Name: DEMAG ACS880-DEMAG 04
Brand: DEMAG
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010420 enUS 211 323 44 719 IS 922

Hardware Manual

ACS880-DEMAG 04 Drives

(200 to 710 kW, 300 to 700 hp)

Table of Contents5
Safety Instructions15
Contents of this Chapter15
Use of Warnings and Notes15
General Safety in Installation, Start-Up and Maintenance16
Electrical Safety in Installation, Start-Up and Maintenance18
Precautions before Electrical Work18
Additional Instructions and Notes19
Grounding20
Additional Instructions for Permanent Magnet Motor Drives21
Safety in Installation, Start-Up and Maintenance21
Introduction to the Manual23
Contents of this Chapter23
Target Audience23
Contents of the Manual24
Categorization by Frame Size and Option Code25
Quick Installation, Commissioning and Operating Flowchart25
Terms and Abbreviations27
Operation Principle and Hardware Description29
Contents of this Chapter29
Product Overview30
Layout31
Standard Drive Module Configuration with Option +E20831
Drive Module for Flat Mounting (Option +C173)33
Drive Module with Full Power Cabling Panels (Option +H381)34
Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) and IP20 Shrouds (Option +0B051)35
Drive Module Configuration with Power Cable Connection Terminals on the Right-Hand Side of the Drive Module (Option +H391)36
Control Unit37
Control Panel37
Overview of Power and Control Connections38
External Control Connection Terminals39
External Control Unit Connection Cables40
Type Designation Label40
Type Designation Key41
Guidelines for Planning the Cabinet Installation45
Contents of this Chapter45
Limitation of Liability45
Installation Positions of the Drive Module45
Basic Requirements for the Cabinet45
Planning the Layout of the Cabinet46
Layout Example, Door Closed46
Layout Example, Door Open (Standard Drive Module Configuration)47
Layout Example, Door Open (Option +H391)48
Layout Example, Door Open (Option +0B051)49
Arranging the Grounding Inside the Cabinet50
Selecting the Busbar Material and Preparation of the Joints50
Tightening Torques50
Planning the Fastening of the Cabinet50
Planning the Cabinet Placement on a Cable Channel51
Planning the Electromagnetic Compatibility (EMC) of the Cabinet51
Planning the Cooling52
Preventing the Recirculation of Hot Air54
Bookshelf Mounting (Standard Drive Module Configuration)55
Bookshelf Mounting (Option +0B051)56
Bookshelf Mounting (Option +H381)57
Flat Mounting (Option +C173)58
Flat Mounting (Option +C173+0B051)59
Required Free Space60
Free Space at the Top of the Drive Module60
Free Space Around the Drive Module60
Other Installation Positions60
Drive Module on Its Back60
Planning the Placement of the Control Panel61
Planning the Use of Cubicle Heaters61
Air Inlet and Outlet Kits61
Guidelines for Planning the Electrical Installation63
Contents of this Chapter63
Selecting the Supply Disconnecting Device64
European Union64
Other Regions64
Selecting the Main Contactor64
Examining the Compatibility of the Motor and Drive64
Protecting the Motor Insulation and Bearings65
Requirements Table65
Additional Requirements for Explosion-Safe (EX) Motors67
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and67
Additional Requirements for the Braking Applications67
Additional Requirements for ABB High-Output and IP23 Motors67
Additional Requirements for Non-ABB High-Output and IP23 Motors67
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage68
Additional Note for Sine Filters68
Additional Note for Common Mode Filters68
Selecting the Power Cables69
General Rules69
Typical Power Cable Sizes70
Alternative Power Cable Types71
Recommended Power Cable Types71
Power Cable Types for Restricted Use71
Not Allowed Power Cable Types71
Motor Cable Shield72
Additional US Requirements72
Conduit72
Armored Cable / Shielded Power Cable72
Planning the Braking System73
Selecting the Control Cables73
Shielding73
Signals in Separate Cables73
