuses

    Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table. DC fuses at supply module output and inverter module input Drive type ACS880-37-… Manufacturer Type = 400 V...

  • Page 186: Fuses On Cvar Varistor Board

    186 Technical data Fuses on CVAR varistor board  The CVAR board is used in units for UL and CSA installations. The fuse type is Ferraz A070GRB10T13/G330010 (10 A 700 V AC). Brake chopper DC fuses  Optional (+D150) brake choppers have two DC fuses each. The fuse type is Bussmann 170M8635 (630 A 1000 V).

  • Page 187: Cooling Data, Noise

    Technical data 187 Cooling data, noise Air flow Heat dissipation Noise Drive type dB(A) /min = 400 V ACS880-37-0450A-3 3760 2215 ACS880-37-0620A-3 3760 2215 ACS880-37-0870A-3 3760 2215 ACS880-37-1110A-3 7220 4250 ACS880-37-1210A-3 7220 4250 ACS880-37-1430A-3 7220 4250 ACS880-37-1700A-3 7220 4250 ACS880-37-2060A-3...

  • Page 188: Sine Output Filter Data

    Sine output filter data Sine output filters are available as option +E206. The table below shows the types and technical data of the filters and filter cubicles used in ACS880-37 drives. The standard filters listed require no current derating. For availability of sine output filters for other types, contact your local ABB representative.

  • Page 189: Electrical Power Network Specification

    Electrical power network specification Voltage (U ACS880-37-xxxxx-3: 380…415 V AC 3-phase ± 10%. This is indicated in the type designation label as typical input voltage level (3~ 400 V AC). ACS880-37-xxxxx-5: 380…500 V AC 3-phase ± 10%. This is indicated in the type designation label as typical input voltage levels (3~ 400/480/500 V AC).

  • Page 190: Control Unit Connection Data

    190 Technical data Frequency 0…±598 Hz (0…±120 Hz with sine output filters [option +E206]) • For higher operational output frequencies, please contact your local ABB representative. • Operation above 150 Hz may require type-specific derating. For more information, contact your local ABB representative.

  • Page 191: Materials

    Technical data 191 Contamination IEC/EN 60721-3-3:2002: IEC 60721-3-1:1997 IEC 60721-3-2:1997 Classification of environmental conditions - Part 3-3: Classification of groups of environmental parameters and their severities - Stationary use of weather protected locations Chemical gases Class 3C2 Class 1C2 Class 2C2 Solid particles Class 3S2.
  • Page 192 IEC 62635 guidelines. To aid recycling, plastic parts are marked with an approppriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.

  • Page 193: Applicable Standards

    Technical data 193 Applicable standards Standard Information European electrical safety requirements product standards IEC/EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety requirements – electrical, thermal and energy IEC 60146-1-1:2009 Semiconductor converters – General requirements and line commutated EN 60146-1-1:2010 converters –...

  • Page 194: Declaration Of Conformity

    194 Technical data the Machinery Directive. These functions of the drive comply with European harmonized standards such as EN 61800-5-2. The related declarations of conformity are shown below. Declaration of Conformity...
  • Page 195 Technical data 195...

  • Page 196: Compliance With En 61800-3:2004

    196 Technical data Compliance with EN 61800-3:2004 Definitions  EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality.

  • Page 197: Category C4

    Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in the hardware manual. 4. The drive is installed according to the instructions given in the hardware manual.

  • Page 198: Rcm Marking

    Protect the input cable with fuses. Suitable IEC (class aR) fuses and UL fuses are listed starting on page 184. Circuit breakers must not be used without fuses in the USA. For suitable circuit breakers, contact your local ABB representative. •...

  • Page 199: Insulation Supports

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any...
  • Page 200 200 Technical data...

  • Page 201: Dimensions

    Dimensions 201 Dimensions What this chapter contains This chapter contains the following dimension data: • Composition of cabinet line-ups in tabular form for each frame size with options (page 202) • Approximate weights of basic line-ups (page 206) • Dimension drawing examples of selected line-ups (page 207) •...

  • Page 202: Cabinet Line-Up Dimensions

    Not all possible configurations are presented. For information on unlisted configurations, contact ABB. • The data given is preliminary. ABB reserves the right to modify the design at any time without notice. Consult ABB for up-to-date, drive-specific information. The tables are followed by selected dimension drawing examples.

  • Page 203: Acs880-37-1110A-3, -1010A-5, -1110A-5, -0660A-7, -0770A-7, -0950A-7, -1130A-7

    Dimensions 203 ACS880-37-1110A-3, -1010A-5, -1110A-5, -0660A-7, -0770A-7, -0950A-7, -1130A-7 2200 2200 2500 2500 1000 3200 3200 3000 3000 3300 3300 1000 4000 4000 2400 + 2400 4800 2500 + 2400 4900 1000 3400 + 2400 5800 3400 3400 3700 3700...

