ABB ACS880-07C User manual

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ABB INDUSTRIAL DRIVES
Hardware manual
ACS880-07C drives
(45 to 710 kW, 50 to 700 hp)

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List of related manuals
You can find manuals and other product documents in PDF format on the Internet. See section
Document library on the Internet on the inside of the back cover. For manuals not available in the
Document library, contact your local ABB representative.
The code below opens an online listing of the manuals applicable to this product.
Drive hardware manuals and guides Code (English) Code (Chinese)
ACS880-07C hardware manual 3AUA0000105718 3AXD50000615896
ACS-AP-X assistant control panels user’s manual 3AUA0000085685 3AXD50000022895
ACS880-07C lifting device user’s manual 3AUA0000131337 3AXD50000016067
ABB Drive Connectivity Control Panel User’s manual 3AXD50000515110 3AXD50000514663
Drive firmware manuals and guides
ACS880 primary control program firmware manual 3AUA0000085967 3AXD50000009105
Quick start-up guide for ACS880 drives with primary
control program
3AUA0000098062 3AXD50000009107
Option manuals and guides
Drive composer start-up and maintenance PC tool
user’s manual
3AUA0000094606
User’s manual for Emergency stop, stop category 0
(+Q951) for ACS880-07C/17/37 drives
3AUA0000119895
User’s manual for Emergency stop, stop category 1
(+Q952) for ACS880-07C/17/37 drives
3AUA0000119896
User’s manual for Emergency stop, stop category 0
(+Q963) for ACS880-07C/17/37 drives
3AUA0000119908
User’s manual for Emergency stop, stop category 1
(+Q964) for ACS880-07C/17/37 drives
3AUA0000119909
ACS880-07C manuals

Hardware manual
ACS880-07C drives
(45 to 710 kW, 50 to 700 hp)
3AXD50000764860 Rev A
EN
EFFECTIVE: 2022-8-26
2022 ABB. All Rights Reserved.
1. Safety instructions
4. Mechanical installation
Table of contents
6. Electrical installation
10. Start-up

5
Table of contents
1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . 16
Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . 20
Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2. Introduction to the manual
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Quick installation, start-up and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3. Operation principle and hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Block diagram of the brake and DC options (+D150) . . . . . . . . . . . . . . . . . . . . . . . . . 27
General information on the cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cabinet layout of frames R6 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cabinet layout of frames R10 to R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Door switches and lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Main switch-disconnector Q1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Control by PC tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Descriptions of cabinet options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
IP22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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

6
Pt100 relays (options +3L506, +5L506, +8L506) . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
What the option contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Moving and unpacking the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Unpacking the transport package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Moving the drive cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fastening the cabinet to the floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fastening methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Alternative 1 – Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Alternative 2 – Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5. Guidelines for planning the electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Selecting the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and
AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Additional requirements for the braking applications . . . . . . . . . . . . . . . . . . . . . . 53
Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . 53
Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . 54
Additional data for calculating the rise time and the peak line-to-line voltage . . . 55
Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7
Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . 60
Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . 61
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . 61
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . 61
Protecting the drive and the input power and motor cables against thermal overload 62
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Units with main contactor (option +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Supplying power for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . 63
Implementing a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . 64
Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connecting a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . 66
6. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Checking the compatibility with grounded systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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 cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connection procedure (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Grounding the outer shields of the control cables at the cabinet lead-through . . . 76
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 buttons (options +Q951, +Q952, +Q963,
+Q964) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Wiring the starter for auxiliary motor fan (options +M600…+M605) . . . . . . . . . . . 81
Wiring the thermistor relay(s) (options +L505 and +2L505) . . . . . . . . . . . . . . . . . . 82
Wiring the Pt100 relays (options +2L506, +3L506, +5L506 and +8L506) . . . . . . . 83

8
Connecting the external power supply cables for the cabinet heater and lighting and
motor heater (options +G300, +G301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Setting the voltage range of the auxiliary control voltage transformer (T21) . . . . . . . . . 86
Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface
modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Wiring I/O extension, fieldbus adapter and pulse encoder interface modules . . . . . 87
7. Control unit of frames R6 to R9
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Default I/O connection diagram of frames R6 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Jumpers and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
External power supply for the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) . . . . . . . 93
DI6 (XDI:6) as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
DIIL input (XD24:1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8. Control unit of frames R10 and R11
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Default I/O connection diagram of frames R10 and R11 . . . . . . . . . . . . . . . . . . . . . . . 101
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Ground isolation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9. Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10. Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Checks/Settings with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Powering up the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Setting up the drive parameters, and performing the first start . . . . . . . . . . . . . 108
On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
11. Fault tracing
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

9
12. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Descriptions of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . 111
Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . . 112
Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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 cooling fan in front of the circuit board compartment (frames R10 and R11)
120
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
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Replacing the control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Transferring the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
13. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . . . . 140
Low noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
High speed mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Low noise mode derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . 146
IEC - standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
IEC - option +E205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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
R6/ R7/R8: Input cable terminal size (incoming switch OT160/OT250, option +F250) .

