ABB ACS880-M04 - Mechanical Installation; Contents of this Chapter; Contents of the Package

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Mechanical installation 49

Mechanical installation

Contents of this chapter

The chapter describes the mechanical installation procedure of the drive.

Contents of the package

The drive is delivered in a cardboard box. To open, remove any banding and lift the

top off the box.

Main Page

Table of Contents5
Safety Instructions13
Contents of this Chapter13
Use of Warning and Notes in this Manual13
General Safety in Installation, Start-Up and Maintenance14
Electrical Safety in Installation, Start-Up and Maintenance15
Precautions before Electrical Work15
Additional Instructions and Notes16
Grounding17
Additional Instructions for Permanent Magnet Motor Drives18
Safety in Installation, Start-Up and Maintenance18
General Safety in Operation19
About the Manual21
Contents of this Chapter21
Applicability21
Intended Audience21
Categorization According to Frame Size21
Categorization According to the + Code22
Contents of the Manual22
Quick Installation and Commissioning Flowchart24
Terms and Abbreviations26
Operation Principle and Hardware Description29
Contents of this Chapter29
ACS880-M04 Drive Overview29
Operation Principle30
Main Circuit30
Motor Control30
Layout31
General31
Module Layout - Frame R132
Module Layout - Frame R433
Power Connections and Control Interfaces34
Type Designation Label35
Type Designation Key36
Planning the Cabinet Installation39
Contents of this Chapter39
Cabinet Construction40
Cabinet Frame40
Disposition of Devices40
Grounding of Mounting Structures40
Free Space Requirements41
Vertically Alone or Side by Side41
Horizontally Alone or Side by Side Back Installation42
Horizontally Alone Side Installation42
Cooling and Degrees of Protection44
Preventing Recirculation of Hot Air45
Cabinets with Multiple Modules46
Cabinet Heaters47
Mechanical Installation49
Contents of this Chapter49
Contents of the Package49
Delivery Check and Drive Module Identification50
Before Installing the Drive51
Checking the Installation Site51
Required Tools for Installing the Drive51
Installing the Drive52
Installing the Drive with Screws52
Installing Drive to a DIN Installation Rail - Frames R1 and R2 Only53
Installing Mains Choke53
Installing EMC Filter53
Installing Brake Resistor53
Planning the Electrical Installation55
Contents of this Chapter55
Checking the Compatibility of the Motor and Drive55
Selecting the Supply Disconnecting Device56
Requirements in European Union (EU) Countries56
Requirements in Non-EU Countries56
Selecting the Power Cables57
Typical Power Cable Sizes58
Alternative Power Cable Types59
Motor Cable Shield60
Additional US Requirements60
Selecting the Control Cables62
Shielding62
Signals in Separate Cables62
Signals Run in the same Cable62
Relay Cable62
Control Panel Cable62
Drive Composer PC Tool Cable63
FPBA-01 PROFIBUS DP Adapter Module Connectors63
Routing the Cables64
General Rules64
Cable Routing Diagram64
Separate Control Cable Ducts65
Continuous Motor Cable Shield or Enclosure for Equipment on the Motor Cable65
Implementing Thermal Overload and Short-Circuit Protection66
Protecting the Drive and Input Power Cable in Short-Circuits66
Protecting the Motor and Motor Cable in Short-Circuits66
Protecting the Drive and the Input Power and Motor Cables against Thermal Overload66
Protecting the Motor against Thermal Overload67
Protecting the Drive against Ground Faults67
Residual Current Device Compatibility67
Implementing the Emergency Stop Function67
Implementing the Safe Torque off Function67
Implementing the Power-Loss Ride-Through Function68
Using a Safety Switch between the Drive and the Motor68
Using a Contactor between the Drive and the Motor68
Implementing a Bypass Connection68
Example of a Bypass Connection69
Changing the Motor Power Supply from the Drive to Direct-On-Line70
Changing the Motor Power Supply from Direct-On-Line to the Drive70
Protecting the Contacts of Relay Outputs71
Electrical Installation73
Contents of this Chapter73
Removing the Cover Assembly74
Checking the Insulation of the Assembly75
Drives75
Input Power Cable75
Motor and Motor Cable Insulation75
Break Resistor Assembly Insulation75
Checking the Compatibility with IT (Ungrounded) and Corner-Grounded TN Systems76
Disconnecting the Internal EMC Filter - All Frame Sizes76
Connecting the Power Cables77
Power Cable Connection Diagram77
Power Cable Connection Procedure78
Installing the Power Cable Clamp Plates80
Power Cable Connections81
DC Connection82
Installing the Optional Modules84
Connecting the Control Unit85
ZCU-14 Layout and Connections85
Control Connections to the ZCU Control Unit86
External Power Supply for the Control Unit (XPOW)87
DI6 as a PTC Sensor Input88
AI1 or AI2 as a Pt100 or KTY84 Sensor Input89
DIIL Input89
Drive-To-Drive Link90
Safe Torque off91