  • Page 204: 3×R8I + 3×R8I

    (ICU) entry cubicle cubicle cubicle (ACU) cubicle 3200 3200 3500 3500 3600 3600 3400 3400 3700 3700 3800 3800 *300 mm double-busbar version with ACS880-37-1450A-7 and -1680A-7. 600 mm with ACS880-37-2530A-3+H353 (top exit). 400 mm with other types...

  • Page 205: 4×R8I + 4×R8I

    Dimensions 205 4×R8i + 4×R8i Auxiliary Common Incoming Adapter Supply Supply Inverter Inverter control motor Line-up cubicle for top module module module module Shipping split widths cubicle terminal width (ICU) entry cubicle 1 cubicle 2 cubicle 1 cubicle 2 (ACU) cubicle 3800 3800...

  • Page 206: Weights

    206 Dimensions Weights  The table below lists the approximate basic weights of the drive types. Drive type Weight ACS880-37-… 0450A-3 0420A-5 0320A-7 0620A-3 0570A-5 0390A-7 1180 2600 0870A-3 0780A-5 0580A-7 1110A-3 1010A-5 0660A-7 1110A-5 0770A-7 1970 4340 0950A-7 1130A-7...

  • Page 207: Dimension Drawing Examples

    Dimensions 207 Dimension drawing examples  Frame 1×R8i + 1×R8i...

  • Page 208: Frame 1×R8I + 1×R8I, Top Cable Entry/Exit (+H351+H353)

    208 Dimensions Frame 1×R8i + 1×R8i, top cable entry/exit (+H351+H353)

  • Page 209: Frame 1×R8I + 1×R8I With Brake Choppers And Resistors (+D150+D151)

    Dimensions 209 Frame 1×R8i + 1×R8i with brake choppers and resistors (+D150+D151)

  • Page 210: Frame 1×R8I + 1×R8I With Sine Output Filter (+E206)

    210 Dimensions Frame 1×R8i + 1×R8i with sine output filter (+E206)

  • Page 211: Frame 2×R8I + 2×R8I (Eg. Acs880-37-1110A-3), Ip22

    Dimensions 211 Frame 2×R8i + 2×R8i (eg. ACS880-37-1110A-3), IP22...

  • Page 212: Frame 2×R8I + 2×R8I (Eg. Acs880-37-1210A-3), Ip54

    212 Dimensions Frame 2×R8i + 2×R8i (eg. ACS880-37-1210A-3), IP54...

  • Page 213: Frame 2×R8I + 2×R8I With Main Breaker (+F255) And Common Motor Terminal Cubicle (+H359), 1/2

    Dimensions 213 Frame 2×R8i + 2×R8i with main breaker (+F255) and common motor terminal cubicle (+H359), 1/2...

  • Page 214: Frame 2×R8I + 2×R8I With Main Breaker (+F255) And Common Motor Terminal Cubicle (+H359), 2/2

    214 Dimensions Frame 2×R8i + 2×R8i with main breaker (+F255) and common motor terminal cubicle (+H359), 2/2...

  • Page 215: Frame 2×R8I + 2×R8I With Main Breaker (+F255) And Top Entry/Top Exit (+H351+H353), 1/2

    Dimensions 215 Frame 2×R8i + 2×R8i with main breaker (+F255) and top entry/top exit (+H351+H353),...

  • Page 216: Frame 2×R8I + 2×R8I With Main Breaker (+F255) And Top Entry/Top Exit (+H351+H353), 2/2

    216 Dimensions Frame 2×R8i + 2×R8i with main breaker (+F255) and top entry/top exit (+H351+H353),...

  • Page 217: Frame 3×R8I + 3×R8I, 1/2

    Dimensions 217 Frame 3×R8i + 3×R8i, 1/2...

  • Page 218: Frame 3×R8I + 3×R8I, 2/2

    218 Dimensions Frame 3×R8i + 3×R8i, 2/2...

  • Page 219: Frame 3×R8I + 3×R8I With Common Motor Terminal Cubicle (+H359), 1/2

    Dimensions 219 Frame 3×R8i + 3×R8i with common motor terminal cubicle (+H359), 1/2...

  • Page 220: Frame 3×R8I + 3×R8I With Common Motor Terminal Cubicle (+H359), 2/2

    220 Dimensions Frame 3×R8i + 3×R8i with common motor terminal cubicle (+H359), 2/2...

  • Page 221: Dimensions Of Empty Cubicles (Options +C199, +C200, +C201)

    Dimensions 221 Dimensions of empty cubicles (options +C199, +C200, +C201)  IP22/IP42...