10
155
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 size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
R11: Input and output cable terminal size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Control unit connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Auxiliary circuit power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Compliance with the EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
14. Dimension drawings
Frame sizes R6 to R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Frame size R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Frame size R10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Frame size R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
15. Safe torque off function
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
16. Resistor braking
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Selecting the brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Selecting a custom resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Selecting and routing the external brake resistor cables . . . . . . . . . . . . . . . . . . . . 182
Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . 183
Mechanical installation of external brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

11
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Terminals and cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

12

Safety instructions 13
1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install and
operate the drive and do maintenance on the drive. If you ignore the safety instructions,
injury, death or damage can occur.
Use of warnings
Warnings tell you about conditions which can cause injury or death, or damage to the
equipment. They also tell you how to prevent the danger. The manual uses these warning
symbols:
Electricity warning tells about hazards from electricity which can cause injury
or death, or damage to the equipment.
General warning tells about conditions, other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
Electrostatic sensitive devices warning tells you about the risk of
electrostatic discharge which can cause damage to the equipment.

14 Safety instructions
General safety in installation, start-up and maintenance
These instructions are for all personnel that install the drive and do maintenance work on
it.
WARNING! Obey these instructions. If you ignore
them, injury or death, or damage to the equipment
can occur.
•Secure the cabinet to the floor (see chapter
Mechanical installation) to prevent it from toppling over
when you pull out the module. The drive module is
heavy and has a high center of gravity.
•Wear protective gloves and long sleeves. Some parts
have sharp edges.
•Handle the drive module carefully:
•Use safety shoes with a metal toe cap to avoid foot injury.
•For frames R10 and R11:
•Lift the module with a lifting device only. Use the designated lifting points.
•Make sure that the module does not topple over when you move it on the floor:
Extend the support legs by pressing each leg a little down (1, 2) and turning it
aside. Whenever possible secure the module also with chains.
•Do not tilt the drive module (A). It is heavy and its center of gravity is high. The
module overturns from a sideways tilt of 5 degrees. Do not leave the module
unattended on a sloping floor.
1
2
3
A

Safety instructions 15
•Do not use the module installation ramp with plinth heights which exceed the
maximum height (50 mm [1.97 in]) marked on the ramp.
•Secure the module installation ramp carefully.
•To prevent the drive module from falling, attach its top lifting lugs with chains to the
cabinet lifting lug before you push the module into the cabinet and pull it from the
cabinet. Work carefully preferably with help from another person as shown below.
Keep a constant pressure with one foot on the base of the module to prevent the
module from falling on its back.
•Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors,
remain hot for a while after disconnection of the electrical supply.
•Keep the drive in its package or protect it otherwise from dust and burr from drilling
and grinding until you install it. Protect also the installed drive against dust and burr.
Electrically conductive debris inside the drive can cause damage or malfunction.
•Vacuum clean the area below the drive before the start-up to prevent the drive cooling
fan from drawing the dust inside the drive.
•Make sure that there is sufficient cooling. See section Examining the installation site
on page 41.
•Before you connect voltage to the drive, make sure that the cabinet doors are closed.
Keep the doors closed during the operation.
•Before you adjust the drive operation limits, make sure that the motor and all driven
equipment can operate throughout the set operation limits.
•Before you activate the automatic fault reset or automatic restart functions of the drive
control program, make sure that no dangerous situations can occur. These functions
reset the drive automatically and continue operation after a fault or supply break.
•The maximum number of drive power-ups is five in ten minutes. Too frequent power-
ups can damage the charging circuit of the DC capacitors.
•Make sure that any safety circuits (for example, emergency stop and Safe torque off)
are validated in start-up. For the Safe torque off, see chapter Safe torque off function
on page 179. For other safety functions, see their separate instructions.
•Beware of the hot air flow from the air inlet.
•Do not block the air inlet or outlet when the drive is running.

16 Safety instructions
Note:
•If you select an external source for start command and it is on, the drive will start
immediately after fault reset unless you configure the drive for pulse start. See the
firmware manual.
•When the control location is not set to Local, the stop key on the control panel will not
stop the drive.
•Only authorized persons are allowed to repair a malfunctioning drive.
Electrical safety in installation, start-up and maintenance
Precautions before electrical work
These warnings are for all personnel who do work on the drive, motor cable or motor.
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur. If you are not a qualified electrician, do not
do installation or maintenance work. Go through these steps before you begin any
installation or maintenance work.
1. Clearly identify the work location.
2. Disconnect all possible voltage sources.
•Open the main switch-disconnector (Q1) of the drive.
•Open the disconnector of the supply transformer as the main switch-disconnector
(Q1) of the drive does not remove the voltage from the input busbars of the drive.
•Make sure that reconnection is not possible. Lock the disconnectors to open
position and attach a warning notice to them.
•If the drive is connected to a permanent magnet motor, disconnect the motor from
the drive with safety switch or by other methods.
•Disconnect any external power sources from the control circuits before you do
work on the control cables.
•After you disconnect the drive, always wait 5 minutes to let the intermediate circuit
capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized.
•Use a multimeter with an impedance of at least 1 Mohm.
•Make sure that the voltage between the drive input power terminals (L1, L2, L3)
and the grounding (PE) busbar is close to 0 V.
•Make sure that the voltage between the drive output power terminals
(T1/U,T2/V,T3/W) and the grounding (PE) busbar is close to 0 V.
•Make sure that the voltage between the drive module UDC+ and UDC- terminals
and the grounding (PE) busbar is close to 0 V.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation work.