Safety Functions (X12)91
Control Unit Connector Data91
Ground Isolation Diagram (ZCU)94
Connecting the Control Cables - All Frame Sizes96
Installation Checklist99
Contents of this Chapter99
Checklist99
Start-Up101
Contents of this Chapter101
Start-Up Procedure101
Maintenance103
Contents of this Chapter103
Safety103
Maintenance Intervals103
Heatsink104
Cooling Fan105
Replacing Fan (Frames R1 and R2)105
Replacing Fan (Frames R3 and R4)106
Reforming the Capacitors107
Memory Unit107
Technical Data109
Contents of this Chapter109
Ratings110
Nominal Ratings with 230 V AC Supply110
Nominal Ratings with 400 V AC Supply110
Nominal Ratings with 460 V AC Supply111
Nominal Ratings with 500 V AC Supply112
Definitions112
Derating113
Ambient Temperature Derating113
Altitude Derating113
Low Motor Noise Derating113
Dimensions and Weights116
Terminal and Lead-Through Data for Power Cables116
Screwdrivers for the Terminals of Main Circuit116
Losses, Cooling Data and Noise117
Supply Cable Fuses118
Gg Fuses119
Gr Fuses120
Ar Fuses121
AC Input (Supply) Connection122
Supply Cable Fuses 119122
DC Connection123
Motor Connection124
ZCU Control Unit125
Ground Isolation Diagram (ZCU)128
Efficiency129
Cooling129
Protection Classes129
Ambient Conditions130
Materials132
Applicable Standards133
CE Marking134
Compliance with the European Low Voltage Directive134
Compliance with the European EMC Directive134
Compliance with the European ROHS Directive134
Compliance with the European Machinery Directive134
Compliance with the en 61800-3:2004135
Definitions135
Category C2135
Category C3136
Category C4136
UL Marking138
UL Checklist138
RCM Marking138
Disclaimers139
Generic Disclaimer139
Cyber Security Disclaimer139
The Safe Torque off Function141
Contents of this Chapter141
Description141
Compliance of STO Function with the European Machinery Directive142
Connecting the STO143
Activation Switch143
Cable Types and Lengths143
Grounding of Protective Shields143
STO Wiring - Single Drive Unit (Internal Power Supply)144
STO Wiring - Multiple Drive Units (Internal Power Supply)145
STO Wiring - Multiple Drive Units (External Power Supply)146
STO Operation Principle147
STO Start-Up and Acceptance Test147
Competency for Testing STO Function147
STO Acceptance Test Reports147
STO Acceptance Test Procedure148
Using the STO Function149
STO Function Maintenance151
Competency for STO Operations151
STO Fault Tracing152
Relevant Failure Modes152
STO Data153
Safety Data153
Temperature Profile for Safety Value Calculations153
STO Indication Data153
STO Abbreviations154
Mains Chokes155
Contents of this Chapter155
When Is a Mains Choke Required155
Selecting a Mains Choke156
Guidelines for Installing the Mains Choke157
Connecting the Mains Choke157
EMC Filters159
Contents of this Chapter159
EMC Standards159
EMC Filter Emission Limits160
EMC Filtering Option160
Selecting EMC Filters161
Installing EMC Filters - JFI-A1/JFI-B1 (Frame R1/R2, Category C3)162
JFI-X1 Filter Installation Guidelines162
JFI-X1 Filter Connection Diagram162
Installing the JFI-A1 Filter163
Installing the JFI-B1 Filter165
Installing EMC Filter - JFI-0X (Frames R1167
JFI-0X Filter Installation Guidelines167
JFI-0X Filter Connection Diagram167
Du/Dt and Common Mode Filtering169
Contents of this Chapter169
When Is Du/Dt or Common Mode Filtering Required169
Selecting the Du/Dt Filters170
Additional Requirements for the Braking Applications171
Installing Du/Dt and Common Mode Filters171
Du/Dt Filters Data172
Du/Dt Filter Types172
Common Mode Filter Types172
Du/Dt Filters Dimensions and Weights172
Du/Dt Filters Degree of Protection172
Resistor Braking173
Contents of this Chapter173
Selecting Brake Choppers and Resistors173
Brake Choppers173
Brake Resistors174
Brake Choppers Data Table175
Brake Resistors Data Table177
Brake Resistors Degree of Protection177
Brake Resistors Dimensions178
Installing and Wiring Brake Resistors179
Contactor Protection of Drive179
Commissioning the Braking Circuit180
Dimension Drawings 182182
Frame Size R1182
Frame Size R2183
Frame Size R3184
Frame Size R4185
Mains Chokes (Type CHK-0X)186
Mains Choke - CHK-XX Dimensions186
EMC Filters (Type JFI-X1)187
Jfi-A1187
Jfi-B1188
EMC Filters (Type JFI-0X)189
EMC Filter - JFI-XX Dimensions190
DIM a MM (In.) 120 (4.72) 150 (5.91) 150 (5.91) 150 (5.91)190
DIM B MM (In.) 146 (5.75) 175 (6.89) 175 (6.89) 175 (6.89)190
DIM C MM (In.) 79 (3.11)190
DIM D MM (In.)190
DIM E MM (In.) 114 (4.49)190
Weight Kg (Lbs) 1.8 (4.0) 3.8 (8.4)190
MM 2 (AWG) (20190
Brake Resistors (Type JBR-XX)191
Brake Resistor - JBR-XX Dimensions192
Tightening Torque - Main Terminals192
Further Information194
Product and Service Inquiries194
Product Training194
Providing Feedback on ABB Drives Manuals194
Document Library on the Internet194

ABB ACS880-M04 - Mechanical Installation; Contents of this Chapter; Contents of the Package

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