ABB industrial drives

Hardware manual
ACS880-104 inverter modules
List of related manuals
General manuals Code (English)
Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301
Electrical planning instructions for ACS880 multidrive cabinets and 3AUA0000102324
modules
Cabinet design and construction instructions for ACS880/ACS880LC 3AUA0000107668
multidrive modules
BCU-02/12/22 control units hardware manual 3AUA0000113605

Supply module manuals

ACS880-204 IGBT supply units as modules hardware manual 3AUA0000131525
ACS880 IGBT supply control program firmware manual 3AUA0000131562
ACS880-304 +A003 diode supply modules hardware manual 3AUA0000102452
ACS880-304 +A018 diode supply modules hardware manual 3AXD50000011408
ACS880 diode supply control program firmware manual 3AUA0000103295
ACS880-904 regenerative rectifier modules hardware manual 3AXD50000020457
ACS880 regenerative rectifier control program firmware manual 3AXD50000020827

Inverter module manuals and guides

ACS880-104 inverter modules hardware manual 3AUA0000104271
ACS880 primary control program firmware manual 3AUA0000085967
ACS880 primary control program quick start-up guide 3AUA0000098062

Brake module and DC/DC converter module manuals

ACS880-604 1-phase brake chopper modules hardware manual 3AUA0000106244
ACS880-604 3-phase brake chopper modules hardware manual 3AXD50000022033
ACS880-604 (3-phase) brake control program firmware manual 3AXD50000020967
ACS880-1604 DC/DC converter modules hardware manual 3AXD50000023642
ACS880 DC/DC converter control program firmware manual 3AXD50000024671

Option manuals and guides

ACS880 +C132 marine type-approved drive modules and module 3AXD50000037752
packages supplement
ACX-AP-x assistant control panels user’s manual 3AUA0000085685
Drive composer start-up and maintenance PC tool user’s manual 3AUA0000094606
Drive (IEC 61131-3) application programming manual 3AUA0000127808
Installation frames for ACS880 multidrive modules hardware manual 3AXD50000010531
FDPI-02 diagnostics and panel interface user’s manual 3AUA0000113618
FSO-12 safety functions module user’s manual 3AXD50000015612
Manuals and quick guides for I/O extension modules, fieldbus adapters,
safety options, etc.

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.
 Hardware manual
ACS880-104 inverter modules

Table of contents

4. Cabinet construction

5. Electrical installation

7. Start-up

 2017 ABB Oy. All Rights Reserved. 3AUA0000104271 Rev G

EN
EFFECTIVE: 2017-01-16
 Table of contents 5

Table of contents

1. Introduction
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Categorization by frame size, option code and component designation . . . . . . . . . . . . . 18
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overview diagram of the drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inverter module hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Frames R1i to R4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Module layout – Frame R1i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Module layout – Frame R4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Overview circuit diagram of an inverter cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cabinet layout and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Frame R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Overview circuit diagram of an inverter cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cabinet layout and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Frames R6i and R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DC connection and capacitor charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overview circuit diagram of a frame R6i inverter unit . . . . . . . . . . . . . . . . . . . . . . 33
Overview circuit diagram of a frame R7i inverter unit . . . . . . . . . . . . . . . . . . . . . . 34
Cabinet layout and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DC connection and capacitor charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connectors X50…X53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fiber optic connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Overview circuit diagram of a frame R8i inverter unit . . . . . . . . . . . . . . . . . . . . . . 39
Overview circuit diagram of a frame 2×R8i inverter unit . . . . . . . . . . . . . . . . . . . . 40
Cabinet layout and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Inverter unit control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Overview of control connections of the ZCU control unit . . . . . . . . . . . . . . . . . . . . . . 41
Overview of control connections of the BCU control unit . . . . . . . . . . . . . . . . . . . . . . 42
The ACS-AP-x control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Control by PC tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6 Table of contents

3. Unpacking the module

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Unpacking – Frames R1i…R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Unpacking – Frames R6i…R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4. Cabinet construction
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
R1i…R4i modules in a 400 mm wide Rittal TS 8 enclosure . . . . . . . . . . . . . . . . . . . 49
Overview of kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Stage 1: Installation of common parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Stage 2: Installation of bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Stage 3: Installation of mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Stage 4: Installation of DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Stage 5: Installation of mounting plate shrouds . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Stage 6: Installation of inverter modules and air guides . . . . . . . . . . . . . . . . . . . . 57
Stage 7: Installation of du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
R1i…R4i modules in a 600 mm wide Rittal TS 8 enclosure . . . . . . . . . . . . . . . . . . . 59
Overview of kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Stage 1: Installation of common parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Stage 2: Installation of bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Stage 3: Installation of mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Stage 4: Installation of DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Stage 5: Installation of mounting plate shrouds . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Stage 6: Installation of inverter modules and air guides . . . . . . . . . . . . . . . . . . . . 67
Stage 7: Installation of du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
R1i…R4i modules in a 800 mm wide Rittal TS 8 enclosure . . . . . . . . . . . . . . . . . . . 69
Overview of kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Stage 1: Installation of common parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Stage 2: Installation of bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Stage 3: Installation of mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Stage 4: Installation of DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Stage 5: Installation of mounting plate shrouds . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Stage 6: Installation of inverter modules and air guides . . . . . . . . . . . . . . . . . . . . 77
Stage 7: Installation of du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
R5i modules in a 400 mm wide Rittal TS 8 enclosure . . . . . . . . . . . . . . . . . . . . . . . . 79
Overview of kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Stage 1: Installation of common parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Stage 2: Installation of bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Stage 3: Installation of inverter module mounting plate . . . . . . . . . . . . . . . . . . . . 84
Stage 4: Installation of DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Stage 5: Installation of front mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Stage 6: Installation of inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Stage 7: Installation of du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
R5i modules in a 600 mm wide Rittal TS 8 enclosure . . . . . . . . . . . . . . . . . . . . . . . . 89
Overview of kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Stage 1: Installation of common parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Stage 2: Installation of bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Stage 3: Installation of inverter module mounting plate . . . . . . . . . . . . . . . . . . . . 94
Stage 4: Installation of DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
 Table of contents 7

Stage 5: Installation of front mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Stage 6: Installation of inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Stage 7: Installation of du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
One R6i/R7i module in a 400 mm wide Rittal TS 8 enclosure . . . . . . . . . . . . . . . . . . 99
Overview of kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Stage 1: Installation of common parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Stage 2: Installation of bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Stage 3: Installation of support beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Stage 4 (R6i): Installation of DC busbars and charging components . . . . . . . . . 105
Stage 4 (R7i): Installation of DC busbars and charging components . . . . . . . . . 106
Stage 5: Installation of common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Stage 6A: Installation of AC busbars (without du/dt filters) . . . . . . . . . . . . . . . . . 108
Stage 6B: Installation of AC busbars (with du/dt filters) . . . . . . . . . . . . . . . . . . . . 109
Stage 7: Installation of inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Stage 8: Installation of shrouding brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
One R8i module in a 400 mm wide Rittal TS 8 enclosure . . . . . . . . . . . . . . . . . . . . 112
Overview of kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Stage 1: Installation of common parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Stage 2A: Installation of DC busbars (1) (without DC switch/charging) . . . . . . . . 116
Stage 2B: Installation of DC busbars (1) (with DC switch/charging) . . . . . . . . . . 117
Stage 3: Installation of module installation parts and lead-throughs . . . . . . . . . . 118
Stage 4A: Installation of quick connector and output (AC) busbars (cable
connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Stage 4B: Installation of quick connector and output (AC) busbars (common
AC output busbar connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Stage 5A: Installation of DC busbars (2) (without DC switch/charging) . . . . . . . . 121
Stage 5B: Installation of DC busbars (2) (with DC switch/charging) . . . . . . . . . . 122
Stage 6: Installation of shrouding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Stage 7: Installation of inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Two R8i modules in a 600 mm wide Rittal TS 8 enclosure . . . . . . . . . . . . . . . . . . . 125
Overview of kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Stage 1: Installation of common parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Stage 2A: Installation of DC busbars (1) (without DC switch/charging) . . . . . . . . 129
Stage 2B: Installation of DC busbars (1) (with DC switch/charging) . . . . . . . . . . 130
Stage 3: Installation of module installation parts and lead-throughs . . . . . . . . . . 131
Stage 4A: Installation of quick connector and output (AC) busbars (cable
connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Stage 4B: Installation of quick connector and output (AC) busbars (cable
connection with bridging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Stage 4C: Installation of quick connector and output (AC) busbars (common
AC output busbar connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Stage 5A: Installation of DC busbars (2) (without DC switch/charging) . . . . . . . . 135
Stage 6: Installation of shrouding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Stage 7: Installation of inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
One R8i module in a 400 mm wide generic enclosure . . . . . . . . . . . . . . . . . . . . . . . 139
Two R8i modules in a 600 mm wide generic enclosure . . . . . . . . . . . . . . . . . . . . . . 141
Three R8i modules in a 800 mm wide generic enclosure . . . . . . . . . . . . . . . . . . . . . 143

5. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Static electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
8 Table of contents

Optical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Power connections – Frames R1i…R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Frames R1i and R2i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Frames R3i…R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . 150
Power connections – Frames R6i…R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
R6i inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
R7i inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
R8i inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
2×R8i inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . 155
Replacing ACS800 R8i modules with ACS880 R8i modules . . . . . . . . . . . . . . . . . . . . 156
Connecting the control cables – All frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Installation of I/O extension and fieldbus adapter modules . . . . . . . . . . . . . . . . . . . 161
Installation of an FSO-xx safety functions module . . . . . . . . . . . . . . . . . . . . . . . . . 162
Installation onto a ZCU control unit (Frames R1i…R7i) . . . . . . . . . . . . . . . . . . . 162
Installation onto a BCU control unit (Frame R8i and multiples) . . . . . . . . . . . . . 163
Installation beside the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Panel bus (Control of several inverter units from one control panel) . . . . . . . . . . . . . . 167

6. Installation checklist

7. Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Checks/Settings with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Connecting voltage to the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Checks with auxiliary voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Powering up the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Checks with voltage connected to the inverter unit . . . . . . . . . . . . . . . . . . . . . . 174
Control from an overriding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

8. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Maintenance timers and counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Cleaning the module heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Cleaning the door air inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Cleaning the door air inlets (IP20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Cleaning the door air inlets (IP42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
 Table of contents 9

Cleaning the door air inlets (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Replacing the module cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Frames R1i and R2i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Frames R3i and R4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Frame R5i – Main cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Frame R5i – Auxiliary cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Frames R6i and R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Frame R8i – Main cooling fan (modules without option +C188) . . . . . . . . . . . . . 185
Frame R8i – Direct-on-line main cooling fan (option +C188) . . . . . . . . . . . . . . . . 187
Frame R8i – Circuit board compartment fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Replacing the cabinet cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Cabinets with ABB air outlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Cabinets with other fan types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Replacing a frame R6i/R7i inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Replacing a frame R8i inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
LED indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Reduced run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Starting reduced run operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Resuming normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

9. Ordering information
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Kit code key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Frames R1i…R4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
ACS-AP-x control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
DC-side components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
DC bus installation parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Module-specific DC fuses (IEC, UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Module-specific DC fuse bases (IEC, UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Main DC switch/disconnector kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Main DC fuses (IEC, UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
AC-side components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Output (du/dt) filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Mechanical installation accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Mounting plate shroud kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Air guide kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Cabinet ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Air inlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Air outlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Frame R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
ACS-AP-x control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
DC-side components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
DC bus installation parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Module-specific DC fuses (IEC, UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
10 Table of contents

