ABB ACS880-07C

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Hardware manual

ACS880-07C drives

(45 to 710 kW, 50 to 700 hp)

3AXD50000764860 Rev A

EFFECTIVE: 2022-8-26

1. Safety instructions

4. Mechanical installation

Table of contents

6. Electrical installation

10. Start-up

Main Page

Table of Contents5
Safety Instructions13
Contents of this Chapter13
Use of Warnings13
General Safety in Installation, Start-Up and Maintenance14
Electrical Safety in Installation, Start-Up and Maintenance16
Precautions before Electrical Work16
Additional Instructions and Notes17
Grounding19
Additional Instructions for Permanent Magnet Motor Drives20
Safety in Installation, Start-Up and Maintenance20
Introduction to the Manual21
Contents of this Chapter21
Target Audience21
Contents of the Manual21
Related Manuals22
Categorization by Frame Size and Option Code22
Quick Installation, Start-Up and Operating Flowchart22
Terms and Abbreviations23
Operation Principle and Hardware Description25
Contents of this Chapter25
Product Overview25
Single-Line Circuit Diagram of the Drive26
Block Diagram of the Brake and DC Options (+D150)27
General Information on the Cabinet Layout28
Cabinet Layout of Frames R6 to R929
Cabinet Layout of Frames R10 to R1130
Overview of Power and Control Connections31
Door Switches and Lights33
Main Switch-Disconnector Q133
Control Panel34
Control by PC Tools34
Descriptions of Cabinet Options34
Degree of Protection34
Definitions34
Ip2234
IP42 (Option +B054)35
Resistor Braking (Options +D150)35
EMC Filters (Options + E200)35
Du/Dt Filter (Option +E205)35
Common Mode Filter (Option +E208)35
Cabinet Heater with External Supply (Option +G300)35
Terminals for External Uninterruptible Control Voltage (Option +G307)35
Additional Terminal Block X504 (Option +L504)36
Thermistor Relays (Options +L505, +2L505)36
Pt100 Relays (Options +3L506, +5L506, +8L506)37
What the Option Contains37
Description37
Type Designation Label37
Type Designation Key38
Mechanical Installation41
Contents of this Chapter41
Examining the Installation Site41
Necessary Tools42
Moving and Unpacking the Drive43
Unpacking the Transport Package44
Checking the Delivery44
Moving the Drive Cabinet44
Fastening the Cabinet to the Floor45
General Rules45
Fastening Methods46
Alternative 1 - Clamping46
Alternative 2 - Using the Holes Inside the Cabinet46
Miscellaneous47
Cable Duct in the Floor below the Cabinet47
Arc Welding48
Guidelines for Planning the Electrical Installation49
Contents of this Chapter49
Limitation of Liability49
Selecting the Supply Disconnecting Device49
Selecting the Main Contactor49
Examining the Compatibility of the Motor and Drive50
Protecting the Motor Insulation and Bearings50
Requirements Table51
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and53
Additional Requirements for the Braking Applications53
Additional Requirements for ABB High-Output and IP23 Motors53
Additional Requirements for Non-ABB High-Output and IP23 Motors54
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage55
Additional Note for Sine Filters55
Selecting the Power Cables56
General Rules56
Typical Power Cable Sizes57
Alternative Power Cable Types58
Recommended Power Cable Types58
Power Cable Types for Limited Use58
Not Allowed Power Cable Types58
Motor Cable Shield58
Planning the Braking System59
Selecting the Control Cables59
Shielding59
Signals in Separate Cables59
Signals Allowed to be Run in the same Cable59
Relay Cable Type59
Control Panel Cable Length and Type59
Routing the Cables59
Separate Control Cable Ducts60
Continuous Motor Cable Shield or Enclosure for Equipment on the Motor Cable60
Implementing Thermal Overload and Short-Circuit Protection61