  • Page 222: Ip54

    222 Dimensions IP54...

  • Page 223: Location And Size Of Input Terminals

    Dimensions 223 Location and size of input terminals Frame 1×R8i + 1×R8i, bottom cable entry  Frame 1×R8i + 1×R8i, top cable entry ...

  • Page 224: Frame 2×R8I + 2×R8I With Main Switch/Disconnector (400 Mm), Top Cable Entry

    224 Dimensions Frame 2×R8i + 2×R8i with main switch/disconnector (400 mm),  bottom cable entry Frame 2×R8i + 2×R8i with main switch/disconnector (400 mm), top  cable entry...

  • Page 225: Frame 2×R8I + 2×R8I With Main Switch/Disconnector (600 Mm), Top Cable Entry

    Dimensions 225 Frame 2×R8i + 2×R8i with main switch/disconnector (600 mm),  bottom cable entry Frame 2×R8i + 2×R8i with main switch/disconnector (600 mm), top  cable entry...

  • Page 226: Units With Main Breaker (600 Mm), Bottom Cable Entry

    226 Dimensions Units with main breaker (600 mm), bottom cable entry  Units with main breaker (600 mm), top cable entry ...

  • Page 227: Location And Size Of Output Terminals (Units Without Common Motor Terminal Cubicle)

    Dimensions 227 Location and size of output terminals (units without common motor terminal cubicle) Frame 1×R8i + 1×R8i (without sine output filter)  See page 223. Inverter module cubicle with two R8i modules, bottom cable exit ...

  • Page 228: Inverter Module Cubicle With Two R8I Modules, Top Cable Exit

    228 Dimensions Inverter module cubicle with two R8i modules, top cable exit  Inverter module cubicle with three R8i modules, bottom cable exit ...

  • Page 229: Inverter Module Cubicle With Three R8I Modules, Top Cable Exit

    Dimensions 229 Inverter module cubicle with three R8i modules, top cable exit  Sine filter (+E206) cubicle, 1000 mm, bottom cable exit ...

  • Page 230: Sine Filter (+E206) Cubicle, 1000 Mm, Top Cable Exit

    230 Dimensions Sine filter (+E206) cubicle, 1000 mm, top cable exit ...

  • Page 231: Location And Size Of Output Terminals (Units With Common Motor Terminal Cubicle)

    Dimensions 231 Location and size of output terminals (units with common motor terminal cubicle) Note: See the dimension tables starting on page as to which common motor terminal cubicle width is used with which drive type. Cubicle width 300 mm, bottom cable exit ...

  • Page 232: Cubicle Width 300 Mm (Double-Busbar Version), Bottom Cable Exit

    232 Dimensions Cubicle width 300 mm (double-busbar version), bottom cable exit  Cubicle width 300 mm, top cable exit ...

  • Page 233: Cubicle Width 300 Mm (Double-Busbar Version), Top Cable Exit

    Dimensions 233 Cubicle width 300 mm (double-busbar version), top cable exit  Cubicle width 400 mm, bottom cable exit ...

  • Page 234: Cubicle Width 400 Mm, Top Cable Exit

    234 Dimensions Cubicle width 400 mm, top cable exit  Cubicle width 600 mm, bottom cable exit ...

  • Page 235: Cubicle Width 600 Mm, Top Cable Exit

    Dimensions 235 Cubicle width 600 mm, top cable exit ...
  • Page 236 236 Dimensions...

  • Page 237: The Safe Torque Off Function

    The Safe torque off function 237 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the inverter (ie. the inverter unit of the drive) and gives instructions for its use. Description The Safe torque off function can be used, for example, to construct safety or supervision circuits that stop the inverter in case of danger (such as an emergency stop circuit).

  • Page 238: Compliance With The European Machinery Directive

    238 The Safe torque off function Standard Name IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 1: General requirements IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 2: Requirements for electrical/electronic/programmable electronic safety-related systems IEC 61511-1:2016 Functional safety –...

  • Page 239: Wiring

    The Safe torque off function 239 Wiring The following diagrams present examples of Safe torque off wiring for • a frame n×R8i inverter unit (page 240) • multiple inverter units (page 241) • multiple inverter units when an external 24 V DC power supply is used (page 242). For information on the specifications of the STO input, see chapter Control units of the drive...

  • Page 240: Frame N×R8I Inverter Unit (Internal Power Supply)

    240 The Safe torque off function Frame n×R8i inverter unit (internal power supply)  WARNING! Frame R8i inverter modules are as standard delivered with a jumper wire set that supplies 24 V from connector X53 to connector X52. The jumper wire set must be removed before wiring the Safe torque off circuit.

