ABB ACS880-04F-504A-3 User manual

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ABB INDUSTRIAL DRIVES
ACS880-04F drive modules
Hardware manual

ACS880-04F drive modules
Hardware manual
Table of contents
1. Safety instructions
5. Mechanical installation
7. Electrical installation
10. Start-up
3AXD50000034664 Rev D
EN
Original instructions
EFFECTIVE: 2022-08-31

Table of contents
1 Safety instructions
13Contents of this chapter ........................................................................
13Use of warnings and notes .....................................................................
14General safety in installation, start-up and maintenance ................................
16Electrical safety in installation, start-up and maintenance ..............................
16Electrical safety precautions ...............................................................
17Additional instructions and notes .........................................................
17Printed circuit boards ....................................................................
18Grounding ......................................................................................
19General safetyin operation .....................................................................
19Additional instructions for permanent magnet motor drives ..........................
19Safety in installation, start-up, maintenance ...........................................
20Safety in operation ...........................................................................
2 Introduction to the manual
21Contents of this chapter ........................................................................
21Applicability ........................................................................................
21Target audience ...................................................................................
21Purpose of the manual ..........................................................................
21Categorization by frame size and option code ............................................
22Quick installation, commissioning and operating flowchart ............................
23Terms and abbreviations .......................................................................
25Related documents ..............................................................................
3 Operation principle and hardware description
27Contents of this chapter ........................................................................
28Product overview .................................................................................
29Layout ...............................................................................................
29Standard drive module configuration ....................................................
31
Drive module without full-size output cable connection terminals (option +0H371)
and IP20 shrouds (option +0B051), with common mode filter (+E208) ...........
31Control unit .....................................................................................
32Overview of power and control connections ...............................................
32Type designation label ..........................................................................
33Type designation key ............................................................................
33Basic code ......................................................................................
34Option codes ...................................................................................
4 Guidelines for planning the mechanical installation
37Contents of this chapter ........................................................................
37Installation alternatives .........................................................................
37Channel installation ..............................................................................
37Basic requirements for the channel wall .................................................
38Installation principle ..........................................................................
Table of contents 5

39Cabinet installation ..............................................................................
39Layout example, outside view ..............................................................
40Layout example, inside view ................................................................
41Mounting the control panel on the cabinet door .......................................
42Installation positions other than vertical ................................................
43Required free space ..............................................................................
5 Mechanical installation
45Contents of this chapter ........................................................................
45Examining the installation site ................................................................
45Moving and unpacking the unit ................................................................
46Unpacking ......................................................................................
47Package drawings ............................................................................
49Examining the delivery .......................................................................
49Lifting ...........................................................................................
51Attaching alternatives ...........................................................................
51Attaching the drive module by the flange ...............................................
52Attaching the drive module by the heatsink ............................................
53Attaching the metallic shroud (standard) ...............................................
53Attaching the external control unit ...........................................................
54Attaching the external control unit to a mounting plate or wall ....................
54Attaching the external control unit vertically on a DIN rail ...........................
55Attaching the external control unit horizontally on a DIN rail .......................
6 Guidelines for planning the electrical installation
57Contents of this chapter ........................................................................
57Limitation of liability .............................................................................
57Selecting the main supply disconnecting device ..........................................
57European Union and United Kingdom ....................................................
58North America .................................................................................
58Other regions ..................................................................................
58Selecting the main contactor ..................................................................
58North America .................................................................................
58Other regions ..................................................................................
58Examining the compatibility of the motor and drive .....................................
59Protecting the motor insulation and bearings .........................................
59Requirements tables .........................................................................
59Requirements for ABB motors, P
n< 100 kW (134 hp) ..............................
60Requirements for ABB motors, P
n> 100 kW (134 hp) ..............................
61Requirements for non-ABB motors, P
n< 100 kW (134 hp) ........................
62Requirements for non-ABB motors, P
n> 100 kW (134 hp) ........................
62Abbreviations ..............................................................................
63Availability of d u /d t filter and common mode filter by drive type ..............
63Additional requirements for explosion-safe (EX) motors .........................
63
Additional requirements for ABB motors of types other than M2_, M3_, M4_,
HX_ and AM_ ................................................................................
63Additional requirements for braking applications .................................
63Additional requirements for ABB high-output and IP23 motors ................
63Additional requirements for non-ABB high-output and IP23 motors ..........
64Additional data for calculating the rise time and the peak line-to-line voltage .
65Additional note for sine filters ..........................................................
6 Table of contents