Module-specific DC fuse bases (IEC, UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Main DC switch/disconnector kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Main DC fuses (IEC, UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
AC-side components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Output (du/dt) filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Mechanical installation accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Mounting plate shroud kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Fuse base shroud kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Cabinet ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Air inlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Air outlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Frames R6i and R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
ACS-AP-x control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
DC-side components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
DC bus installation parts (for Rittal TS 8 enclosures) . . . . . . . . . . . . . . . . . . . . . 236
DC fuses (IEC, UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
DC switch/disconnector kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Charging kit (R7i only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
DC connection kit (for Rittal TS 8 enclosures) . . . . . . . . . . . . . . . . . . . . . . . . . . 238
DC busbars with common mode filter holder (for Rittal TS 8 enclosures) . . . . . 240
DC busbars with fuse and common mode filter holders (for generic
enclosures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
AC-side components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
AC busbar kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Output (du/dt) filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Mechanical installation accessories and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Inverter module mounting parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Shrouding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Cabinet ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Air inlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Air outlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Cooling fan for IP54 air outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
ACS-AP-x control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Control electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Inverter control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Fiber optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Control circuit plug connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Wire sets for use with the reduced run function . . . . . . . . . . . . . . . . . . . . . . . . . 251
DC-side components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
DC bus installation parts (for Rittal TS 8 enclosures) . . . . . . . . . . . . . . . . . . . . . 251
DC connection parts 1 of 2 (for Rittal TS 8 enclosures) . . . . . . . . . . . . . . . . . . . 252
DC connection parts 1 of 2 (for generic enclosures) . . . . . . . . . . . . . . . . . . . . . 254
DC connection parts 2 of 2 (for Rittal TS 8 or generic enclosures) . . . . . . . . . . 256
Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
DC fuses (IEC, UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
DC switch/disconnector kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Charging kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Charging resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
 Table of contents 11

AC-side components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Quick connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Output busbars/shrouds kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Lead-through kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Mechanical installation accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Inverter module top/bottom guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Ramp (for Rittal TS 8 enclosures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Shrouding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Cabinet ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Air inlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Air outlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Cooling fans for IP54 air outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

10. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Output frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Cooling characteristics, noise, DC capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Allowable mounting orientations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Input power (DC) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Motor (AC) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Auxiliary power consumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Control equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Cabinet cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Fuse data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Ferrules used with 400 V and 500 V units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Ferrules used with 690 V units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Flush-end fuse blocks used with 400 V and 500 V units . . . . . . . . . . . . . . . . . . . . . 290
Flush-end fuse blocks used with 690 V units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Common tightening torques for screw connections . . . . . . . . . . . . . . . . . . . . . . . . . 291
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Mechanical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Insulation supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
12 Table of contents

11. The inverter control unit

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
ZCU-12 layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
ZCU-14 layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
BCU layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Default I/O connection diagram (ZCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Default I/O connection diagram (BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . 301
ZCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
BCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
DI6 as a PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
AI1 or AI2 as a Pt100, Pt1000 or KTY84 sensor input . . . . . . . . . . . . . . . . . . . . . . 302
DIIL input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Drive-to-drive link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Safe torque off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
FSO-xx safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . 304
SDHC memory card slot (BCU-x2 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Control unit connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

12. The Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 310
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Single inverter unit (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Dual-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Single-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Frame n×R8i inverter unit (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . 313
Multiple inverter units (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Multiple inverter units (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

13. Resistor braking using frame R1i…R4i inverter modules

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Using R1i…R4i modules for resistor braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
 Table of contents 13

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Selecting the brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Selecting and routing the brake resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Placing the brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Protecting the resistor cable against short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Checking the insulation of the brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . 329
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Resistor dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Resistor connectors on inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

14. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Frame R1i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Frame R2i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Frame R3i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Frame R4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Frame R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Frame R6i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Frame R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Frame R8i with option +P942 (ACS800 retrofit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Control electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
ZCU-14 control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
BCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
DPMP-01 door mounting kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
DC fuses and fuse bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Fuse, 14 × 51 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Mersen US141 (Z331153F) fuse disconnector (for 14 × 51 mm fuses) . . . . . . . . . . 351
Fuse, 27 × 60 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Mersen US271MI (R227600C) fuse disconnector (for 27 × 60 mm fuses) . . . . . . . . 352
Mersen PS272PREMCPS (N220076) fuse disconnector (for R5i, 27 × 60 mm
fuses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
DC fuse blocks for frames R5i…R8i (Bussmann) . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Switchgear and charging components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
OS_ switch fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
OS100GJ04FP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
OS160GD04F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
OS200DZ22F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
OT_ switch/disconnectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
OT200E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
OT400E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
OT400E22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
OT400U11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
14 Table of contents

OT400U22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
OT600U11, OT630E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
OT1200U__, OT1600E__ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
OT2500E22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
OHB_ switch handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
OHB65J6, OHB125J12, OHB145J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
OHB150J12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
OHB274J12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
OA1G10/OA3G01 auxiliary contact blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
AF190-30-22-13 contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Charging controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
CAV 120 C resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
ZRF 30/165 resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
Miscellaneous components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
R3G225-RH17-23 / R2E225-RA92-17 cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . 372
CRBB/4-400/188 cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Output (du/dt) filters for frames R1i…R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Quick connector for frame R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Insertion/extraction ramp for frame R8i modules . . . . . . . . . . . . . . . . . . . . . . . . . . 376

15. Circuit diagrams

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Component designations used in the diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Frames R1i…R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Frame R6i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Frames R1i…R4i – Sheet 001 (Main circuit, control unit) . . . . . . . . . . . . . . . . . . . . . . 383
Frames R1i…R4i – Sheet 020 (Auxiliary voltage distribution) . . . . . . . . . . . . . . . . . . . 384
Frames R1i…R4i – Sheet 026 (Cabinet cooling fan control) . . . . . . . . . . . . . . . . . . . . 385
Frame R5i – Sheet 001 (Main circuit, control unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Frame R5i – Sheet 020 (Auxiliary voltage distribution) . . . . . . . . . . . . . . . . . . . . . . . . 387
Frame R5i – Sheet 026 (Cabinet cooling fan control) . . . . . . . . . . . . . . . . . . . . . . . . . 388
Frame R6i – Sheet 001 (Main circuit, control unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Frame R6i – Sheet 020 (Auxiliary voltage distribution) . . . . . . . . . . . . . . . . . . . . . . . . 390
Frame R7i – Sheet 001 (Main circuit, control unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Frame R7i – Sheet 020 (Auxiliary voltage distribution) . . . . . . . . . . . . . . . . . . . . . . . . 392
Frame R8i (with DC switch) – Sheet 001 (DC circuit) . . . . . . . . . . . . . . . . . . . . . . . . . 393
Frame R8i (with DC switch) – Sheet 005 (Inverter module) . . . . . . . . . . . . . . . . . . . . 394
Frame R8i (with DC switch) – Sheet 020 (Auxiliary voltage distribution) . . . . . . . . . . . 395
Frame R8i (with DC switch) – Sheet 040 (Control unit) . . . . . . . . . . . . . . . . . . . . . . . . 396
Frame R8i (with DC switch) – Sheet 061 (STO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Frame 2×R8i – Sheet 001 (DC circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Frame 2×R8i – Sheet 003 (Inverter modules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Frame 2×R8i – Sheet 020 (Auxiliary voltage distribution) . . . . . . . . . . . . . . . . . . . . . . 400
Frame 2×R8i – Sheet 040 (Control unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Frame 2×R8i – Sheet 061 (STO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
 Table of contents 15

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
16 Table of contents
 Introduction 17

1
Introduction

Contents of this chapter

This chapter gives the basic information on the manual.

Applicability
The manual applies to ACS880-104 inverter modules intended for user-defined cabinet
installations.

Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, or use the
drive. The complete safety instructions are given in ACS880 multidrive cabinets and
modules safety instructions (3AUA0000102301 [English]).
• Read the task-specific safety instructions before starting the task. See the section
describing the task.

Target audience
This manual is intended for people who plan the installation, install, commission, use and
service ACS880-104 inverter modules. Read the manual before working on the modules.
The reader is expected to know the standard electrical wiring practices, electronic
components, and electrical schematic symbols.
18 Introduction

Contents of the manual

• Hardware description
• Unpacking the module
• Cabinet construction
• Electrical installation
• Installation checklist
• Start-up
• Maintenance
• Ordering information
• Technical data
• The inverter control unit
• The Safe torque off function
• Resistor braking using frame R1i…R4i inverter modules
• Dimension drawings
• Circuit diagrams.

Related documents
The user documentation of a multidrive module delivery includes a USB memory stick with
all manuals for the product series.
You can find all documentation related to ACS880 multidrive modules on the Internet at
https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content.
For other manuals, see the inside of the front cover. If needed, contact your local ABB
representative.

Categorization by frame size, option code and

component designation
The instructions and technical data which concern only certain module or frame sizes are
marked with the size identifier.
The module size can be identified from the basic code visible on the type designation
label, for example, ACS880-104-0100A-3 where 0100A is the module size. The option
codes of the module are listed after the plus sign. Section Type designation label on page
44 explains the type designation code in detail.
The frame size of a module can be, for example, R1i, R4i, R7i, R8i or 3×R8i (the latter
describing an inverter unit consisting of three parallel-connected R8i inverter modules).
The Ratings table on page 277 lists the units and frame sizes.
Some device names in the manual include the component designations in brackets, for
example “[K1]” to make it possible to identify the components in the circuit diagrams of the
drive.
 Introduction 19

Terms and abbreviations

Term/abbreviation Explanation

BCON Type of control board. See BCU.

BCU Type of control unit.

The BCU is used to control inverter units of frame sizes R8i and up. It is
connected to the inverter modules using fiber optic cables.
The external I/O control signals of the inverter unit are mostly connected to the
BCU, or optional I/O extensions mounted onto it.
See also ZCON and ZCU.

BDPS Internal power supply board in frame R8i modules. The BDPS is a double-fed
(AC/DC) power supply which internally powers the circuit boards of the
module. The board switches between the AC (connector X50) and DC (main
DC terminals) supplies automatically. The board switches from AC to DC
always when the DC voltage is above 300 V.

BFPS Type of a power supply and control board for the speed-controlled cooling fan
in frame R8i modules. The BFPS is located in the fan control box below the
main cooling fan of the module.

Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to the
brake resistor when necessary. The chopper operates when the DC link
voltage exceeds certain maximum limit. The voltage rise is typically caused by
deceleration (braking) of a high inertia motor.

CMF Common mode filtering

Cubicle One section of a cabinet-installed drive. A cubicle is typically behind a door of

its own.

DC link DC circuit between supply unit and inverter unit(s)

DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage. Contained
within the inverter module.

DC switch/disconnector Main switch and disconnecting device for an inverter unit. See Inverter unit.

DDCS Distributed drives communication system; a protocol used in optical fiber

communication

DPMP Optional mounting platform for door mounting of control panel

Drive Frequency converter for controlling AC motors

EFB Embedded fieldbus

EMC Electromagnetic compatibility

EMI Electromagnetic interference

FAIO Optional analog I/O extension module

FBA Fieldbus adapter

FCAN Optional CANopen adapter module

FCNA Optional ControlNet adapter module

FDCO Optional DDCS communication module

FDNA Optional DeviceNet adapter module

FDPI Optional diagnostics and panel interface

FECA Optional EtherCAT adapter module

20 Introduction

Term/abbreviation Explanation

FEN-01 Optional TTL encoder interface module

FEN-11 Optional absolute encoder interface module

FEN-21 Optional resolver interface module

FEN-31 Optional HTL encoder interface module

FENA-11 Optional EtherNet/IP, Modbus/TCP and PROFINET IO adapter module

FENA-21 Optional dual-port EtherNet/IP, Modbus/TCP and PROFINET IO adapter

module

FEPL Optional POWERLINK adapter module

FIO-01 Optional digital I/O extension module

FIO-11 Optional analog I/O extension module

Four-quadrant operation Operation of a machine as a motor or generator in quadrants I, II, III and IV as
shown below. Also used as an attribute of a drive; a regenerative drive can
operate the electric machine in all four quadrants, a non-regenerative only in
two. In quadrants I and III, the machine operates as a motor, whereas in
quadrants II and IV it operates as a generator (regenerative braking).

FPBA Optional PROFIBUS DP adapter module

Frame (size) Refers to the construction type of the inverter module. For example, several
inverter modules with different power ratings have the same basic
construction, and the frame size is is used in reference to all those module
types.
To determine the frame size of a specific inverter module, see the rating tables
in chapter Technical data (page 277).

