ABB ACS880-107

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External power supply

OUT

SGND

IN1

IN2

OUT

SGND

IN1

IN2

OUT

SGND

IN1

IN2

+24 V

24 V DC

–+

XSTO

Inverter unit1

Control unit2

Activation switchK

* OUT1 in inverters with ZCU-12 control units.

198 The Safe torque off function

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Table of Contents5
Introduction to the Manual11
Contents of this Chapter11
Applicability11
Safety Instructions11
Target Audience11
Categorization by Frame Size, Option Code and Item Designation12
Use of Component Designations12
Terms and Abbreviations12
Related Documents13
Operation Principle and Hardware Description15
Contents of this Chapter15
Overview Diagram of the Drive System15
Inverter Unit Hardware17
General17
Cabinet System17
Cooling17
Inverter Module Frame Sizes R1I18
General18
Module Layout Examples18
Standard Cabinet Layout19
Layout of Cubicle with Frame R1I20
Inverter Module Frame Size R5I23
General23
Module Layout23
Standard Cabinet Layout23
Layout of Cubicle with Frame R5I Modules in Their Own Compartments (Option +C204)24
Inverter Module Frame Sizes R6I and R7I26
Module Layout26
Cabinet Layout26
Motor Cabling27
Inverter Module Frame Size R8I and Multiples28
Cooling Fans29
Control Electronics29
Cabinet Layout29
Motor Cabling31
Control Interfaces32
Overview of Control Connections of the ZCU Control Unit32
Overview of the Control Connections of the BCU Control Unit33
The ACS-AP-W Control Panel33
Control by PC Tools34
Fieldbus Control34
Other Control Devices34
DC Switch-Disconnector (Option +F286)34
Charging Switch (Frame R8I and Multiples Only)34
Type Designation Labels35
Inverter Unit Type Designation Label35
Inverter Module Type Designation Label35
Type Designation Key37
Type Designation Key of the Inverter Unit37
Option Codes37
Type Designation Key of the Inverter Module41
Electrical Installation43
Contents of this Chapter43
Warnings43
Electrical Safety Precautions44
General Notes45
Printed Circuit Boards45
Handling Fiber Optic Cables45
Measuring the Insulation46
Measuring the Insulation Resistance of the Drive46
Measuring the Insulation Resistance of the Motor and Motor Cable46
Connecting the Motor Cable - Frame Sizes R1I47
Connection Diagram47
Motor Cable Connection Procedure47
Connecting the Motor Cable - Frame Sizes R6I and R7I49
Connection Diagram49
Motor Cable Connection Procedure49
Motor Terminal Cubicle or Sine Output Filter52
Motor Connection Diagram (Without Option +H366)52
Motor Connection Diagram (with Option +H366)52
Procedure53
Removing an Inverter Module53
Removing the Fan Carriage of an Inverter Module54
Connecting the Motor Cables56
Installing the Fan Carriage of an Inverter Module58
Installing an Inverter Module58
Terminal Cubicle59
Output Busbars59
Connection Diagram59
Procedure59
Use of Fasteners in Cable Lug Connections61
Installing Optional Modules on the Control Unit62
Installing an FSO Safety Functions Module (Frame Sizes R1I62
Installing an FSO Safety Functions Module (Frame Sizes R8I and Multiples)63
Installation of I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules65
Connecting the Control Cables66
Control Cable Connection Procedure66
Grounding the Outer Shields of the Control Cables 360° at the Cabinet Entry66
Routing the Control Cables Inside the Cabinet68
Connecting Control Cabling68
Connecting a 230/115 V AC Auxiliary Voltage Supply (UPS, Option +G307)69
Connecting the Emergency Stop Push Buttons (Options +Q951, +Q952, +Q963, +Q964, +Q978,+Q979)69
Connecting the Emergency Stop Push Buttons (Option +Q951)70
Wiring the Starter for Auxiliary Motor Fan (Options +M6Xx)70
Wiring the PTC Thermistor Relay(S) (Options +L505, +2L505, +L513 and +2L513)70
Wiring the Pt100 Relays (Option +Nl506)70
Wiring the Pt100 Relays (Option +Nl514)71
Powering the Heating and Lighting Equipment (Options +G300, +G301 and +G313)71
Connecting a PC72
Panel Bus (Control of Several Units from One Control Panel)73
Control Units of the Drive77
Contents of this Chapter77
General77
Layout78
Layout79
Default I/O Diagram of the Inverter Control Unit (ZCU)80
BCU Layout83
Default I/O Diagram of the Inverter Control Unit (BCU)85
Additional Information on the Connections89
Power Supply for the Control Unit (XPOW)89
DIIL Input89
The XD2D Connector89
Safe Torque off (XSTO, XSTO OUT)90
FSO Safety Functions Module Connection (X12)90
SDHC Memory Card Slot91
Connector Data92
BCU Ground Isolation Diagram95