Safety instructions 17
Additional instructions and notes
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
•Keep the cabinet doors closed when the drive is powered. With the doors open, a risk
of a potentially fatal electric shock, arc flash or high-energy arc blast exists.
•Make sure that the electric power supply network, motor/ generator meet the
specification of the drive.
•If you have a cardiac pacemaker or other electronic medical device, keep away from
the area near motor, drive, and the drive power cabling when the drive is in operation.
There are electromagnetic fields present which can interfere with the function of such
devices. This can cause a health hazard.
•If you are not a qualified electrician, do not do installation or maintenance work.
•Do not install a drive with EMC filter option +E200 on an ungrounded power system or
a high resistance-grounded (over 30 ohms) power system.
•Do not connect the drive to a voltage higher than what is on the type designation label.
If you do, the brake chopper starts to operate which causes the overheating of the
brake resistor (if present). Overvoltage can also cause the motor to rush to its
maximum speed.
•We do not recommend that you secure the cabinet by arc welding. If you have to, obey
the instructions in section Arc welding on page 48.
Note:
•The motor cable terminals of the drive are at a dangerous voltage when the input
power is on, regardless of whether the motor is running or not.
•The DC bus and brake resistor terminals (UDC+, UDC-, R+ and R-) are at a
dangerous voltage.
•External wiring can supply dangerous voltages to the terminals of relay outputs
(XRO1, XRO2 and XRO3).
•The Safe torque off function does not remove the voltage from the main and auxiliary
circuits. The function is not effective against deliberate sabotage or misuse.
WARNING! Use a grounding wrist band when you handle the printed circuit
boards. Do not touch the boards unnecessarily. The boards contain components
sensitive to electrostatic discharge.
WARNING! Obey these instructions. If you ignore them, equipment malfunction
and damage to the fiber optic cables can occur.

18 Safety instructions
•Handle the fiber optic cables with care.
•When you unplug the cables, always hold the connector, not the cable itself.
•Do not touch the ends of the fibers with bare hands as the ends are extremely
sensitive to dirt.
•Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is
35 mm (1.4 in).

Safety instructions 19
Grounding
These instructions are for all personnel who are responsible for the grounding of the drive.
WARNING! Obey these instructions. If you ignore them, injury or death and
equipment malfunction can occur, and electromagnetic interference can increase.
•If you are not a qualified electrician, do not do grounding work.
•Always ground the drive, the motor and adjoining equipment. This is necessary for the
personnel safety. Proper grounding also reduces electromagnetic emission and
interference.
•Make sure that the conductivity of the grounding conductors is sufficient. See section
Selecting the power cables on page 56. Obey the local regulations.
•Connect the power cable shields to protective earth (PE) of the drive to make sure of
personnel safety.
•Make a 360° grounding of the power and control cable shields at the cable entries to
suppress electromagnetic disturbances.
•In a multiple-drive installation, connect each drive separately to the protective earth
(PE) busbar of the switch board or the transformer.
Note:
•You can use power cable shields as grounding conductors only when their conductivity
is sufficient.
•As the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you
must use a fixed protective earth connection. See standard EN 61800-5-1, 4.3.5.5.2.

20 Safety instructions
Additional instructions for permanent magnet motor
drives
Safety in installation, start-up and maintenance
These are additional warnings concerning permanent magnet motor drives. The other
safety instructions in this chapter are also valid.
WARNING! Obey these instructions. If you ignore them, injury or death and
equipment malfunction can occur.
•Only qualified electricians are allowed to carry out installation and maintenance.
•Do not do work on the drive when the permanent magnet motor is rotating. A rotating
permanent magnet motor energizes the drive including its input power terminals.
Before installation, start-up and maintenance work on the drive:
•Stop the motor.
•Disconnect the motor from the drive with a safety switch or by other means.
•If you cannot disconnect the motor, make sure that the motor cannot rotate during
work. Make sure that no other system, like hydraulic crawling drives, can rotate the
motor directly or through any mechanical connection like felt, nip, rope, etc.
•Measure that the installation is de-energized.
•Use a multimeter with an impedance of at least 1 Mohm.
•Make sure that the voltage between the drive output terminals (U2, V2, W2) and
the grounding (PE) busbar is close to 0 V.
•Make sure that the voltage between the drive input power terminals (L1, L2, L3)
and the grounding (PE) busbar is close to 0 V.
•Make sure that the voltage between the drive module UDC+ and UDC- terminals
and the grounding (PE) busbar is close to 0 V.
•Install temporary grounding to the drive output terminals (U2, V2, W2). Connect the
output terminals together as well as to the PE.
•Make sure that the operator cannot run the motor over the rated speed. Motor
overspeed causes overvoltage can damage or explode the capacitors in the
intermediate circuit of the drive.