FSCA Optional Modbus RTU adapter module

FSO Optional safety functions module

Generic enclosure Parts that are labeled suitable for generic enclosures are not designed for any
specific enclosure system. These parts are intended as a basis for further
engineering, and may require modifications and/or additional parts to be fully
usable.
Installation accessories designed for generic enclosures are in fact designed
for an inside width of 50 mm less than the nominal width of the enclosure. For
example, a mechanical kit intended for 800 mm wide generic enclosure is
designed for an inside width of 750 mm, and will not fit a 800 mm wide Rittal
TS 8 enclosure.

HTL High-threshold logic

I/O Input/Output

IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type

widely used in inverters and IGBT supply units due to their easy controllability
and high switching frequency

Intermediate circuit See DC link.

INU Inverter unit

Inverter Converts direct current and voltage to alternating current and voltage.

Inverter module Inverter bridge, related components and drive DC link capacitors enclosed
inside a metal frame or enclosure. Intended for cabinet installation.
 Introduction 21

Term/abbreviation Explanation

Inverter unit Inverter module(s) under control of one control board, and related
components. One inverter unit typically controls one motor. See Inverter
module.

Main circuit breaker Electrically-controlled main switching and protecting device. A withdrawable
breaker can also be used as the main disconnector.

Main contactor Electrically-controlled main switching device

Main switch/disconnector Manually-controlled main switch/disconnector

Multidrive Drive for controlling several motors which are typically coupled to the same
machinery. Includes one supply unit, and one or several inverter units.

NBRA Series of optional brake choppers

Parameter User-adjustable operation instruction to the drive, or signal measured or

calculated by the drive

PLC Programmable logic controller

Power unit (Frame sizes R1i…R7i) Contains the power electronics and connections of the
drive module. The control unit is connected to the power unit.

RCD Residual current device

RFI Radio-frequency interference

SIL Safety integrity level

STO Safe torque off

THD Total harmonic distortion

TS 8 Enclosure system by Rittal (www.rittal.com)

TTL Transistor-transistor logic

UPS Uninterruptible power supply

ZCON Type of control board. See ZCU.

ZCU Type of control unit. In effect, a ZCON board in a plastic housing.

The ZCU control unit is used with frame R1i…R7i inverter modules.
The external I/O control signals of an inverter unit are mostly connected to the
ZCU, or optional I/O extensions mounted onto it.

ZMU Type of memory unit attached to the control unit. Contains the inverter control
program.
22 Introduction
 Hardware description 23

2
Hardware description

Contents of this chapter

This chapter describes a typical drive system and the hardware of ACS880-104 inverter
modules.
24 Hardware description

Overview diagram of the drive system

The diagram below depicts a common DC bus drive system.

1 – AC supply
2 – Input (AC) fuses
3 – Supply unit
4 – DC bus
5 – Inverter DC fuses (with or without a DC switch/disconnector)
6 – Inverter units (in this example, one of the two units consists of two inverter modules
connected in parallel)
7 – Brake chopper. Resistor(s) are not shown.
8 – Motor(s)

The supply unit connects to the AC supply network and converts the AC voltage into DC.
The DC voltage is distributed through the DC bus to all inverter units. The inverter unit,
consisting of one or more ACS880-104 inverter modules, converts the DC back to AC that
rotates the motor.
The ACS880-104 inverter modules can be used for controlling asynchronous AC induction
motors, permanent magnet synchronous motors, AC induction servomotors and ABB
synchronous reluctance (SynRM) motors.
 Hardware description 25

Inverter module hardware

 General
An inverter unit contains the components required to control one motor. These include one
or more inverter modules connected in parallel, together with the necessary auxiliary
equipment such as control electronics, fusing, cabling and switchgear.
ACS880-104 inverter modules can be used to construct inverter units with a power rating
from 2.5 kW up to several megawatts. Up to approximately 500 kW, inverter units consist
of one module only; higher power ratings are achieved by connecting multiple modules in
parallel.
All ACS880-104 inverter modules have coated circuit boards as standard.
The dimension drawings of the inverter modules are presented starting on page 335.
26 Hardware description

 Frames R1i to R4i

General
The DC input terminals are located at the top of the module; the AC output are located at
the bottom. The ZCU-14 control unit is mounted onto the module; the control unit contains
the basic I/Os and slots for optional I/O modules. For descriptions of the I/O terminals on
the control unit, see chapter The inverter control unit (page 293). Other optional equipment
is primarily installed on separate mounting plates.
The module should be fitted with external DC fuses. Frame R1i…R4i modules have an
internal capacitor pre-charge circuit.

Module layout – Frame R1i

(Frame R2i has a similar layout.)

3 Item Explanation
1 DC (input) connection (obscured)
2 Motor (output) connection (obscured)
8
3 Grounding/clamping plates for power
13
cables
4 ZCU-14 control unit
6 5 Power unit
6 Slots for optional I/O modules
7 I/O terminal blocks
8 Grounding/clamping plate for control
4 5 cables
9 Memory unit
12
6 10 Control panel connector
11 Air temperature sensor
7
12 Cover with control panel holder (can
optionally be left out)
13 Varistor board connecting screw
(VAR). Should not be present in an
ACS880-104.
6

9
3
10
2

11
 Hardware description 27

Module layout – Frame R4i

(Frame R3i has a similar layout.)

8
1

6
13

12 6
5
7

2
9
10

11
3

Item Explanation
1 DC (input) connection (under connector cover)
2 Motor (output) connection (under connector cover)
3 Grounding/clamping plates for power cables
4 ZCU-14 control unit
5 Power unit
6 Slots for optional I/O modules
7 I/O terminal blocks
8 Grounding/clamping plate for control cables
9 Memory unit
10 Control panel connector
11 Air temperature sensor
12 Cover with control panel holder (can optionally be left out)
13 Varistor board connecting screw (VAR). Should not be present in an ACS880-104.
28 Hardware description

Overview circuit diagram of an inverter cubicle

The following figure shows a simplified connection example of an inverter cubicle
containing several frame R1i…R4i inverter modules.

Item Explanation Available through

A Inverter cubicle -

1 DC supply -

2 DC switch/disconnector ABB or third party

3 Common DC fuses ABB or third party

4 Fuse disconnector ABB or third party

5 Inverter modules ABB

6 Motor ABB (not part of ACS880-104 product offering) or third party

Cabinet layout and cooling

See chapter Cabinet construction (page 47).
 Hardware description 29

 Frame R5i
General
The DC input and AC output terminals are located at the bottom of the module. The
ZCU-12 control unit is mounted underneath the front cover; the control unit contains the
basic I/Os and slots for optional I/O modules. For descriptions of the I/O terminals on the
control unit, see chapter The inverter control unit (page 293). Other optional equipment is
primarily installed on separate mounting plates.
The module should be fitted with external DC fuses. Frame R5i modules have an internal
capacitor pre-charge circuit.

Module layout

Item Explanation
8
1 DC (input) connection
2 Motor (output) connection
3 ZCU-12 control unit
4 I/O terminal blocks
5 Slots for optional I/O modules
7 6 Memory unit
7 Control panel holder
8 Cooling fan
9 Front cover
6 10 Front cover retaining clip
To remove the front cover, use a
screwdriver to push the clip down,
and pull cover outwards by its bottom
3 edge.
5 11 Varistor board and EMC filter
11
connecting screws (VAR and EMC).
Should not be present in an
ACS880-104.

9 4

10 1 2
30 Hardware description

Overview circuit diagram of an inverter cubicle

The following figure shows a simplified connection example of an inverter cubicle
containing several frame R5i inverter modules.

Item Explanation Available through

A Inverter cubicle -

1 DC supply -

2 DC switch/disconnector ABB or third party

3 Common DC fuses ABB or third party

4 Fuse disconnector ABB or third party

5 Inverter modules ABB

6 Motor ABB (not part of ACS880-104 product offering) or third party

Cabinet layout and cooling

See chapter Cabinet construction (page 47).
 Hardware description 31

 Frames R6i and R7i

The DC input terminals are located at the top of the module; the AC output are located at
the bottom. The ZCU-14 control unit is mounted onto the module; the control unit contains
the basic I/Os and slots for optional I/O modules. For descriptions of the I/O terminals on
the ZCU control unit, see chapter The inverter control unit (page 293). Other equipment is
primarily installed on separate mounting plates.

DC connection and capacitor charging

The module must be equipped with external DC fuses. A DC switch/disconnector can be
installed if quick isolation of the module from the DC bus is required.
A capacitor charging circuit must be fitted if
• the inverter module is connected to the DC bus through a DC switch/disconnector, or
• the inverter unit is directly connected to the DC bus and the supply unit of the system
does not have a charging capability.
Frame R6i modules ordered with option +F272 have an internal capacitor charging circuit.
Frame R7i modules require, in addition to option +F272, a charging contactor and
charging resistors which must be fitted outside the module. The contactor is controlled by
an internal monitoring board using a voltage of 230 V DC.
32 Hardware description

Module layout
(Frame R6i shown.)

1 Item Explanation
8
1 DC (input) connection
2 Motor (output) connection
8
3 ZCU-14 control unit (with I/O connections and slots
for optional I/O modules)
4 I/O terminal blocks
5 Control panel connector, memory unit
10 6 Grounding/clamping plates for control cables
9 7 Cooling fan holder with one (R6i) or two (R7i) fans
8 Lifting eyes
9 Terminal block X7 for connection of charging
contactor (R7i only)
10 Unpainted fastening holes. The grounding point (PE)
between module frame and cabinet frame.

4 6

7
 Hardware description 33

Overview circuit diagram of a frame R6i inverter unit

The following figure shows a simplified connection example of an inverter unit based on a
frame R6i inverter module.

Item Explanation Available through

A Inverter cubicle -

1 DC supply -

2 DC switch/disconnector (optional) ABB or third party

3 DC fuses ABB or third party

4 Common mode filters ABB

5 Inverter module ABB

6 Motor ABB (not part of ACS880-104 product offering) or third party

34 Hardware description

Overview circuit diagram of a frame R7i inverter unit

The following figure shows a simplified connection example of an inverter unit based on a
frame R7i inverter module.

Item Explanation Available through

A Inverter cubicle -

1 DC supply -

2 DC switch/disconnector (optional) ABB or third party

3 DC fuses ABB or third party

4 Charging contactor (optional) ABB or third party

5 Charging resistors (optional) ABB or third party

6 Common mode filters ABB

7 Inverter module ABB

8 Motor ABB (not part of ACS880-104 product offering) or third party

Cabinet layout and cooling

See chapter Cabinet construction (page 47).
 Hardware description 35

 Frame R8i and multiples

Frame R8i modules are used to achieve output powers from approximately 250 kW
upwards in single or parallel configurations. R8i modules run on wheels, and can easily be
removed from the cubicle for cable installation or service.
The motor connection is via a quick connector at the back of the module that couples
when the module is inserted into the cubicle. Each parallel-connected module is cabled
separately to the motor, or connected by busbars to adjacent modules to reduce the
number of cables. It is also possible to build an AC bus from each module to a separate
output cubicle.
As standard, the cooling fan is automatically speed-controlled according to the loading of
the inverter module. The fan is supplied internally. A direct-on-line fan is optionally
available by specifying option code +C188; for this option, the customer must connect an
external supply of 400 V 50/60 Hz to terminal block X50 (see page 37).
Internal du/dt filtering is optional for single-module 400/500 volt inverter units, but
mandatory with all 690 volt units and all parallel-connected modules.
Frame R8i to 6×R8i inverter units are controlled by a single BCU control unit installed
separately from the module(s). The control unit is connected to each inverter module by a
fiber optic link. The control unit can be powered from the inverter module (terminal block
X53), from an external 24 V DC supply, or both for redundancy. The control unit contains
the basic I/Os and slots for optional I/O modules. For descriptions of the I/O terminals on
the BCU control unit, see chapter The inverter control unit (page 293). Other equipment is
primarily installed on separate mounting plates.