65Selecting the power cables .....................................................................
65General guidelines ............................................................................
66Typical power cable sizes ...................................................................
66Power cable types .............................................................................
66Preferred power cable types ............................................................
66Alternate power cable types ............................................................
67Not allowed power cable types .........................................................
67Additional guidelines, North America ....................................................
68Metal conduit ...............................................................................
68Power cable shield ............................................................................
69Grounding requirements ........................................................................
70Additional grounding requirements – IEC ...............................................
70Additional grounding requirements – UL (NEC) ........................................
70Selecting the control cables ....................................................................
70Shielding ........................................................................................
71Signals in separate cables ...................................................................
71Signals that can be run in the same cable ...............................................
71Relay cable ......................................................................................
71Control panel to drive cable ................................................................
71PC tool cable ...................................................................................
71Routing the cables ...............................................................................
71General guidelines – IEC .....................................................................
72General guidelines – North America .......................................................
73
Continuous motor cable shield/conduit or enclosure for equipment on the
motor cable ....................................................................................
73Separate control cable ducts ...............................................................
74
Protecting the drive, input power cable, motor and motor cable in short circuit
situations and against thermal overload ....................................................
74Protecting the drive and the input power cable in short-circuits ...................
74Protecting the motor and motor cable in short-circuits .............................
74Protecting the motor cables against thermal overload ..............................
75Protecting the motor against thermal overload .......................................
75
Protecting the motor against overload without thermal model or temperature
sensors ..........................................................................................
75Protecting the drive against ground faults .................................................
76Residual current device compatibility ....................................................
76Connecting drive modules to a common DC system .....................................
76Implementing a motor temperature sensor connection .................................
76
Connecting a motor temperature sensor to the drive through an option mod-
ule ................................................................................................
78Implementing the emergency stop function ...............................................
78Implementing theSafe torque offfunction .................................................
78Implementing the functions provided by the FSO safety functions module ........
78Using power factor compensation capacitors with the drive ..........................
79Using a safety switch between the drive and the motor .................................
79Implementing an ATEX-certified motor thermal protection ............................
79Implementing the power loss ride-through function .....................................
80Controlling a contactor between drive and motor ........................................
80Implementing a bypass connection ..........................................................
81Example bypass connection ................................................................
81Switching the motor power supply from drive to direct-on-line ................
82Switching the motor power supply from direct-on-line to drive ................
Table of contents 7

82Protecting thecontacts of relayoutputs ....................................................
7 Electrical installation
83Contents of this chapter ........................................................................
83Safety ...............................................................................................
83Grounding the motor cable shield at the motor end ......................................
84Measuring theinsulation ........................................................................
84Measuring the insulation resistance of the drive ......................................
84Measuring the insulation resistance of the input power cable ......................
84Measuring the insulation resistance of the motor and motor cable ...............
84Measuring the insulation resistance of the brake resistor circuit ..................
85Grounding system compatibility check ......................................................
85Corner-grounded and midpoint-grounded 525…690 V delta systems ............
85Grounding the drive module ...................................................................
86Connecting the power cables ..................................................................
87Power cable connection diagram ..........................................................
88Preparing the cable ends and making 360-degree grounding at the cable entry .
89Power cable connection procedure .......................................................
89.................................................................................................
90DC connection .................................................................................
90Removing the control panel holder from the external control unit ....................
91Attaching the control cable clamp plate .....................................................
91Connecting the external control unit to the drive module ...............................
91Control unit connection cables ............................................................
92Routing the control unit cables into the drive module ................................
92Connections to the drive module ..........................................................
93Connections tothe controlunit ............................................................
94Connecting the control cables to the terminals of the external control unit ........
95Installing the control panel holder back onto the external control unit ..............
96Connecting a control panel .....................................................................
96Panel bus (Control of several units from one control panel) ............................
98Connecting a PC ..................................................................................
99Installing option modules .......................................................................
8 Control unit of the drive
101Contents of this chapter ........................................................................
102ZCU-14 layout ......................................................................................
103Default I/O diagram of the drive control unit (ZCU-1x) ..................................
105Additional informationon the connections .................................................
105External power supply for the control unit (XPOW) ...................................
105DI6 as a PTC sensor input ...................................................................
105AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input ............................
106DIIL input ........................................................................................
106The XD2D connector ..........................................................................
107Safe torque off (XSTO) .......................................................................
107FSO safety functions module connection (X12) ........................................
108Connector data ...................................................................................
110ZCU-1x ground isolation diagram .........................................................
9 Installation checklist
111Contents of this chapter ........................................................................
8 Table of contents

