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ABB ACS880-07 Series User Manual

ABB ACS880-07 Series
270 pages
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ABB INDUSTRIAL DRIVES
ACS880-07 drives (45 to 710 kW, 50 to 700 hp)
Hardware manual

Table of Contents

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ABB ACS880-07 Series Specifications

General IconGeneral
SeriesACS880-07
CategoryDC Drives
TypeIndustrial drive
Control MethodVector control
Cooling MethodAir-cooled or liquid-cooled
Voltage Range380V to 690V
Enclosure TypeIP21, IP54
Communication ProtocolsEthernet, Profibus, CANopen, Modbus
Built-in OptionsBrake chopper, EMC filter
Protection FeaturesOvervoltage, Undervoltage, Overcurrent
Ambient Temperature Range-10 to +40 °C
Relative Humidity5 to 95 % (non-condensing)

Summary

1 Safety instructions

General safety in installation, start-up and maintenance

General safety instructions for all personnel working on the drive.

Electrical safety in installation, start-up and maintenance

Specific electrical safety precautions for installation, start-up, and maintenance.

Electrical safety precautions

Detailed steps and precautions for ensuring electrical safety during work.

4 Mechanical installation

Examining the installation site

Ensuring the installation site meets ventilation, ambient, and space requirements.

Attaching the cabinet to the floor and wall or roof

General rules and procedures for securing the cabinet.

General rules

General guidelines for cabinet installation and required clearances.

5 Guidelines for planning the electrical installation

Examining the compatibility of the motor and drive

Ensuring compatibility between the motor and the AC drive.

Protecting the motor insulation and bearings

Measures to protect motor insulation and bearings from drive-related stress.

Selecting the power cables

Guidelines for selecting appropriate power cables.

General guidelines

General guidelines for selecting power and motor cables based on regulations.

Preferred power cable types

Recommended power cable types for EMC compliance.

Selecting the control cables

Guidelines for selecting and wiring control cables.

Shielding

Recommendations for shielding control cables.

Routing the cables

General guidelines for routing cables within the system.

General guidelines – IEC

General cable routing guidelines according to IEC standards.

General guidelines – North America

General cable routing guidelines for North America.

Protecting the drive and input power cable in short-circuit situations

Measures for protecting the drive and input power cable during short circuits.

Protecting the motor and motor cable in short-circuits

Protection measures for the motor and motor cable against short circuits.

Protecting the drive and the power cables against thermal overload

Protection of drive and power cables against thermal overload.

Protecting the motor against thermal overload

Ensuring motor thermal overload protection as per regulations.

Protecting the motor against overload without thermal model or temperature sensors

Motor overload protection methods without thermal models or sensors.

Implementing the emergency stop function

Instructions for implementing the emergency stop function.

Implementing the Prevention of unexpected start-up function

Guidance on implementing the prevention of unexpected start-up function.

Implementing a motor temperature sensor connection

Steps for connecting a motor temperature sensor to the drive.

Connecting motor temperature sensor to the drive via an option module

Details on connecting sensors via option modules.

6 Electrical installation

Safety

General safety warnings for electrical installation professionals.

Measuring the insulation

Instructions for measuring insulation resistance.

Measuring the insulation of the drive

Warning against performing insulation tests on the drive itself.

Measuring the insulation of the input power cable

Procedure for measuring input power cable insulation.

Measuring the insulation of the motor and motor cable

Steps to measure insulation resistance of motor and cable.

Grounding system compatibility check

Checks for compatibility with different grounding systems.

Connecting the power cables

Detailed instructions for connecting power cables.

Connection diagram

Schematic diagram for power cable connections.

Connection procedure (IEC)

Step-by-step procedure for connecting cables according to IEC standards.

Connection procedure (US)

Step-by-step procedure for connecting cables according to US standards.

Connecting the control cables

Detailed instructions for connecting control cables.

Control cable connection procedure

Step-by-step procedure for connecting control cables.

Connecting the control unit cables

Instructions for connecting cables to the control unit.

Installing option modules

General procedure for installing option modules.

7 Control units of the drive

Default I/O diagram of the drive control unit (ZCU-1x)

Diagram illustrating the default inputs and outputs of the ZCU-1x control unit.

8 Installation checklist

Checklist

A checklist for verifying mechanical and electrical installation before start-up.

9 Start-up

Start-up procedure

Step-by-step procedure for starting up the drive.

10 Fault tracing

Warning and fault messages

Guidance on interpreting warning and fault messages from the firmware manual.