DC connection and capacitor charging

The module must be equipped with external DC fuses. A DC switch/disconnector can be
installed if quick isolation of the module from the DC bus is required.
A capacitor charging circuit must be fitted if
• the inverter module is connected to the DC bus through a DC switch/disconnector, or
• the inverter unit is directly connected to the DC bus and the supply unit of the system
does not have a charging capability.
The charging circuit design presented in this manual consists of a charging switch,
resistors and a charging controller. When the inverter unit is connected to an energized
DC bus, the charging switch is closed first. When the charging is finished, the main DC
switch/disconnector can be closed and the charging switch opened. (The inverter unit will
not start if the charging switch is closed.)
Common mode filtering is implemented by running the DC bus through ferrite cores at the
input of the module.
36 Hardware description

Module layout

Front view Rear view

1 12

8 10

3 11

2
9

5
4

Description

1. DC input busbars

2. Handle

3. LEDs (see section LED indications on page 200)

Fiber optic connectors (see section Fiber optic connectors on page 38)

4. Cooling fan (standard speed-controlled fan shown; a direct-on-line fan is available as option +C188)

5. Quick connector (AC output) (the counterpart fastened to the cabinet behind the module)

6. Wheels

7. Type designation label

8. Terminal block (power supply for internal boards, optional direct-on-line fan, and module heating
element (optional)) [X50]. See section Connectors X50…X53 below.

9. STO and power to BCU connectors (24 V DC) [X51], [X52], [X53]. See section Connectors X50…X53
below.

10. Unpainted fastening hole. The grounding point (PE) between module frame and cabinet frame.

11. Circuit board compartment fan

12. Lifting eyes

 Hardware description 37

Connectors X50…X53
R8i modules contain a power supply (BDPS) that provides 24 V DC for the circuit boards
of the module. The BDPS is powered internally from the DC link. An auxiliary voltage of
230 V AC (standard) or 115 V AC (option +G304) can optionally be fed to X50 (X50:4 and
X50:5) to power the BDPS even when the DC link is not live. The 24 V DC voltage
provided by the BDPS is available on X53, and can be used to power the BCU control unit
of a single R8i inverter module.
Note: With an inverter unit consisting of parallel-connected R8i modules, it is strongly
recommended to use an external 24 V DC supply to power the BCU control unit.
If present, the heating element (option +C183) and direct-on-line cooling fan (option
+C188) must also be supplied by auxiliary voltages through X50.
If the Safe torque off (STO) function is used, STO OUT on the BCU control unit is wired to
X52 (STO IN); see chapter The Safe torque off function (page 309). X51 on the R8i
module forwards the STO signals to the X52 connector of the next module (if present).
If the Safe torque off function is not used, the “24V” inputs on X52 must be connected to
+24 V (X53, for example) on each inverter module. X51 is to be left unconnected.Note: As
a factory standard, Safe torque off is disabled by a jumper connection between connectors
X52 and X53.

X50
# Description
9 Not in use
8 N
115/230 V AC (50/60 Hz) input for optional heating element (option +C183)
7 L
6 Not in use
5 N Optional 230 V AC 50 Hz input for internal power supply (BDPS)
4 L (115 V AC 60 Hz with option +G304)
3 W 400 V AC (50/60 Hz) supply for optional DOL (direct-on-line) cooling fan
2 V (option +C188).
1 U Note: In modules without +C188, the DOL wiring is present but not in use.

STO OUT
X51
FE

GND

24V

GND

24V

STO signal forwarding output to next inverter module (if present)

STO IN
X52
FE

GND

24V

GND

24V

STO signals from BCU control unit

24V OUT
X53
FE

24V

GND

24V

GND

24 V DC output (for eg. BCU control unit)

38 Hardware description

Fiber optic connectors

Name Description
V50
BSFC BSFC Charging controller connection (see section DC
V60
connection and capacitor charging on page 35).
V30
BFPS Must be connected by the installer.
V40
BFPS Fan control connection (to fan control box).
V10
BCU Connected at the factory.
V20 BCU Control unit connection. Must be connected by
the installer.
 Hardware description 39

Overview circuit diagram of a frame R8i inverter unit

The following figure shows a simplified connection example of an inverter unit based on a
frame R8i inverter module.

Item Explanation Available through

A Inverter cubicle -

1 DC supply -

2 DC switch/disconnector (optional) ABB or third party

3 Charging switch (optional) ABB or third party

4 Charging resistors (optional) ABB or third party

5 DC fuses ABB or third party

6 Common mode filters ABB

7 Inverter module ABB

8 Motor ABB (not part of ACS880-104 product offering) or third party

40 Hardware description

Overview circuit diagram of a frame 2×R8i inverter unit

The following figure shows a simplified connection example of an inverter unit based on
two parallel-connected frame R8i inverter modules.

Item Explanation Available through

A Inverter cubicle -

1 DC supply -

2 DC switch/disconnector (optional) ABB or third party

3 Charging switch (optional) ABB or third party

4 Charging resistors (optional) ABB or third party

5 DC fuses ABB or third party

6 Common mode filters ABB

7 Inverter modules ABB

8 Motor ABB (not part of ACS880-104 product offering) or third party

Cabinet layout and cooling

See chapter Cabinet construction (page 47).
 Hardware description 41

Inverter unit control interfaces

 Overview of control connections of the ZCU control unit
The diagram shows the control connections and interfaces of the ZCU-14 control unit,
used with module frame sizes R1i…R7i. Frame R5i modules employ a type ZCU-12 unit
which has a different layout but the same connectivity as the ZCU-14.

X
R
FXX O
1
SLOT 1
1
X
R
O
2

X
R
O
3

X
P
O
W
J1J2

2 X
A
FXX I

SLOT 2
6
X
A
X12 O
SAFETY
OPTION
J3

X
D
FSO 2

5 D

X208 X
FAN2 S
T
O

3 X210
FAN1

X
D
I

FXXX
SLOT 3 X209 X
D
AIR IN I
TEMP O
J6

X
D
2
4

X13 X205
CONTROL PANEL MEMORY UNIT

CLOSE

1 Option modules can be inserted into slots 1, 2 and 3 as follows:

2 Modules Slots
3 Analog and digital I/O extension modules 1, 2, 3*
Feedback interface modules 1, 2, 3*
Fieldbus communication modules 1, 2, 3
FSO-xx safety functions module 2 (X12)
*When installed into slot 3 of a ZCU-14 control unit, the module will extend over the edge. We
recommend you use slot 1 or 2 instead whenever possible.
4 Memory unit (see page 198)
5 Connector for FSO-xx safety functions module (X12). The module reserves slot 2 when connected.
6 I/O terminal blocks. See chapter The inverter control unit (page 293).
7 See section The ACS-AP-x control panel (page 43).
42 Hardware description

 Overview of control connections of the BCU control unit

The diagram shows the control connections and interfaces of the BCU control unit, used
with module frame size R8i and multiples.

CLOSE
7

9 FXX
1

FXX
2

3
FXXX
6
5 10

No. Description No. Description

1 Analog and digital I/O extension modules 7 Control panel. See also section Connecting a
2 and fieldbus communication modules can be PC (page 166).
3 inserted into slots 1, 2 and 3.

4 Memory unit 8 Fiber optic links to supply modules

5 Slot 4 for RDCO-0x 9 Ethernet interface

6 Terminal blocks. See chapter The inverter 10 Safety option interface (FSO-xx)
control unit (page 293).
 Hardware description 43

 The ACS-AP-x control panel

The ACS-AP-x is the user interface of the inverter unit, providing the essential controls
such as Start/Stop/Direction/Reset/Reference, and the parameter settings for the control
program.
The control panel can be mounted on the cabinet door using a DPMP-01 mounting
platform (available separately). With frame R1i…R5i inverter modules, the panel can be
mounted on the panel holder on the cover of the module.
One control panel can be used to control several inverter units through a panel link
provided that each unit is equipped with panel holder or an FDPI-02 module (see page
167).
Note: A control panel is required for the commissioning of an ACS880 drive system, even
if the Drive composer PC tool is used.
For details on the control panel, see ACX-AP-x Assistant control panels User’s manual
(3AUA0000085685 [English]).

Control by PC tools
There is a USB connector on the front of the panel that can be used to connect a PC to the
drive. When a PC is connected to the control panel, the control panel keypad is disabled.
For more information, see page 166.
44 Hardware description

Type designation label

Each inverter module has a type designation label attached to it. The type designation
stated on the label contains information on the specifications and configuration of the unit.
The first digits express the basic construction of the unit, for example “ACS880-104-
0100A-3”. Any optional selections are given thereafter, separated by plus signs.
Quote the complete type designation and serial number when contacting technical support
on the subject of individual inverter modules. Examples of the label are shown below.

3 5

1 2 4 6

3 5

1 2 4 6

No. Description
1 Frame size
2 Degree of protection; additional UL/CSA specifications
3 Type designation. See chapter Ordering information (page 203).
4 Ratings. See also sections Ratings (page 277) and Input power (DC) connection (page 285).
Valid markings. See Electrical planning instructions for ACS880 multidrive cabinets and modules
5
(3AUA0000102324 [English]).
Serial number. The first digit refers to the manufacturing plant. The next four digits indicate
6 manufacturing year and week respectively (yyww). The remaining digits complete the serial number
so that there are no two units with the same number.
 Unpacking the module 45

3
Unpacking the module

Contents of this chapter

This chapter gives basic information on unpacking the module.

Unpacking – Frames R1i…R5i

The module is delivered in a corrugated cardboard box. The module and its parts (such as
grounding/clamp plates, terminal blocks, etc.) are placed in the different compartments of
the box.
1. Remove any banding and lift off the cover of the box.
2. Lift the module out of the box.
3. Check all the compartments in the box for accessories. Note that some parts may be
placed in a compartment directly underneath the module.
Dispose of or recycle the packaging according to the local regulations.
46 Unpacking the module

Unpacking – Frames R6i…R8i

The modules are delivered on a wooden base, boxed in corrugated cardboard. The
cardboard box is tied to the base with PET bands.
1. Cut off the bands.
2. Lift off the cardboard box.
3. Remove any filling material.
4. Cut open the plastic wrapping of the module.
5. Lift off the module.
6. Check that there are no signs of damage.
Dispose of or recycle the packaging according to the local regulations.
If you need to pack the modules, see the package information in section Materials (page
287).
 Cabinet construction 47

4
Cabinet construction

Contents of this chapter

This chapter contains instructions for constructing the cabinet for ACS880-104 inverter
modules.
For general instructions, refer to Cabinet design and construction instructions for ACS880
multidrive modules (3AUA0000107668 [English]).

Liability
The installation must always be designed and made according to applicable local laws and
regulations. ABB does not assume any liability whatsoever for any installation which
breaches the local laws and/or other regulations.

General
See chapter Technical data (page 277) for module-specific cooling requirements and
allowable mounting orientations.
48 Cabinet construction

Installation examples

WARNING! The code labels attached to mechanical parts such as

busbars, shrouds and sheet metal parts must be removed before
installation as they may cause bad electrical connections, or, after peeling
off and collecting dust in time, cause arcing or block the cooling air flow.

This section includes installation examples of inverter modules in Rittal TS 8 series

enclosures. Each example includes a table that lists:
• installation stages of different equipment in the order in which the installation into the
cabinet should be performed
• code of the step-by-step instructions
• equipment kit code
• kit ordering code.
You can find the kit-specific assembly drawings, step-by-step instructions and kit
information on the Internet
(https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content). If necessary,
contact your local ABB representative.
The example includes also cabinet assembly drawings that show each stage listed in the
table. More detailed steps of each stage are described in the kit-specific assembly
drawings.
For general instructions, refer to Cabinet design and construction instructions for ACS880
multidrive modules (3AUA0000107668 [English]).
 Cabinet construction 49

 R1i…R4i modules in a 400 mm wide Rittal TS 8 enclosure

A maximum of four frame R1i or R2i modules, or two frame R3i or R4i modules can be
fitted into a 400 mm wide TS 8 enclosure, but the number can be reduced by optional
equipment.