Signals Allowed to be Run in the same Cable73
Relay Cable Type73
Control Panel Cable Length and Type73
Routing the Cables73
Separate Control Cable Ducts74
Continuous Motor Cable Shield or Enclosure for Equipment in the Motor Cable74
Implementing Thermal Overload and Short-Circuit Protection75
Protecting the Drive and Input Power Cable in Short-Circuits75
Circuit Breakers75
Protecting the Motor and Motor Cable in Short-Circuits76
Protecting the Motor against Thermal Overload77
Protecting the Drive against Ground Faults77
Residual Current Device Compatibility77
Connecting Drive Modules to a Common DC System77
Implementing the Emergency Stop Function78
Implementing the Safe Torque off Function78
Implementing the ATEX-Certified Safe Motor Disconnection Function (Option +Q971)78
Q972 and +Q973)78
Implementing the Power Loss Ride-Through Function79
Using Power Factor Compensation Capacitors with the Drive79
Implementing a Safety Switch between the Drive and the Motor79
Using a Contactor between the Drive and the Motor80
Implementing a Bypass Connection80
Example Bypass Connection81
Switching the Motor Power Supply from Drive to Direct-On-Line81
Switching the Motor Power Supply from Direct-On-Line to Drive82
Protecting the Contacts of Relay Outputs82
Implementing a Motor Temperature Sensor Connection83
Drive I/O, I/O Extension and Encoder Interface Modules83
Example Circuit Diagram84
Installation Instructions85
Contents of this Chapter85
Safety85
Checking the Installation Site85
Moving and Unpacking the Unit86
Package Drawings87
Checking the Delivery91
Installing the Motor Cable at the Motor End91
Checking the Insulation of the Assembly92
Drive92
Input Cable92
Motor and Motor Cable92
Brake Resistor and Resistor Cable93
Checking the Compatibility with IT (Ungrounded) Systems93
Installation Alternatives93
Standard Drive Module Configuration (Bookshelf Mounting)94
Drive Module Configuration for Flat Mounting (Option +C173)94
Optional Input Power Cable Connection Terminals and Ground Busbar Assembly (+H370)94
Drive Module with Full Cabling Panels (Option +H381)95
Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) and IP20 Shrouds (Option +0B051)95
Drive Module Configuration with Power Cable Connection Terminals on the Right-Hand Side of the Drive Module (Option +H391)95
Drive Module Without Pedestal (Option +0H354)96
Attaching the Drive Module to a Mounting Plate or Wall96
Attaching the Drive Module to a Mounting Plate or Wall (Option +H391)96
Alternatives for Grounding the Drive Module97
Installing the Bottom Grille for IP20 Degree of Protection98
Installing the EMC Filter (Option +E202)98
Connecting the Power Cables98
Power Cable Connection Diagram99
Power Cable Connection Procedure100
DC Connection100
Removing the Control Panel Holder from the External Control Unit101
Fastening the Control Cable Clamp Plate102
Connecting the External Control Unit to the Drive Module103
Routing the Control Unit Cables into the Drive Module103
Connections to the Drive Module103
Connections to the Control Unit104
Mounting the External Control Unit105
Mounting the External Control Unit to Wall105
Mounting the External Control Unit Vertically on a DIN Rail106
Mounting the Control Unit Horizontally on a DIN Rail106
Connecting the Control Cables to the Terminals of the Control Unit107
Default I/O Connection Diagram108
Notes109
External Power Supply for the Control Unit109
AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 Sensor Inputs (XAI, XAO)110
DI6 (XDI:6) as PTC Sensor Input111
DIIL Input (XD24:1)111
Drive-To-Drive Link (XD2D)111
Safe Torque off (XSTO)112
Safety Functions Module Connection (X12)112
Installing the Control Panel Holder Back Onto the External Control Unit112
Connecting the Control Cables to the Internal Control Unit (Option +P905)113
Connecting the Control Cables to the Internal Control Unit (Options +P905 and +0B051)114
Connecting a Control Panel115