111Checklist ............................................................................................
10 Start-up
113Contents of this chapter ........................................................................
113Reforming the capacitors .......................................................................
113Start-up procedure ...............................................................................
11 Fault tracing
115Contents of this chapter ........................................................................
115LEDs .................................................................................................
115Warning and fault messages ...................................................................
12 Maintenance
117Contents of this chapter ........................................................................
117Maintenance intervals ...........................................................................
117Description of symbols ......................................................................
118Recommended maintenance intervals after start-up .................................
119Cabinet .............................................................................................
119Cleaning the interior of the cabinet .......................................................
119Heatsink ............................................................................................
120Cleaning the interior of the heatsink .....................................................
121Fans .................................................................................................
121Replacing the circuit board compartment cooling fans ..............................
123Replacing the main cooling fans ...........................................................
124Replacing the standard drive module ........................................................
125Capacitors .........................................................................................
125Reforming the capacitors ...................................................................
125Control panel ......................................................................................
125Replacing the ZCU-14 control unit battery ..................................................
126Replacing the memory unit of ZCU-14 .......................................................
127Functional safety components ................................................................
13 Ordering information
129Contents of this chapter ........................................................................
129Output (d u /d t ) filters ............................................................................
129Sine filters ..........................................................................................
130FSO accessories kit ..............................................................................
130Retrofit accessory kits ...........................................................................
14 Technical data
131Contents of this chapter ........................................................................
131Electrical ratings ..................................................................................
133Output derating ..................................................................................
133When is derating necessary .................................................................
133Ambient temperature derating ............................................................
134Altitude derating ..............................................................................
135Deratings for special settings in the drive control program .........................
137High speed mode .............................................................................
Table of contents 9

139Fuses (IEC) .........................................................................................
139Calculating the short-circuit current of the installation ..............................
140Calculation example ......................................................................
141Fuses (UL) ..........................................................................................
142Circuit breakers ...................................................................................
142Dimensions, weights and free space requirements .......................................
143Package dimensions .........................................................................
144Losses, cooling data and noise ................................................................
145Typical power cable sizes .......................................................................
146Terminal and entry data for the power cables .............................................
146
Units without full-size output cable connection terminals and with a common
mode filter (+E208) ...........................................................................
146Terminal data for the control cables .........................................................
146Electrical power network specification ......................................................
146Motor connection data ..........................................................................
147Brake resistor data ...............................................................................
147d u /d t and sine filters ............................................................................
148DC connection data ..............................................................................
148Control panel type ................................................................................
148Efficiency ...........................................................................................
149Energy efficiency data (ecodesign) ...........................................................
149Protection classes for module .................................................................
150Ambient conditions ..............................................................................
151Colors ...............................................................................................
151Materials ............................................................................................
151Drive .............................................................................................
151Package materials for module products .................................................
151Package materials for options, accessories and spare parts .......................
151Materials of manuals .........................................................................
151Disposal ............................................................................................
152Applicable standards ............................................................................
152Markings ............................................................................................
153EMC compliance (IEC/EN 61800-3) ...........................................................
153Definitions ......................................................................................
154Category C3 ....................................................................................
154Category C4 ....................................................................................
155Compliance with the European Machinery Directive ......................................
156UL checklist ........................................................................................
156Disclaimers .........................................................................................
156Generic disclaimer ............................................................................
157Cybersecurity disclaimer ....................................................................
15 Dimension drawings
159Contents of this chapter ........................................................................
160Standard configuration – IP20 (UL Type Open) ............................................
161Drive module with options +E208 and +H370 – IP20 (UL Type Open) .................
162Drive module with options +0B051+E208+0H371 – IP00 (UL Type Open) ............
163Drive module with options +0B051+E208+0H371+C217 – IP00 (UL Type Open) ....
164Drive module with options +0B051+0H371 – IP00 (UL Type Open) ....................
165Mounting plate opening ........................................................................
167External control unit .............................................................................
10 Table of contents