3 3 Description
1 Cubicle including:
2 1. DC input
2. DC switch/disconnector for all inverter modules
3. Main DC fuses
4 4. DC fuse disconnectors for each inverter module
5. Inverter modules
6. Air outlet with exhaust fan

5
50 Cabinet construction

# Installation stage Instruction code Kit code Kit ordering code

1 Common parts:
• Baying parts 3AUA0000114535 - -
• PE busbar 3AUA0000114475 - -
• Divider panel 3AUA0000115695 - -
• DC busbars 3AUA0000115891 A-468-X-001 3AUA0000115906
2 Bottom plate - - -
3 Mounting plate (IEC) 3AUA0000114470 - -
Mounting plate (UL) 3AXD50000003890 - -
4 DC busbars (IEC) 3AUA0000114418 A-4-1234-272 3AUA0000114423
DC busbars (UL) 3AXD50000003895 A-4-1234-274 3AXD50000003918
5 Mounting plate shrouds 3AUA0000114444 A-4-1234-403 3AUA0000114448
6 Inverter modules and air guides:
• R1i 3AUA0000114397 A-468-1-422 3AUA0000114398
• R2i 3AUA0000114397 A-468-2-423 3AUA0000114330
• R3i 3AUA0000114397 A-468-3-424 3AUA0000114404
• R4i 3AUA0000114397 A-468-4-425 3AUA0000114405
7 du/dt filters 3AUA0000114483 - See page 212
8 Cooling fan 3AUA0000115290 A-4-X-060 3AUA0000114967
 Cabinet construction 51

Overview of kits
52 Cabinet construction

Stage 1: Installation of common parts

 Cabinet construction 53

Stage 2: Installation of bottom plate

54 Cabinet construction

Stage 3: Installation of mounting plate

 Cabinet construction 55

Stage 4: Installation of DC busbars

56 Cabinet construction

Stage 5: Installation of mounting plate shrouds

 Cabinet construction 57

Stage 6: Installation of inverter modules and air guides

58 Cabinet construction

Stage 7: Installation of du/dt filters

 Cabinet construction 59

 R1i…R4i modules in a 600 mm wide Rittal TS 8 enclosure

A maximum of eight frame R1i or R2i modules, or four frame R3i or R4i modules can be
fitted into a 600 mm wide TS 8 enclosure, but the number can be reduced by optional
equipment.

Description
1 Cubicle including:
3 2 3
1. DC input
2. DC switch/disconnector for all inverter
modules
4 3. Main DC fuses
4. DC fuse disconnectors for each inverter
module
5. Inverter modules
6. Air outlet with exhaust fan

5
60 Cabinet construction

# Installation stage Instruction code Kit code Kit ordering code

1 Common parts:
• Baying parts 3AUA0000114535 - -
• PE busbar 3AUA0000114475 - -
• Divider panel 3AUA0000115695 - -
• DC busbars 3AUA0000115891 A-468-X-001 3AUA0000115906
2 Bottom plate - - -
3 Mounting plate 3AUA0000114480 - -
4 DC busbars 3AUA0000114054 A-6-1234-271 3AUA0000114079
5 Mounting plate shrouds 3AUA0000114434 A-6-1234-402 3AUA0000114436
6 Inverter modules and air guides:
• R1i 3AUA0000114397 A-468-1-422 3AUA0000114398
• R2i 3AUA0000114397 A-468-2-423 3AUA0000114330
• R3i 3AUA0000114397 A-468-3-424 3AUA0000114404
• R4i 3AUA0000114397 A-468-4-425 3AUA0000114405
7 du/dt filters 3AUA0000114472 - See page 212
8 Cooling fan 3AUA0000115152 A-6-X-031 3AUA0000114971
 Cabinet construction 61

Overview of kits
62 Cabinet construction

Stage 1: Installation of common parts

 Cabinet construction 63

Stage 2: Installation of bottom plate

64 Cabinet construction

Stage 3: Installation of mounting plate

 Cabinet construction 65

Stage 4: Installation of DC busbars

66 Cabinet construction

Stage 5: Installation of mounting plate shrouds

 Cabinet construction 67

Stage 6: Installation of inverter modules and air guides

68 Cabinet construction

Stage 7: Installation of du/dt filters

 Cabinet construction 69

 R1i…R4i modules in a 800 mm wide Rittal TS 8 enclosure

A maximum of twelve frame R1i or R2i modules, or six frame R3i or R4i modules can be
fitted into a 800 mm wide TS 8 enclosure, but the number can be reduced by optional
equipment.

Description
1 Cubicle including:
3 2 3 1. DC input
2. DC switch/disconnector for all inverter
modules
4 3. Main DC fuses
4. DC fuse disconnectors for each inverter
module
5. Inverter modules
6. Air outlets with exhaust fans

5
70 Cabinet construction

# Installation stage Instruction code Kit code Kit ordering code

1 Common parts:
• Baying parts 3AUA0000114535 - -
• PE busbar 3AUA0000114475 - -
• Divider panel 3AUA0000115695 - -
• DC busbars 3AUA0000115891 A-468-X-001 3AUA0000115906
2 Bottom plate - - -
3 Mounting plate (IEC) 3AUA0000114481 - -
Mounting plate (UL) 3AXD50000003698 - -
4 DC busbars (IEC) 3AUA0000114413 A-8-1234-273 3AUA0000114426
DC busbars (UL) 3AXD50000003875 A-8-1234-275 3AXD50000003919
5 Mounting plate shrouds 3AUA0000114419 A-8-1234-404 3AUA0000114450
6 Inverter modules and air guides:
• R1i 3AUA0000114397 A-468-1-422 3AUA0000114398
• R2i 3AUA0000114397 A-468-2-423 3AUA0000114330
• R3i 3AUA0000114397 A-468-3-424 3AUA0000114404
• R4i 3AUA0000114397 A-468-4-425 3AUA0000114405
7 du/dt filters 3AUA0000114485 - See page 212
8 Cooling fan 3AUA0000115290 2 × A-4-X-060 2 × 3AUA0000114971
 Cabinet construction 71

Overview of kits
72 Cabinet construction

Stage 1: Installation of common parts

 Cabinet construction 73

Stage 2: Installation of bottom plate

74 Cabinet construction

Stage 3: Installation of mounting plate

 Cabinet construction 75

Stage 4: Installation of DC busbars

76 Cabinet construction

Stage 5: Installation of mounting plate shrouds

 Cabinet construction 77

Stage 6: Installation of inverter modules and air guides

78 Cabinet construction

Stage 7: Installation of du/dt filters

 Cabinet construction 79

 R5i modules in a 400 mm wide Rittal TS 8 enclosure

Description

1 2 Cubicle including:
1. DC input
2. DC switch/disconnector handle for all inverter modules.
The main DC fuses are installed next to the
switch/disconnector behind the shroud
3
3. DC fuse disconnectors for each inverter module
4. Inverter modules
5. Air outlet with exhaust fan

4
80 Cabinet construction

# Installation stage Instruction code Kit code Kit ordering code

1 Common parts:
• Baying parts 3AUA0000114535 - -
• PE busbar 3AUA0000114475 - -
• Divider panel 3AUA0000115695 - -
• DC busbars 3AUA0000115891 A-468-X-001 3AUA0000115906
2 Bottom plate - - -
3 Mounting plates and 3AXD50000014638 - -
supports
4 DC busbars 3AXD50000013532 A-4-5-276 3AXD50000013505
5 Mounting plates/shrouds:
• Mounting plate 3AUA0000114444 A-4-1234-403 3AUA0000114448
shrouds
• Fuse base shroud 3AXD50000015303 A-X-5-356 3AXD50000015328
6 Inverter modules - - -
7 du/dt filters 3AXD50000015332 - See page 226
8 Cooling fan 3AUA0000115290 A-4-X-060 3AUA0000114967
 Cabinet construction 81

Overview of kits
82 Cabinet construction

Stage 1: Installation of common parts

 Cabinet construction 83

Stage 2: Installation of bottom plate

84 Cabinet construction

Stage 3: Installation of inverter module mounting plate

 Cabinet construction 85

Stage 4: Installation of DC busbars

86 Cabinet construction

Stage 5: Installation of front mounting plate

 Cabinet construction 87

Stage 6: Installation of inverter modules

88 Cabinet construction

Stage 7: Installation of du/dt filters

 Cabinet construction 89

 R5i modules in a 600 mm wide Rittal TS 8 enclosure

Description

1 2 Cubicle including:
1. DC input
2. DC switch/disconnector handle for all inverter modules.
The main DC fuses are installed next to the
switch/disconnector behind the shroud
3
3. DC fuse disconnectors for each inverter module
4. Inverter modules
5. Air outlet with exhaust fan

4
90 Cabinet construction

# Installation stage Instruction code Kit code Kit ordering code

1 Common parts:
• Baying parts 3AUA0000114535 - -
• PE busbar 3AUA0000114475 - -
• Divider panel 3AUA0000115695 - -
• DC busbars 3AUA0000115891 A-468-X-001 3AUA0000115906
2 Bottom plate - - -
3 Mounting plates and 3AXD50000014638 - -
supports
4 DC busbars 3AXD50000013496 A-6-5-277 3AXD50000013506
5 Mounting plates/shrouds:
• Mounting plate 3AUA0000114434 A-6-1234-402 3AUA0000114436
shrouds
• Fuse base shroud - A-X-5-356 3AXD50000015328
6 Inverter modules - - -
7 du/dt filters 3AXD50000015332 - See page 226
8 Cooling fan 3AUA0000115290 A-4-X-060 3AUA0000114967
 Cabinet construction 91

Overview of kits
92 Cabinet construction

Stage 1: Installation of common parts

 Cabinet construction 93

Stage 2: Installation of bottom plate

94 Cabinet construction

Stage 3: Installation of inverter module mounting plate

 Cabinet construction 95

Stage 4: Installation of DC busbars

96 Cabinet construction

Stage 5: Installation of front mounting plate

 Cabinet construction 97

Stage 6: Installation of inverter modules

98 Cabinet construction

Stage 7: Installation of du/dt filters

 Cabinet construction 99

 One R6i/R7i module in a 400 mm wide Rittal TS 8 enclosure

Description
2
Cubicle including:
1
1. DC bus
2. DC switch/disconnector and DC fuses
3. Charging contactor and resistors (frame R7i only)
3 4. Inverter module
5. AC output
6. PE busbar

6
100 Cabinet construction

# Installation stage Instruction code Kit code Kit ordering code

1 Common parts:
• Baying parts 3AUA0000114535 - -
• PE busbar 3AUA0000114475 - -
• Divider panel 3AUA0000115695 - -
• DC busbars 3AUA0000115891 A-468-X-001 3AUA0000115906
2 Bottom plate - - -
3 Support beams 3AUA0000117053 - -
4 DC busbars and charging components:
• R6i without DC switch 3AUA0000123371 A-4-67-283 3AUA0000122202
• R6i with DC switch (IEC) 3AUA0000123369 A-4-6-281 3AUA0000122201
• R6i with DC switch (UL) 3AXD50000004422 A-4-6-285 3AXD50000004381
• R7i without DC switch or 3AUA0000123371 A-4-67-283 3AUA0000122202
charging
• R7i without DC switch, 3AUA0000123372 A-4-7-282 3AUA0000122237
with charging
• R7i (400/500 V) with DC 3AUA0000117112 A-4-7-280 3AXD50000008846
switch and charging
• R7i (690 V) with DC switch 3AXD50000010177 A-4-7-286 3AXD50000009135
and charging
• R7i (690 V) without DC 3AXD50000010309 A-4-7-287 3AXD50000009137
switch, with charging
5 Common mode filters (filters 3AUA0000123359 A-4-67-241 3AUA0000122152
not included in kit)
6A AC busbars without output 3AUA0000117543 A-4-67-181 3AUA0000122145
(du/dt) filters
6B AC busbars with output 3AXD50000010077 A-4-67-186 3AXD50000010037
(du/dt) filters
7 Inverter module 3AUA0000117085 A-4-67-302 3AUA0000117090
8 Shroud brackets 3AUA0000114211 A-4-67-350 3AUA0000114215
 Cabinet construction 101

Overview of kits
102 Cabinet construction

Stage 1: Installation of common parts

 Cabinet construction 103

Stage 2: Installation of bottom plate

104 Cabinet construction

Stage 3: Installation of support beams

 Cabinet construction 105

Stage 4 (R6i): Installation of DC busbars and charging components

106 Cabinet construction

Stage 4 (R7i): Installation of DC busbars and charging components

 Cabinet construction 107

Stage 5: Installation of common mode filters

108 Cabinet construction

Stage 6A: Installation of AC busbars (without du/dt filters)

 Cabinet construction 109

Stage 6B: Installation of AC busbars (with du/dt filters)

110 Cabinet construction

Stage 7: Installation of inverter module

 Cabinet construction 111

Stage 8: Installation of shrouding brackets

112 Cabinet construction

 One R8i module in a 400 mm wide Rittal TS 8 enclosure

With DC Without DC
switch/disconnector switch/disconnector
and charging and charging