Protecting the Drive and Input Power Cable in Short-Circuits61
Protecting the Motor and Motor Cable in Short-Circuits61
Protecting the Drive and the Input Power and Motor Cables against Thermal Overload62
Protecting the Motor against Thermal Overload62
Protecting the Drive against Ground Faults62
Residual Current Device Compatibility62
Implementing the Emergency Stop Function62
Implementing the Safe Torque off Function63
Implementing the Power-Loss Ride-Through Function63
Units with Main Contactor (Option +F250)63
Supplying Power for the Auxiliary Circuits63
Using Power Factor Compensation Capacitors with the Drive63
Implementing a Safety Switch between the Drive and the Motor64
Using a Contactor between the Drive and the Motor64
Implementing a Bypass Connection65
Protecting the Contacts of Relay Outputs65
Connecting a Motor Temperature Sensor to the Drive I/O66
Electrical Installation67
Contents of this Chapter67
Warnings67
Checking the Insulation of the Assembly67
Drive67
Input Cable67
Motor and Motor Cable68
Brake Resistor Assembly68
Checking the Compatibility with Grounded Systems68
Connecting the Power Cables70
Connection Diagram70
Layout of the Power Cable Connection Terminals and Lead-Throughs (Frames R6 to R9)71
Layout of the Power Cable Connection Terminals and Lead-Throughs (Frames R10 to R11)72
Lead-Through of External Resistor and DC Cables73
Connection Procedure (IEC)73
Grounding the Motor Cable Shield at the Motor End75
Connecting the Control Cables75
Control Cable Connection Procedure75
Grounding the Outer Shields of the Control Cables at the Cabinet Lead-Through76
Routing the Control Cables Inside the Cabinet (Frames R6 to R9)78
Routing the Control Cables Inside the Cabinet (Frames R10 and R11)79
Connecting the External 230 V Uninterruptible Control Voltage (UPS, Option +G307)81
Connecting the Emergency Stop Push Buttons81
Q964)81
Wiring the Starter for Auxiliary Motor Fan (Options +M60081
Wiring the Thermistor Relay(S) (Options +L505 and +2L505)82
Wiring the Pt100 Relays (Options +2L506, +3L506, +5L506 and +8L506)83
Connecting the External Power Supply Cables for the Cabinet Heater and Lighting and Motor Heater (Options +G300, +G301)84
Connecting a PC85
Setting the Voltage Range of the Auxiliary Control Voltage Transformer (T21)86
Installing Option Modules87
Mechanical Installation of I/O Extension, Fieldbus Adapter and Pulse Encoder Interface87
Modules87
Wiring I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules87
Control Unit of Frames R6 to R989
Contents of this Chapter89
Layout90
Default I/O Connection Diagram of Frames R6 to R991
Notes92
Jumpers and Switches92
External Power Supply for the Control Unit92
AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 Sensor Inputs (XAI, XAO)93
DI6 (XDI:6) as PTC Sensor Input94
DIIL Input (XD24:1)94
Drive-To-Drive Link (XD2D)94
Safe Torque off (XSTO)95
Technical Data95
Control Unit of Frames R10 and R1199
Contents of this Chapter99
Layout100
Default I/O Connection Diagram of Frames R10 and R11101
Notes102
Drive-To-Drive Link (XD2D)102
Ground Isolation Diagram104
Installation Checklist105
Contents of this Chapter105
Warnings105
Checklist105
Start-Up107
Contents of this Chapter107
Start-Up Procedure107
Checks/Settings with no Voltage Connected107
Powering up the Drive107
Setting up the Drive Parameters, and Performing the First Start108
On-Load Checks108
Fault Tracing109
Contents of this Chapter109
Leds109
Warning and Fault Messages109
Maintenance111
Contents of this Chapter111
Maintenance Intervals111
Descriptions of Symbols111
Recommended Annual Maintenance Actions by the User111
Recommended Maintenance Intervals after Start-Up112