Controlling Several Drives from One Control Panel through Panel Bus116
Connecting a PC117
Installing Optional Modules117
Installing the FSO Safety Functions Module (Options +Q972 and +Q973)117
Case 1: FSO Safety Functions Module on Slot 2118
Case 2: FSO Safety Functions Module above the Control Unit119
Installing I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules120
Wiring the Optional Modules120
Installation Example of the Standard Drive Module Configuration121
Contents of this Chapter121
Limitation of Liability121
Safety121
Required Parts122
Required Tools122
Overall Flowchart of the Installation Process122
Installing the Drive Module into a Cabinet123
Connecting the Power Cables and Installing the Shrouds123
Installing the Roof and Door (Rittal Parts)125
Installing the Roof and Door (ABB Air Filters and Roof)126
Removing the Protective Covering from the Drive Module Air Outlet127
Miscellaneous127
Input Power Cable Lead-Through from Top127
Attaching the Drive Module to a Mounting Plate127
Installation Example with Full Cabling Panels (Option +H381)129
Contents of this Chapter129
Limitation of Liability129
Safety129
Required Parts130
Required Tools130
Overall Flowchart of the Installation Process131
Installing the Mechanical Accessories into the Cabinet131
Connecting the Power Cables132
Connection Diagram132
Power Cable Connection Procedure133
Installing the Drive Module into the Cabinet135
Installation Procedure135
Assembly Drawing of Installing the Drive Module to the Cabinet (Frame R10)138
Assembly Drawing of Installing the Drive Module to the Cabinet (Frame R11)139
Assembly Drawing of Installing the Roof and Door140
Removing the Protective Covering from the Drive Module Air Outlet141
Miscellaneous141
Installations with Input and Motor Cables of Size 4 × 240 Mm2 Per Phase141
Installing the Rubber Grommet142
Modular Design of Rittal TS8 Cabinets143
Installation Checklist145
Contents of this Chapter145
Start-Up149
Contents of this Chapter149
Start-Up Procedure149
Fault Tracing151
Contents of this Chapter151
Leds with Options +J410151
Warning and Fault Messages151
Maintenance153
Contents of this Chapter153
Maintenance Intervals153
Descriptions of Symbols153
Recommended Annual Maintenance Actions by the User153
Recommended Maintenance Intervals after Start-Up154
Cabinet154
Cleaning the Interior of the Cabinet154
Heatsink155
Cleaning the Interior of the Heatsink155
Fans156
Replacing the Circuit Board Compartment Cooling Fan156
Replacing the Main Cooling Fans157
Replacing the Standard Drive Module158
Replacing the Drive Module with Option +H381160
Capacitors162
Reforming the Capacitors162
Replacing the Control Panel Battery162
Replacing the Control Unit Battery163
Replacing the Memory Unit164
Ordering Information165
Contents of this Chapter165
ACS-AP-W Control Panel165
Brake Resistors166
Output (Du/Dt) Filters166
Sine Filters166
Cabinet Ventilation166
Air Inlet Kits166
Air Outlet Kits169
Cooling Fans171
EMC Filter ARFI-10172
FSO Accessories Kit173
Retrofit Accessory Kits173
Technical Data175
Contents of this Chapter175
Marine Type-Approved Drives (Option +C132)175
Ratings175
When Is Derating Needed177
Ambient Temperature Derating177
Altitude Derating178
Deratings for Special Settings in the Drive Control Program178
Ex Motor, Sine Filter, Low Noise178
High Speed Mode180
Fuses (IEC)181
Ultrarapid (Ar) Fuses181
Fuses (UL)182
Dimensions, Weights and Free Space Requirements183
Losses, Cooling Data and Noise184
Terminal and Lead-Through Data for the Power Cables184
Units with Optional Cabling Panels (+H381)184
Mode Filter (+E208)185
Terminal Data for the Control Cables185
Electrical Power Network Specification185
Motor Connection Data185
Brake Resistor Connection Data185
DC Connection Data186
Control Unit Connection Data (ZCU-14)187
Control Panel Type189
Efficiency190
Protection Classes190
Ambient Conditions190
Materials191
Applicable Standards191