Description

Cubicle including:
1 1. DC switch/disconnector (obscured)
2. DC fuses
2 2 3. Charging switch
4. Common mode filters
3 4 5. Inverter module
4

5 5
 Cabinet construction 113

# Installation stage Instruction code Kit code Kit ordering code

1 Common parts:
• Baying parts 3AUA0000114535 - -
• PE busbar 3AUA0000114475 - -
• Divider panel 3AUA0000115695 - -
• DC busbars 3AUA0000115891 A-468-X-001 3AUA0000115906
2A DC connection 1 of 2 (from DC bus to DC fuses) without DC switch/charging:
• Busbar assembly 3AXD50000004851 A-4-8-252 3AXD50000004416
• Busbars 3AXD50000005729 A-46-8-206 3AXD50000004411
2B DC connection 1 of 2 (from DC bus to DC fuses) with DC switch/charging:
• DC switch/charging 3AXD50000043516 A-4-8-288 3AXD50000044554
mechanics
• Busbar assembly 3AXD50000043504 A-4-8-290 3AXD50000044557
• Busbars 3AXD50000004834 A-46-8-207 3AXD50000004412
3 Module mechanical installation parts, lead-throughs:
• Module top/bottom guides 3AXD50000004842 A-4-8-310 3AXD50000004415
• Lead-throughs 3AXD50000004817 A-468-8-441 3AXD50000004385
4A Quick connector, output (AC) busbars (cable connection):
• Quick connector 3AUA0000118667 A-468-8-100 3AUA0000119227
• Busbars and shrouds 3AXD50000004838 A-4-8-132 3AXD50000004414
4B Quick connector, output (AC) busbars (common AC output busbar connection):
• Quick connector 3AUA0000118667 A-468-8-100 3AUA0000119227
• Busbars and shrouds 3AXD50000010278 A-4-8-140 3AXD50000008705
5A DC connection 2 of 2 (from DC fuses to inverter module) without DC switch/charging:
• DC connection flanges 3AXD50000028384 A-468-8-246 3AXD50000028403
• DC busbars with common 3AXD50000028418 A-468-8-235 3AXD50000028401
mode filters (filters not
included in kit)
5B DC connection 2 of 2 (from DC fuses to inverter module) with DC switch/charging:
• DC connection flanges 3AXD50000043466 A-468-8-248 3AXD50000044553
• DC busbars with common 3AXD50000043411 A-468-8-247 3AXD50000044551
mode filters (filters not
included in kit)
6 Shrouding 3AXD50000045749 A-4-8-359 3AXD50000045738
7 Inverter module - - -
114 Cabinet construction

Overview of kits
 Cabinet construction 115

Stage 1: Installation of common parts

116 Cabinet construction

Stage 2A: Installation of DC busbars (1) (without DC switch/charging)

 Cabinet construction 117

Stage 2B: Installation of DC busbars (1) (with DC switch/charging)

118 Cabinet construction

Stage 3: Installation of module installation parts and lead-throughs

 Cabinet construction 119

Stage 4A: Installation of quick connector and output (AC) busbars (cable
connection)
120 Cabinet construction

Stage 4B: Installation of quick connector and output (AC) busbars (common AC
output busbar connection)
 Cabinet construction 121

Stage 5A: Installation of DC busbars (2) (without DC switch/charging)

122 Cabinet construction

Stage 5B: Installation of DC busbars (2) (with DC switch/charging)

 Cabinet construction 123

Stage 6: Installation of shrouding

124 Cabinet construction

Stage 7: Installation of inverter module

 Cabinet construction 125

 Two R8i modules in a 600 mm wide Rittal TS 8 enclosure

With DC Without DC
switch/disconnector switch/disconnector
and charging and charging

2
4

3 4

5 5 5 5

Description

Cubicle including:
1. DC switch/disconnector (obscured)
2. DC fuses
3. Charging switch
4. Common mode filters
5. Inverter module
126 Cabinet construction

# Installation stage Instruction code Kit code Kit ordering code

1 Common parts:
• Baying parts 3AUA0000114535 - -
• PE busbar 3AUA0000114475 - -
• Divider panel 3AUA0000115695 - -
• DC busbars 3AUA0000115891 A-468-X-001 3AUA0000115906
2A DC connection 1 of 2 (from DC bus to DC fuses) without DC switch/charging:
• Busbar assembly 3AXD50000004860 A-6-8-255 3AXD50000005053
• Busbars 3AXD50000005729 A-46-8-206 3AXD50000004411
2B DC connection 1 of 2 (from DC bus to DC fuses) with DC switch/charging:
• DC switch/charging 3AXD50000043542 A-6-8-289 3AXD50000044555
assembly
• Busbar assembly 3AXD50000043555 A-6-8-291 3AXD50000044558
• Busbars 3AXD50000004834 A-46-8-207 3AXD50000004412
3 Module mechanical installation parts, lead-throughs:
• Module top/bottom guides 3AXD50000004859 A-6-8-309 3AXD50000005052
• Lead-throughs 3AXD50000004817 A-468-8-441 3AXD50000004385
4A Quick connector, output (AC) busbars (cable connection without bridging):
• Quick connector 3AUA0000118667 A-468-8-100 3AUA0000119227
• Busbars and shrouds 3AXD50000004594 A-6-8-133 3AXD50000005051
4B Quick connector, output (AC) busbars (cable connection with bridging):
• Quick connector 3AUA0000118667 A-468-8-100 3AUA0000119227
• Busbars and shrouds 3AXD50000005189 A-6-8-134 3AXD50000005244
4C Quick connector, output (AC) busbars (common AC output busbar connection):
• Quick connector 3AUA0000118667 A-468-8-100 3AUA0000119227
• Busbars and shrouds 3AXD50000008157 A-6-8-141 3AXD50000008707
5A DC connection 2 of 2 (from DC fuses to inverter module) without DC switch/charging:
• DC connection flanges 3AXD50000028384 A-468-8-246 3AXD50000028403
• DC busbars with common 3AXD50000028418 A-468-8-235 3AXD50000028401
mode filters
5B DC connection 2 of 2 (from DC fuses to inverter module) with DC switch/charging:
• DC connection flanges 3AXD50000043466 A-468-8-248 3AXD50000044553
• DC busbars with common 3AXD50000043411 A-468-8-247 3AXD50000044551
mode filters (filters not
included in kit)
6 Shrouding 3AXD50000045798 A-6-8-360 3AXD50000045779
7 Inverter modules - - -
 Cabinet construction 127

Overview of kits
128 Cabinet construction

Stage 1: Installation of common parts

 Cabinet construction 129

Stage 2A: Installation of DC busbars (1) (without DC switch/charging)

130 Cabinet construction

Stage 2B: Installation of DC busbars (1) (with DC switch/charging)

 Cabinet construction 131

Stage 3: Installation of module installation parts and lead-throughs

132 Cabinet construction

Stage 4A: Installation of quick connector and output (AC) busbars (cable
connection)
 Cabinet construction 133

Stage 4B: Installation of quick connector and output (AC) busbars (cable
connection with bridging)
134 Cabinet construction

Stage 4C: Installation of quick connector and output (AC) busbars (common AC
output busbar connection)
 Cabinet construction 135

Stage 5A: Installation of DC busbars (2) (without DC switch/charging)

136 Cabinet construction

Stage 5B: Installation of DC busbars (2) (with DC switch/charging)

 Cabinet construction 137

Stage 6: Installation of shrouding

138 Cabinet construction

Stage 7: Installation of inverter modules

 Cabinet construction 139

 One R8i module in a 400 mm wide generic enclosure

Parts to be installed Instruction code Kit code Kit ordering code
DC switch/charging mechanics 3AXD50000043644 A-4-8-292 3AXD50000044559
(optional)
DC busbars (without DC switch/charging):
• Busbar assembly 3AXD50000006441 A-4-8-256 3AXD50000006418
• DC busbars with common mode 3AXD50000028418 A-468-8-235 3AXD50000028401
filters (filters not included in kit)
• DC connection flanges 3AXD50000028384 A-468-8-246 3AXD50000028403
DC busbars (with DC switch/charging):
• Busbar assembly 3AXD50000043686 A-4-8-295 3AXD50000044582
• DC busbars with common mode 3AXD50000043411 A-468-8-247 3AXD50000044551
filters (filters not included in kit)
• DC connection flanges 3AXD50000043466 A-468-8-248 3AXD50000044553
Module mechanical installation parts, lead-throughs:
• Module top/bottom guides 3AXD50000005874 A-4-8-315 3AXD50000005875
• Lead-throughs 3AXD50000004817 A-468-8-441 3AXD50000004385
Quick connector, output (AC) busbars:
• Quick connector 3AUA0000118667 A-468-8-100 3AUA0000119227
• Busbars and shrouds 3AXD50000006497 A-4-8-135 3AXD50000006435
Inverter module - - -
Shrouding - - -
140 Cabinet construction
 Cabinet construction 141

 Two R8i modules in a 600 mm wide generic enclosure

Parts to be installed Instruction code Kit code Kit ordering code
DC switch/charging mechanics 3AXD50000043784 A-6-8-293 3AXD50000044560
(optional)
DC busbars (without DC switch/charging):
• Busbar assembly 3AXD50000006447 A-6-8-257 3AXD50000006444
• DC busbars with common mode 3AXD50000028418 A-468-8-235 3AXD50000028401
filters (filters not included in kit)
• DC connection flanges 3AXD50000028384 A-468-8-246 3AXD50000028403
DC busbars (with DC switch/charging):
• Busbar assembly 3AXD50000043737 A-6-8-296 3AXD50000044583
• DC busbars with common mode 3AXD50000043411 A-468-8-247 3AXD50000044551
filters (filters not included in kit)
• DC connection flanges 3AXD50000043466 A-468-8-248 3AXD50000044553
Module mechanical installation parts, lead-throughs:
• Module top/bottom guides 3AXD50000005864 A-6-8-311 3AXD50000005876
• Lead-throughs 3AXD50000004817 A-468-8-441 3AXD50000004385
Quick connector, output (AC) busbars:
• Quick connector 3AUA0000118667 A-468-8-100 3AUA0000119227
• Busbars and shrouds (without 3AXD50000006489 A-6-8-136 3AXD50000006491
bridging)
• Busbars and shrouds (with 3AXD50000006505 A-6-8-138 3AXD50000006493
bridging)
Inverter modules - - -
Shrouding - - -
142 Cabinet construction
 Cabinet construction 143

 Three R8i modules in a 800 mm wide generic enclosure

Parts to be installed Instruction code Kit code Kit ordering code
DC switch/charging mechanics 3AXD50000044586 A-8-8-294 3AXD50000044581
(optional)
DC busbars (without DC switch/charging):
• Busbar assembly 3AXD50000006455 A-8-8-258 3AXD50000006450
• DC busbars with common mode 3AXD50000028418 A-468-8-235 3AXD50000028401
filters (filters not included in kit)
• DC connection flanges 3AXD50000028384 A-468-8-246 3AXD50000028403
DC busbars (with DC switch/charging):
• Busbar assembly 3AXD50000044574 A-8-8-297 3AXD50000044584
• DC busbars with common mode 3AXD50000043411 A-468-8-247 3AXD50000044551
filters (filters not included in kit)
• DC connection flanges 3AXD50000043466 A-468-8-248 3AXD50000044553
Module mechanical installation parts, lead-throughs:
• Module top/bottom guides 3AXD50000005848 A-8-8-312 3AXD50000005877
• Lead-throughs 3AXD50000004817 A-468-8-441 3AXD50000004385
Quick connector, output (AC) busbars:
• Quick connector 3AUA0000118667 A-468-8-100 3AUA0000119227
• Busbars and shrouds (without 3AXD50000006503 A-8-8-137 3AXD50000006492
bridging)
• Busbars and shrouds (with 3AXD50000006498 A-8-8-139 3AXD50000006494
bridging)
Inverter modules - - -
Shrouding - - -
144 Cabinet construction
 Electrical installation 145

5
Electrical installation

Contents of this chapter

This chapter describes the electrical installation of ACS880-104 inverter modules.
The wiring diagrams in this chapter are simplified presentations. See chapter Circuit
diagrams for details.
For more information on cable selection, protections, etc., see Electrical planning
instructions for ACS880 multidrive cabinets and modules (3AUA0000102324 [English]).