  • Page 241: Multiple Inverter Units (Internal Power Supply)

    The Safe torque off function 241 Multiple inverter units (internal power supply)  Inverter unit Control unit XSTO OUT1 +24 V SGND Inverter unit Control unit XSTO OUT1 SGND Inverter unit Control unit XSTO OUT1 SGND...

  • Page 242: Multiple Inverter Units (External Power Supply)

    242 The Safe torque off function Multiple inverter units (external power supply)  Inverter unit 24 V DC – Control unit XSTO OUT1 +24 V SGND Inverter unit Control unit XSTO OUT1 SGND Inverter unit Control unit XSTO OUT1 SGND...

  • Page 243: Operation Principle

    The Safe torque off function 243 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs on the inverter control unit de-energize. 3. The control unit cuts off the control voltage from the inverter IGBTs. 4.

  • Page 244: Acceptance Test Procedure

    244 The Safe torque off function Acceptance test procedure  After wiring the Safe torque off function, validate its operation as follows. Notes: • If the drive is equipped with safety option +Q950, +Q951, +Q952, +Q957, +Q963, +Q964, +Q978 or +Q979, do the procedure shown in the documentation of the option. If the drive is equipped with safety option +Q972 or Q973, do the procedure shown in the FSO module documentation.

  • Page 245: Use

    The Safe torque off function 245 Action Test the operation of the failure detection of the inverter. The motor can be stopped or running. • Open the 1st channel of the STO circuit (wire coming to IN1). If the motor was running, it should coast to a stop.

  • Page 246: Maintenance

    If any wiring or component change is needed after start up, or the parameters are restored, follow the test given in section Acceptance test procedure (page 244). Use only ABB approved spare parts. Record all maintenance and proof test activities in the machine logbook. Competence ...

  • Page 247: Safety Data

    Any failures of the Safe torque off function must be reported to ABB. Safety data The safety data for the Safe torque off function is given below.

  • Page 248: Abbreviations

    248 The Safe torque off function Abbreviations  Abbr. Reference Description Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition, and which is achieved by the structural arrangement of the parts, fault detection and/or by their reliability.

  • Page 249: Resistor Braking

    Resistor braking 249 Resistor braking Contents of this chapter This chapter tells how to select, protect and wire brake choppers and resistors. The chapter also contains the related technical data. Operating principle The brake chopper handles the energy generated by a decelerating motor. The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program.

  • Page 250: Factory-Installed Brake Choppers And Resistors

    250 Resistor braking Factory-installed brake choppers and resistors The following brake choppers (option +D150) and resistors (+D151) are available for the ACS880-37 as factory-installed. It is also possible to use option +D150 with a custom resistor assembly. ACS880-37 type Brake chopper type (+D150)

  • Page 251: Technical Data

    Resistor braking 251 Technical data Ratings of chopper/resistor combinations  Duty Cycle Duty Cycle (10/60 s) (1/5 min) brmax brcont Chopper(s) Resistors (ohm) (kW) (kW) (kW) (kW) NBRA-659 2 × SAFUR180F460 400 V 2 × NBRA-659 2 × (2 × SAFUR180F460) 1090 3 ×...

  • Page 252: Planning The Braking System

    252 Resistor braking Planning the braking system Verifying the capacity of the braking equipment  1. Calculate the maximum power generated by the motor during braking (P 2. Ensure that the braking power of the chopper is equal to or greater than P The P values specified in the ratings table on page are for the reference...

  • Page 253: Calculating The Maximum Braking Power (Pbr)

    Resistor braking 253 Calculating the maximum braking power (P • Braking energy transferred during any ten minute period must be less than or equal to the energy transferred during the reference braking cycle. • The braking power must not exceed the rated maximum value P brmax n ×...

  • Page 254: Selecting And Routing The Cables Of A Custom Resistor

    The maximum length of the resistor cable(s) is 50 m (164 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.

  • Page 255: Thermal Protection Of The Resistors

    Resistor braking 255 Thermal protection of the resistors The standard resistors available as option +D151 are equipped with a thermal switch. The switches of the resistors are wired in series and connected to the Enable input of the brake chopper. The relay output of the chopper is wired to the supply control unit so that a chopper fault condition stops the supply unit.

  • Page 256: Connection Procedure

    256 Resistor braking Connection procedure  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Do the steps in section Electrical safety precautions (page 19) before you start the work.

  • Page 257: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 258 Contact us www.abb.com/drives www.abb.com/drivespartners 3AXD50000020437 Rev B (EN) 2017-03-27...

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