Cleaning the Interior of the Cabinet113
Heatsink113
Fans113
Replacing the Cabinet Fans (Frames R6 to R9)114
Replacing the Cabinet Fans (Frames R10 to R11)115
Replacing the Drive Module Main Fans (Frames R6 to R8)116
Replacing the Auxiliary Cooling Fan of the Drive Module (Frames R6 to R9)117
Replacing the Drive Module Main Fans (Frame R9)118
Replacing the Drive Module Main Fans (Frames R10 and R11)119
Replacing the Circuit Board Compartment Cooling Fan (Frames R10 and R11)122
Replacing the Drive Module (Frames R6 to R9)123
Replacing the Drive Module (Frames R10 and R11)127
Capacitors133
Reforming the Capacitors133
Replacing the Control Panel Battery134
Replacing the Control Unit Battery134
Memory Unit134
Transferring the Memory Unit135
Technical Data137
Contents of this Chapter137
Ratings137
Definitions138
Derating139
Ambient Temperature Derating139
Altitude Derating140
Deratings for Special Settings in the Drive Control Program140
Low Noise140
High Speed Mode142
Low Noise Mode Derating143
Dimensions and Weights145
Free Space Requirements145
Losses, Cooling Data and Noise146
Terminal and Lead-Through Data for the Power Cables146
IEC - Standard Configuration146
IEC - Option +E205147
R6: Input and Output Cable Terminal Size (Incoming Switch OT160)148
R7: Input and Output Cable Terminal Size (Incoming Switch OT160/OT250)149
R8: Input and Output Cable Terminal Size (Incoming Switch OT160/OT250)150
R7: Input and Output Cable Terminal Size (Incoming Switch OT315)151
R8: Input and Output Cable Terminal Size (Incoming Switch OT315)152
R9: Input and Output Cable Terminal Size (Incoming Switch OT315/OT400)153
R9: Input and Output Cable Terminal Size (Incoming Switch OT630)154
R7/R8: Input Cable Terminal Size (Incoming Switch OT315, Option +F250)156
R9: Input Cable Terminal Size (Incoming Switch OT315/OT400, Option +F250)157
R9: Input Cable Terminal Size (Incoming Switch OT630, Option +F250)158
R6/ R7/R8: Output Cable Terminal Size (DU/DT Filter, Option +E205)159
R9: Output Cable Terminal Size (DU/DT Filter, Option +E205)160
R10: Input and Output Cable Terminal Size161
R11: Input and Output Cable Terminal Size164
Terminal Data for the Control Cables167
Electrical Power Network Specification167
Motor Connection Data167
Control Unit Connection Data167
Efficiency167
Protection Classes168
Ambient Conditions168
Auxiliary Circuit Power Consumption168
Compliance with the en 61800-3:2004169
Definitions169
Materials169
Applicable Standards169
Category C3170
Category C4170
Cyber Security Disclaimer171
Disclaimer171
Dimension Drawings173
Frame Sizes R6 to R8174
Frame Size R9175
Frame Size R10176
Frame Size R11177
Safe Torque off Function179
Contents of this Chapter179
Resistor Braking181
Contents of this Chapter181
Operation Principle and Hardware Description181
Planning the Braking System181
Selecting the Brake Circuit Components181
Selecting a Custom Resistor182
Selecting and Routing the External Brake Resistor Cables182
Minimizing Electromagnetic Interference182
Maximum Cable Length183
EMC Compliance of the Complete Installation183
Placing the Brake Resistors183
Protecting the System against Thermal Overload183
Protecting the Resistor Cable against Short-Circuits183
Mechanical Installation of External Brake Resistors184
Electrical Installation184
Checking the Insulation of the Assembly184
Connection Diagram184
Connection Procedure184
Start-Up184
Technical Data185
Ratings185
Terminals and Cable Lead-Through Data186
Further Information187
Product and Service Inquiries187
Product Training187
Providing Feedback on ABB Drives Manuals187
Document Library on the Internet187

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