WARNING! Only qualified electricians are allowed to do the work described in this
chapter. Read the safety instructions given in Safety instructions for ACS880
multidrive cabinets and modules (3AUA0000102301 [English]) before you install,
commission, use or service the drive.

Note: The installation must always be designed and made according to applicable local
laws and regulations. ABB does not assume any liability whatsoever for any installation
that breaches the local laws and/or other regulations. Furthermore, if the
recommendations given by ABB are not followed, the drive system may experience
problems that the warranty does not cover.
146 Electrical installation

Electrical safety precautions

WARNING! Perform the electrical safety precautions before starting any work on
the installation. Ignoring the precautions can cause physical injury or death, or
damage to the equipment. Only a qualified electrician is allowed to work on the
installation.

1. Clearly identify the work location.

2. Disconnect all possible voltage sources.
• Open the main disconnecting device of the drive system.
• Open the disconnector of the supply transformer as the main disconnecting device
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.
• Disconnect any external power sources from the control circuits before you do
work on the control cables.
• After you disconnect the drive, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you continue.
3. Protect any 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 and the
grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive DC busbars (+ and –) and the
grounding (PE) busbar is close to 0 V.
6. Install temporary grounding as required by the local regulations. Close the grounding
switch if present, or connect the AC and DC busbars to PE with a temporary
grounding tool.
7. Ask for a permit to work from the person in control of the electrical installation work.

General notes
Static electricity

WARNING! Circuit boards contain components sensitive to electrostatic

discharge (ESD). Wear a grounding wrist band when handling the boards. Do not
touch the boards unnecessarily.
 Electrical installation 147

Optical components
Handle fiber optic cables with care. When unplugging optic cables, always grab the
connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the
fiber is extremely sensitive to dirt. The specifications of the optic cable are as follows:
• Storage temperature: -55 … +85 °C
• Installation temperature: -20 … +70 °C
• Maximum short-term tensile force: 50 N
• Minimum short-term bend radius: 25 mm
• Minimum long-term bend radius: 35 mm
• Maximum long-term tensile load: 1 N
• Flexing: Max. 1000 cycles
ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components from
Avago Technologies’ Versatile Link range. Please note that the optical component type is
not directly related to the actual communication speed.
Note: The optical components (transmitter and receiver) on a fiber optic link must be of the
same type.
Plastic optical fiber (POF) cables can be used with both 5 MBd and 10 MBd optical
components. 10 MBd components also enable the use of Hard Clad Silica (HCS®) cables,
which allow longer connection distances thanks to their lower attenuation. HCS® cables
cannot be used with 5 MBd optical components.
The maximum lengths of fiber optic links for POF and HCS® cables are 20 and 200 meters
respectively.
HCS® is a trademark of SpecTran Corporation.

Checking the insulation of the assembly

WARNING! Check the insulation before connecting the drive system to the main
power supply. Make sure that the drive system is disconnected from the main
power supply.

 Inverter modules
Every ACS880-104 inverter module has been tested for insulation between the main
circuit and the chassis (2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not
make any voltage tolerance or insulation resistance tests (e.g. hi-pot or megger) on the
inverter units or modules.

 Motor and motor cable

Check the insulation of the motor and motor cable as follows:
• Check that the motor cable is connected to the motor, and disconnected from the drive
output terminals U2, V2 and W2.
• Measure the insulation resistance between each phase conductor and then between
each phase conductor and the Protective Earth (PE) conductor using a measuring
voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed
100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other
motors, please consult the manufacturer’s instructions.
148 Electrical installation

Note: Moisture inside the motor casing will reduce the insulation resistance. If
moisture is suspected, dry the motor and repeat the measurement.

U1
M
V1
3~
ohm W1
PE

 Brake resistor assembly

See section Checking the insulation of the brake resistor assembly (page 329).
 Electrical installation 149

Power connections – Frames R1i…R5i

A simplified diagram of the power connections is presented below. For more detailed
diagrams, see page 383.

A Inverter cubicle
1 DC supply
2 DC switch/disconnector for all inverter modules
3 Main DC fuses
4 DC fuse disconnectors for each inverter module
5 Inverter modules
6 Motors

 Power cable connection procedure

Frames R1i and R2i

WARNING! Read and follow the instructions given in Safety instructions

for ACS880 multidrive cabinets and modules (3AUA0000102301
[English]). Ignoring the instructions can cause physical injury or death,
or damage to the equipment.

1. Run the output (motor) cable into the cubicle through a cable gland or grommet. In
case a grounding cable gland is available, remove the outer jacket of the cable where
it passes through the cable gland.
2. Cut the input (DC) and output cables to suitable length and strip the ends of the
individual conductors.
3. Twist the shield strands of the output cable together to form a separate conductor and
crimp a ring terminal onto it. Do the same for the input cable if it is a shielded type.
4. Connect the conductors to the terminal blocks. Connect the cable shields to grounding
terminals near the terminal blocks.
5. Secure the cables inside and outside the cabinet mechanically.
6. Tighten the cable gland if present.
7. Connect the motor cable as described under Grounding the motor cable shield at the
motor end (page 150).
150 Electrical installation

Frames R3i…R5i
1. Run the output (motor) cable into the cubicle through a cable gland or grommet. 360°
grounding of the cable shield is recommended to suppress interference. In case a
grounding cable gland is available, remove the outer jacket of the cable where it
passes through the cable gland.
2. Remove the shrouds covering the terminals of the inverter module.
3. Cut the input (DC) and output cables to suitable length and strip the ends of the
individual conductors.
4. Twist the shield strands of the output cable together to form a separate conductor.
Crimp a suitable ring terminal onto the end, and cover the remaining bare screen with
tape as shown below. Do the same for the input cable if it is a shielded type.

5. Insert the conductors to the terminals and tighten the Allen screw.
Note that the original screw lugs can be replaced by crimp ring terminals connected
directly to the connection post. Make note of the order and orientation of the washers
on the connection post.
6. Connect the cable shields to ground near the terminals.
7. Reinstall the terminal covers.
8. Secure the cables inside and outside the cabinet mechanically.
9. Tighten the cable gland if present.
10. Connect the motor cable as shown below.

Grounding the motor cable shield at the motor end

For minimum radio-frequency interference, ground the cable shield 360 degrees at the
lead-through of the motor terminal box.
 Electrical installation 151

Power connections – Frames R6i…R8i

Simplified diagrams of the power connections are presented below. For more detailed
diagrams, see page 389.

 R6i inverter module

A Inverter cubicle
1 DC supply
2 DC switch/disconnector
3 DC fuses
4 Common mode filter
5 Inverter module
6 Motor
152 Electrical installation

 R7i inverter module

A Inverter cubicle
1 DC supply
2 DC switch/disconnector
3 DC fuses
4 Charging circuit (contactor and resistors)
5 Common mode filter
6 Inverter module
7 Motor

 R8i inverter module

A Inverter cubicle
1 DC supply
2 DC switch/disconnector
3 Charging circuit (fuses, resistors, charging controller)
4 DC fuses
5 Common mode filter
6 Inverter module
7 Motor
 Electrical installation 153

 2×R8i inverter unit

A Inverter cubicle
1 DC supply
2 DC switch/disconnector
3 Charging circuit (fuses, resistors, charging controller)
4 DC fuses
5 Common mode filters
6 Inverter modules
7 Motor
154 Electrical installation

 Connection procedure

WARNING! Read and follow the instructions given in Safety instructions

for ACS880 multidrive cabinets and modules (3AUA0000102301
[English]). Ignoring the instructions can cause physical injury or death,
or damage to the equipment.

1. Ground the inverter modules by the top edge of the front plate. The grounding point is
marked on the module. Connect the front plate to the frame support bracket with
screws. The bracket should have a galvanic connection to the PE busbar through the
cabinet frame.
Notes:
• If the cabinet frame is painted (such as with Rittal TS 8 enclosures), it is important
to make sure that a good galvanic connection to ground (PE busbar) is achieved.
You can, for example, remove the paint from the connection points and use star
washers.
• The connection to ground merely through the mounting screws and the cabinet
chassis is not always good enough. To ensure the continuity of the protective
bonding circuit, you can connect the modules to the cabinet PE busbar with a
copper busbar or cable. The inductance and impedance of the PE conductor must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when a ground fault
occurs). See Electrical planning instructions for ACS880 multidrive cabinets and
modules (3AUA0000102324 [English]).
2. Run the output (motor) cable into the cubicle through a cable gland or grommet. 360°
grounding of the cable shield is recommended to suppress interference. In case a
grounding cable gland is available, remove the outer jacket of the cable where it
passes through the cable gland.
3. Cut the output cable to suitable length and strip the ends of the individual conductors.
4. Twist the shield strands of the output cable together to form a separate conductor and
wrap tape around it as shown.

5. Crimp suitable cable lugs to the conductors as well as the twisted shield. Connect the
phase conductors to the output busbars. Connect the cable shield to a PE busbar.
6. Secure the cables inside and outside the cabinet mechanically.
7. Tighten the cable gland if present.
 Electrical installation 155

Grounding the motor cable shield at the motor end

For minimum radio-frequency interference, ground the cable shield 360 degrees at the
lead-through of the motor terminal box.
156 Electrical installation

Replacing ACS800 R8i modules with ACS880 R8i

modules
ACS880 R8i modules can be ordered with option +P942 for mechanical compatibility with
ACS800 R8i modules. A dimension drawing is presented on page 345.
The following procedure explains the additional wiring changes that are required.

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Replace the inverter module(s).

2. If needed, connect an auxiliary voltage supply of 230 V AC 50 Hz (standard) or
115 V AC 60 Hz (with option +G304) to X50:4…5 on the module to power the BDPS
(internal power supply of the module) even when the DC link is not live.
3. Replace the RDCU control unit with a BCU-x2 inverter control unit (with a sufficient
number of inverter module connections – see page 250). Connect the control unit to a
24 V DC power supply. (An external power supply is recommended for an inverter unit
consisting of parallel-connected modules; with a single-module configuration,
connectors X53:1 and X53:2 on the module can be used.)
4. Connect the BCU to the inverter module(s) using fiber optic cables. In case of parallel-
connected modules, remove the existing APBU branching unit.
5. If the module is equipped with option +C188 (direct-on-line cooling fan), connect a
3-phase 400 V 50/60 Hz supply to X50:1…3.
6. If the inverter unit is equipped with a DC switch/disconnector and charging controller,
connect terminals V50 and V60 of the inverter module to the charging controller using
fiber optic cables.
Note: With an ACS880 R8i module used with the ACS800 charging circuit, only one
charging cycle in five minutes is allowed.
 Electrical installation 157

2 5

7. On the BCU control unit, connect the DIIL input to a +24VD terminal.

8. If the Safe torque off (STO) function is to be used, remove the jumper connection
between X52 and X53 on each module. Wire the STO link to all inverter modules of
the inverter unit. Connect the device triggering the STO function to the BCU control
unit.
158 Electrical installation

STO OUT
X51
STO signal forwarding output to next
FE
GND
24V
GND
24V

inverter module (if present)

STO IN
X52
FE
GND
24V
GND
24V

STO signals from BCU control unit

9. Connect an ACS-AP-x control panel to X13 on the BCU control unit.

10. If the modules are equipped with option +C183 (heating elements), connect a
230/115 V AC (50/60 Hz) supply to X50:7…8.
 Electrical installation 159

Connecting the control cables – All frame sizes

For technical data and default I/O connections of the inverter control unit, refer to chapter
The inverter control unit (page 293).
1. In the cabinet, remove shrouding wherever necessary to allow access to the cable
entries and any trunking inside the cubicle.
2. Run the control cables into the cubicle. If possible, arrange for a 360° grounding of the
cable shield at the cable entry.
If the outer surface of the shield is non-conductive, turn the shield inside out as shown
below and wrap copper foil around the cable to keep the shielding continuous. Do not
cut the grounding wire (if present).
Stripped cable Conductive surface of Stripped part covered
the shield exposed with copper foil

Copper foil

Cable shield Shielded twisted pair

Grounding wire

3. Run the cables to the control unit of the inverter (or other connection point) using cable
trunking wherever possible.
4. (Only when running the cable to the inverter module) The inverter control units have a
clamp plate attached. Remove the outer sheathing of the cable at one of the clamps
on the plate. Tighten the clamp onto the bare cable shield.
5. Cut the cables to suitable length.
160 Electrical installation

6. Strip the cable ends and conductors. When connecting to the drive I/O, also remove
the shield along with the outer sheathing, and use electrical tape or shrink tubing to
contain the strands. Elsewhere, twist the outer shield strands into a bundle, crimp a
lug onto it and connect it to the nearest chassis grounding point.