ZCU Ground Isolation Diagram96
Installation Checklist97
Contents of this Chapter97
Checklist97
Start-Up99
Contents of this Chapter99
Start-Up Procedure99
Maintenance103
Contents of this Chapter103
Maintenance Intervals103
Description of Symbols103
Recommended Maintenance Intervals after Start-Up103
Maintenance Timers and Counters104
Cabinet105
Cleaning the Interior of the Cabinet105
Cleaning the Exterior of the Drive105
Cleaning the Door Air Inlets (IP22 and IP42)106
Replacing the Inlet Door Filters (IP54)107
Replacing the Roof Outlet Filters (IP54)107
Cleaning the Heatsink107
Cooling Fans108
Module Cooling Fans109
Replacing the R1I and R2I Module Cooling Fan109
Replacing the R3I and R4I Module Cooling Fan110
Replacing the R5I Module Main Cooling Fan (Without Option +C204)111
Replacing the R5I Module Main Cooling Fan (with Option +C204)112
Replacing the R5I Module Auxiliary Cooling Fan113
Replacing the R6I and R7I Module Cooling Fan113
Replacing R8I Module Cooling Fan (Speed-Controlled Version)115
Replacing R8I Module Cooling Fan (Direct-On-Line Version)116
Replacing the Circuit Board Compartment Fan118
Cabinet Cooling Fans119
Replacing R1I119
Replacing the Control Cubicle Fan (Frame R8I and Multiples)121
Inverter Modules121
Replacing R1I121
Replacing R5I Inverter Module (Without Option +C204)122
Replacing R5I Inverter Module (with Option +C204, Modules in Their Own Compartments)123
Replacing R6I and R7I Inverter Modules124
Replacing R8I Inverter Modules126
Removing an Inverter Module126
Installing an Inverter Module131
Activating the Reduced Run Function of the Inverter Unit133
Replacing DC Fuses (Frame R8I and Multiples)135
Capacitors136
Reforming the Capacitors137
Functional Safety Components137
Control Units137
Replacing the Memory Unit (ZCU or BCU Control Unit)137
Replacing the ZCU-14 Control Unit Battery138
Replacing the BCU Control Unit Battery139
Control Panel140
Technical Data141
Contents of this Chapter141
Ratings141
Definitions144
Derating145
Surrounding Air Temperature Derating145
Altitude Derating145
Inverter Modules Used, DC Fuses, and DC Capacitances146
Noise and Cooling Characteristics150
Sine Output Filter Data153
Input Power (DC) Connection154
Motor Connection Data154
Typical Power Cable Sizes155
Terminal and Cable Entry Data for the Power Cables156
Output Terminals (Frames R1I156
Output Terminals (Frames R6I157
Output Terminals (Frame R8I)158
Connection Capability (Frame R8I)158
Control Connections159
Efficiency159
Energy Efficiency Data (Ecodesign)160
Protection Classes160
Ambient Conditions160
Cooling161
Colors161
Materials161
Drive161
Packaging of Drive161
Packaging of Options162
Manuals162
Disposal162
Applicable Standards162
Markings163
Tightening Torques163
Electrical Connections163
Mechanical Connections163
Insulation Supports163
Cable Lugs163
Disclaimers164
Generic Disclaimer164
Cyber Security Disclaimer164
Dimensions and Weights165
Contents of this Chapter165
Frames R1I165
Weights165
Frames R6I and R7I166
Dimension Drawing - 400 MM Wide Cubicle167
Frame R8I and Multiples168
Dimension Drawing - R8I (Without +C128 or +H353), Bottom Cable Exit169
Dimension Drawing - R8I (Without +C128 or +H353), Top Cable Exit170
Dimension Drawing - 2×R8I (Without +C128 or +H353), Bottom Cable Exit171
Dimension Drawing - 2×R8I (Without +C128 or +H353), Top Cable Exit172
Dimension Drawing - 3×R8I (Without +C128 or +H353), Bottom Cable Exit173
Dimension Drawing - 3×R8I (Without +C128 or +H353), Top Cable Exit174
Dimension Drawing - Drive Control Unit (DCU) (300 MM)175
Location and Size of Output Terminals176
Units Without Common Motor Terminal Cubicle176
Units with Common Motor Terminal Cubicle (+H359)184
The Safe Torque off Function191
Contents of this Chapter191
Description191
Chinery (Safety) Regulations192
Wiring193
Activation Switch193
Cable Types and Lengths193
Grounding of Protective Shields193
Dual-Channel Connection with Internal Power Supply194
Frames R1I194
Frame R8I and Multiples195
Single-Channel Connection of Activation Switch196
Multiple Inverter Units197
Internal Power Supply197
External Power Supply198
Operation Principle199
Start-Up Including Validation Test200
Competence200
Validation Test Reports200
Validation Test Procedure200
Use202
Maintenance204
Competence204
Perfect Proof Test Procedure205
Simplified Proof Test Procedure205
Fault Tracing206
Safety Data207
Terms and Abbreviations209
TÜV Certificate210

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