11 Maintenance

Recommended annual maintenance actions by the user

Annual inspections recommended for optimal reliability and performance.

Replacing the inlet door filters (IP54)

Procedure for replacing inlet door filters on IP54 cabinets.

Replacing the outlet (roof) filters (IP54)

Procedure for replacing outlet filters on IP54 units.

Cleaning the heatsink

Procedure for cleaning the drive module heatsink fins.

Replacing cooling fans

Instructions for replacing cooling fans and resetting running time.

Replacing the cabinet “door

Procedure for replacing the fans located on the cabinet door.

Replacing the cabinet fans (frames R6 to R9)

Procedure for replacing cabinet fans in frames R6 to R9.

Replacing the drive module main fans (frames R6 to R8)

Procedure for replacing main fans of the drive module in frames R6 to R8.

Replacing the auxiliary cooling fan of the drive module (frames R6 to R9)

Procedure for replacing auxiliary cooling fans in drive modules (R6 to R9).

Replacing the drive module main fans (frame R9)

Procedure for replacing main fans of the drive module in frame R9.

Replacing the drive module main fans (frames R10 and R11)

Procedure for replacing main fans of the drive module in frames R10 and R11.

Replacing the circuit board compartment cooling fan (frames R10 and R11)

Procedure for replacing cooling fans in circuit board compartments.

Replacing the IP54 (UL type 12) roof fan of frames R6 to R8

Procedure for replacing IP54 roof fans in frames R6 to R8.

Replacing the IP54 (UL type 12) roof fan of frame R9

Procedure for replacing IP54 roof fans in frame R9.

Replacing the IP54 (UL type 12) roof fan of frames R10 and R11

Procedure for replacing IP54 roof fans in frames R10 and R11.

Replacing the drive module (frames R6 to R8)

Procedure for replacing the drive module in frames R6 to R8.

Replacing the drive module (frame R9)

Procedure for replacing the drive module in frame R9.

Replacing the drive module (frames R10 and R11)

Procedure for replacing the drive module in frames R10 and R11.

Replacing the battery

Procedure for replacing the control panel battery for the real-time clock.

Replacing the memory unit of ZCU-12

Procedure for transferring parameters by replacing the ZCU-12 memory unit.

Replacing the ZCU-12 control unit battery

Instructions for replacing the ZCU-12 control unit battery.

Replacing the memory unit of ZCU-14

Procedure for transferring parameters by replacing the ZCU-14 memory unit.

Replacing the ZCU-14 control unit battery

Procedure for replacing the ZCU-14 control unit battery.

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

Procedure for replacing faulty safety functions modules.

12 Technical data

Free space requirements

Required clearances around the drive for installation and ventilation.

Typical power cable sizes

Recommended power cable sizes for various drive types and current ratings.

Terminal and entry data for the power cables

Data on terminals and cable entry points for power cables.

IEC

Terminal and entry data for power cables according to IEC standards.

US

Terminal and entry data for power cables according to US standards.

Terminal data for the control cables

Terminal data specific to control cable connections.

Motor connection data

Data related to motor types, voltage, frequency, current, and switching frequency.

Motor types

Lists compatible motor types for the drive.

14 The Safe torque off function

Description

Describes the Safe Torque Off (STO) function and its application.

Wiring

Detailed wiring instructions for the STO connection.

Activation switch

Information on the activation switch component for STO.

Operation principle

Explanation of how the Safe Torque Off function operates.

Start-up including validation test

Procedure for validating the Safe Torque Off function during start-up.

Validation test procedure

Step-by-step procedure for validating the STO function's operation.

Use

Instructions on how to activate and deactivate the Safe Torque Off function.

Fault tracing

Guidance on troubleshooting the Safe Torque Off function.

Safety data

Provides safety data, including SIL/PL ratings and failure modes.

15 Resistor braking

Planning the braking system

Guidelines for planning the selection and configuration of the braking system.

Selecting the brake circuit components

Steps for selecting default and custom brake system components.

Selecting the default brake system components

Procedure for selecting standard drive, chopper, and resistor combinations.

Selecting a custom brake resistor

Guidelines for selecting a custom brake resistor, including resistance values.

Protecting the system against thermal overload

Measures to protect the system from thermal overload.

Protecting the brake resistor cable against short-circuits

Protection for the brake resistor cable against short circuits.

Measuring the insulation of the custom brake resistor circuit

Procedure for measuring insulation resistance of custom brake resistor circuits.

Parameter settings

Recommended parameter settings for brake chopper and resistor.

Ratings

Technical data tables for internal brake choppers and example brake resistors.

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