CE Marking192
Compliance with the European Low Voltage Directive192
Compliance with the European EMC Directive192
Compliance with the European Rohs Directive192
Compliance with the European Machinery Directive192
Compliance with en 61800-3:2004192
Definitions192
Category C2193
Category C3193
Category C4193
UL Marking194
UL Checklist194
CSA Marking195
China Rohs Marking195
EAC (Eurasian Conformity) Marking195
Approvals195
Generic Disclaimer195
Cybersecurity Disclaimer196
Dimension Drawings197
Contents of this Chapter197
R10 - Standard Configuration198
R10 with Options +E208+H370+J414+P905199
R10 with Options +0B051+C173+E208+H356+0H354+0H371200
R10 with Options +0B051+E208+H356+0H371201
R10 with Options +E208+H356+H381+J414+P905202
R10 - Cabling Panels (+H381) Installed into a Rittal TS 8 Cabinet203
Frame R10 with Options +E208+H370+H391+0J400204
R11 - Standard Configuration205
R11 with Options +E208+H370+J414+P905206
R11 with Options +0B051+E208+H356+0H371207
R11 with Options +E208+H356+H381+J414+P905208
R11 with Options +0B051+C173+E208+H356+0H354+0H371209
Frame R11 - Cabling Panels (+H381) Installed into a Rittal TS 8 Cabinet210
Bottom Plate for Option +H381 in Rittal TS 8 400 MM Wide Cabinet Installation211
Frame R11 with Options +E208+H370+H391+0J400212
Air Baffles for the Standard Drive Module and Option +C173213
Air Baffles for Option +H381 in Rittal TS 8 400 MM Wide Cabinet Installation214
External Control Unit215
Example Circuit Diagram 217217
Contents of this Chapter217
Example Circuit Diagram218
Safe Torque off Function219
Contents of this Chapter219
Description219
Compliance with the European Machinery Directive220
Wiring220
Activation Switch220
Cable Types and Lengths220
Grounding of Protective Shields221
Single Drive (Internal Power Supply)221
Dual-Channel Connection221
Single-Channel Connection222
Multiple Drives (Internal Power Supply)223
Multiple Drives (External Power Supply)224
Operation Principle225
Start-Up Including Acceptance Test225
Competence225
Acceptance Test Reports225
Acceptance Test Procedure225
Use227
Maintenance228
Competence228
Fault Tracing228
Safety Data229
Abbreviations229
Resistor Braking231
Contents of this Chapter231
Operation Principle and Hardware Description231
Planning the Braking System231
Selecting the Default Brake Circuit Components231
Selecting a Custom Resistor232
Selecting and Routing the External Brake Resistor Cables232
Minimizing Electromagnetic Interference233
Maximum Cable Length233
EMC Compliance of the Complete Installation233
Placing the Brake Resistors233
Protecting the System against Thermal Overload233
Protecting the Resistor Cable against Short-Circuits234
Mechanical Installation of External Brake Resistors234
Electrical Installation234
Checking the Insulation of the Assembly234
Connection Diagram234
Connection Procedure234
Start-Up234
Technical Data235
You Can Find the Technical Data of the Brake Resistors in the Manual „Technical Data Drives Accessories235
SAFUR Resistors235
Dimensions and Weights235
Terminals and Cable Lead-Through Data235
Du/Dt and Sine Filters237
Contents of this Chapter237
Du/Dt Filters237
When Is a Du/Dt Filter Needed237
Selection Table238
Ordering Codes238
Description, Installation and Technical Data of the FOCH Filters238
Sine Filters (on Request Only)238
When Is a Sine Filter Needed238
Derating239
Description, Installation and Technical Data of the Sine Filters239
Step-By-Step Drawings for Installing Full Cabling Panels (Option +H381) in a Rittal TS 8 400 MM Wide Cabinet245
Installation Procedure245
Step-By-Step Drawings for a Flat Installation Example in Rittal TS 8 600 MM Wide Cabinet 247247

Category	Controller
Model	ACS880-DEMAG 04
Series	ACS880
Control Method	Vector control
Output Frequency	0 ... 500 Hz
Cooling Method	Air-cooled

DEMAG ACS880-DEMAG 04 User Manual

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DEMAG ACS880-DEMAG 04 Specifications