Keep as short as possible

4 SHIELD*
3
2
1

*If no dedicated “shield” connector

is provided, ground the inner cable
shields to the chassis.

At the other end of the cable, leave Where grounding clamps are not
the shield unconnected, or connect available, twist the shield strands
it to ground via a capacitor with a into a bundle, crimp a lug terminal
value of a few nanofarads. onto it and fasten the lug to the
chassis. Secure the cable into place
with eg. cable ties.

7. Connect the conductors to appropriate terminals (refer to chapter The inverter control
unit and the circuit diagrams in chapter Circuit diagrams).
8. Refit any shrouds removed earlier.
 Electrical installation 161

Installing optional modules

 Installation of I/O extension and fieldbus adapter modules
Note: Pay attention to the free space required by the cabling or terminals coming to the
optional modules.
1. Disconnect the inverter unit from the supply, lock out the disconnecting device, and
ensure by measuring that there is no voltage present.
2. Switch off any potentially dangerous control voltages coming to the inverter unit.
Ensure by measuring that the I/O terminals of the control unit (especially the relay
output terminals) are safe.
3. Insert the module into a free option module slot on the control unit. Refer to chapter
The inverter control unit (page 293).
4. Fasten the module as described in its documentation.
5. Connect the necessary wiring to the module as described in its documentation and
section Connecting the control cables – All frame sizes (page 159).
6. Check the installation and that it is safe to reconnect power.
7. Configure the module. Refer to the instructions given in the documentation of the
module as well as the appropriate firmware manual.
162 Electrical installation

 Installation of an FSO-xx safety functions module

Installation onto a ZCU control unit (Frames R1i…R7i)
1. Stop the inverter unit and do the steps in section Electrical safety precautions (page
146) before you start the work.
2. The FSO-xx comes with alternative bottom plates for mounting on different units. For
mounting on the ZCU, the mounting points should be located at the short edges of the
module as shown. Replace the bottom plate of the FSO-xx if necessary.
3. Connect the data cable to connector X12 on the control unit.
4. Put the FSO-xx into its position on slot 2 of the control unit.
5. Tighten the FSO-xx electronics grounding screw. Note: The screw tightens the
connections and grounds the module. It is essential for fulfilling the EMC requirements
and for proper operation of the module.
6. Fasten the module by the bottom plate with four screws.
7. Connect the other end of the data cable to connector X110 on the FSO-xx.
8. To complete the installation, refer to the instructions in the User’s manual delivered
with the FSO-xx.

2
5

3
 Electrical installation 163

Installation onto a BCU control unit (Frame R8i and multiples)

1. Stop the inverter unit and do the steps in section Electrical safety precautions (page
146) before you start the work.
2. The FSO-xx comes with alternative bottom plates for mounting on different units. For
mounting on the BCU, the mounting points should be located at the long edges of the
module as shown. Replace the bottom plate of the FSO-xx if necessary.
3. Fasten the FSO-xx onto slot 3 of the BCU control unit.
4. Tighten the FSO-xx electronics grounding screw. Note: The screw tightens the
connections and grounds the module. It is essential for fulfilling the EMC requirements
and for proper operation of the module.
5. Connect the data cable between connector X12 on the control unit and connector
X110 on the FSO-xx.
6. To complete the installation, refer to the instructions in the User’s manual delivered
with the FSO-xx.
164 Electrical installation

3
 Electrical installation 165

Installation beside the control unit

To reserve the slots of the control unit for other modules, you can install the FSO-xx
separate from the control unit using mounting kit 3AXD50000025495. The kit contains the
parts for mounting the FSO-xx either onto a DIN rail nearby the ZCU or BCU control unit,
or onto the grounding/clamping plate of a ZCU-14 (used in frames R1i…R4i) control unit.
The kit also contains longer cables for connecting the FSO-xx to the control unit.
Refer to instruction 3AXD50000025583 for installation details.

Mounting on DIN rail

Mounting on ZCU-14 grounding/clamping

plate (with frames R1i…R4i)
166 Electrical installation

Connecting a PC
A PC (with eg. the Drive composer PC tool) can be connected to the inverter unit as
follows:
1. Connect an ACS-AP-W or ACS-AP-I control panel to the inverter control unit either by
using an Ethernet (eg. CAT5E) networking cable, or by inserting the panel into the
panel holder (if present).

WARNING! Do not connect the PC directly to the control panel connector of the
inverter unit as this can cause damage.

2. Remove the USB connector cover on the front of the control panel.
3. Connect an USB cable (Type A to Type Mini-B) between the USB connector on the
control panel (3a) and a free USB port on the PC (3b).
4. The panel will display an indication whenever the connection is active.

Stop Loc/Rem Start

2 3b
3a

USB connected

Stop Loc/Rem Start

See the documentation of the PC tool for setup instructions.

 Electrical installation 167

Panel bus (Control of several inverter units from one

control panel)
One control panel (or PC) can be used to control several inverter units by constructing a
panel bus. This is done by daisy-chaining the panel connections of the units. Frame
R1i…R5i modules have the necessary panel connectors in the control panel holder which
is optional for some frame sizes (for details, see chapter Ordering information). Frame
R6i…R8i modules require the mounting of an FDPI-02 module (available separately) on
the control unit. For further information, see FDPI-02 diagnostics and panel interface
user’s manual (3AUA0000113618 [English]).
1. Connect the panel to one unit using an Ethernet (eg. CAT5E) cable.
• Use Menu – Settings – Edit texts – Drive to give a descriptive name to the unit
• Use parameter 49.01 to assign the unit with a unique node ID number
• Set other parameters in group 49 if necessary
• Use parameter 49.06 to validate any changes.
Repeat the above for each unit.
2. With the panel connected to one unit, link the units using Ethernet cables.
3. Switch on the bus termination on the unit that is farthest from the control panel in the
chain. With units that have the panel mounted on the front cover, move the terminating
switch into the outer position. With an FDPI-02 module, move termination switch S2
into the TERMINATED position. Termination should be off on all other units.
4. On the control panel, switch on the panel bus functionality (Options – Select drive –
Panel bus). The unit to be controlled can now be selected from the list under Options –
Select drive.
If a PC is connected to the control panel, the inverters on the panel bus are
automatically displayed in the Drive composer tool.

1 2 3

1
168 Electrical installation
 Installation checklist 169

6
Installation checklist

Check the mechanical and electrical installation of the drive before start-up. Go through
the checklist below together with another person.

Check that…

MECHANICAL INSTALLATION

The unit is properly fastened to the floor.

There is sufficient free space around the unit.

The ambient operating conditions are fulfilled; see section Ambient conditions (page 286).

The cooling air is able to flow freely.

The motor and the driven equipment are ready for start; see section Motor (AC) connection (page 285),
and separate document ACS880 multidrive cabinets and modules electrical planning instructions
(3AUA0000102324, English).

ELECTRICAL INSTALLATION
See chapter Electrical installation (page 145), and separate document ACS880 multidrive cabinets and
modules electrical planning instructions [3AUA0000102324, English])

The DC capacitors of the inverter modules are reformed if stored over one year. Refer to Capacitor
reforming instructions (3BFE64059629, English).

The drive system is grounded properly.

The input (DC) voltage matches the nominal input voltage of the inverter unit.

The power connections at UDC+ and UDC– and their tightening torques are OK.
170 Installation checklist

Check that…

Appropriate DC fuses are installed.

The motor is of the correct voltage.

The star/delta connection in the motor terminal box is correct.

The motor connections at U2, V2 and W2 and their tightening torques are OK.

The motor cable is routed away from other cables.

There are no power factor compensation capacitors in the motor cable.

The external control connections to the inverter unit are OK (including wiring of emergency stop, safe
torque off and prevention of unexpected start-up circuits).

There are no tools, foreign objects or debris inside the modules or the cabinet.

All shrouds and covers are in place.

 Start-up 171

7
Start-up

Contents of this chapter

This chapter contains the start-up procedure of the inverter.
Note: These instructions do not cover all possible cabinet constructions. Always refer to
the delivery-specific circuit diagrams when proceeding with the start-up.

WARNING! Only qualified electricians are allowed to do the work described in this
chapter. Read the complete safety instructions and repeat the steps described in
section Electrical safety precautions (page 146). The complete safety instructions
are given in Safety instructions for ACS880 multidrive cabinets and modules
[3AUA0000102301 (English)]. Ignoring the instructions can cause physical injury or death,
or damage to the equipment.

Note: The customer is fully responsible for implementing and testing the functional safety
circuits according to the relevant legislation and acceptance testing regulations. The
functional safety option manuals give examples on implementing the safety circuits in
ACS880 multidrives. For information on the Safe torque off function, see chapter The Safe
torque off function (page 309).

Start-up procedure
Tasks
Safety
WARNING! Obey the safety instructions during the start-up procedure. See Safety
instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]) and
Electrical safety precautions (page 146).
172 Start-up

Tasks
Checks/Settings with no voltage connected
Check the mechanical and electrical installation. See Installation checklist (page 169).

Make sure that the insulation resistance of the assembly has been checked. See Checking the
insulation of the assembly (page 147).

The supply unit of the drive system has been set up according to the instructions in its manuals.

The supply unit is off, and the drive system has been isolated from the supply network.

Check that any circuit breakers and protection switches in the cooling fan supply circuit are closed.
Refer to the circuit diagrams.

Check the following data for each inverter unit and note down any deviations from delivery
documents.

• Motor, pulse encoder and cooling fan rating plate data correspond to the values in the motor list.

• Motor temperature method: Pt100, PTC, KTY84, other?

• Motor fan of separately ventilated motors. Check the current, the overcurrent protection setting
and the functioning of the fan output control circuit.

• Direction of motor rotation.

• Maximum and minimum speeds, fixed speeds.

• Speed scaling factor, gear ratio, roll diameter, etc.

• Acceleration and deceleration times.

• Inertia compensation.

• Operating modes, stop mode, emergency stop mode, etc.

Connecting voltage to the auxiliary circuits

Disconnect any auxiliary voltage (230 or 115 V AC) cables that lead from the terminal blocks to the
outside of the equipment and have not yet been checked. Also disconnect any uncompleted wiring.

Disconnect the communication link between the drive system and any overriding system.

Make sure the main contactor/breaker cannot be switched on inadvertently by remote control.

Be ready to trip the main breaker of the supply transformer in case something abnormal occurs.

Ensure all cabinet doors are closed.

Close the main breaker of the supply transformer. This will energize the input terminals of the drive
system.

Close the auxiliary voltage switch (if present).

Checks with auxiliary voltage connected

Check that the cooling fans rotate freely in the right direction, and the air flows upwards.
Notes:
• Speed-controlled cooling fans of frame R8i modules (ie. without option +C188) will not rotate until
the DC voltage to the module is connected.
• Depending on the wiring of the drive system and the type of inverter modules, it may be
necessary to have the supply unit powered before the fans are started. If so, check the cooling
fans after powering the supply unit.
 Start-up 173

Tasks
Set the parameters for each inverter unit. Refer to the firmware manual and/or start-up guide of the
control program. You can also use the start-up assistant if available in the particular control program.
In addition to the parameter settings required by the application, make the following settings:

• Set 31.23 Wiring or earth fault to “No action”.

• Set 95.04 Control board supply according to how the inverter control unit is powered.

• Edit 95.08 DC switch monitoring if necessary (ie. with R1i…R7i modules equipped with a DC
switch/disconnector).

• Edit 95.09 Fuse switch control if necessary (ie. with R8i modules without a DC
switch/disconnector and charging controller).

• With R8i modules with option +C188 (direct-on-line cooling fan), set bit 14 of 95.20 HW options
word 1.

• With parallel-connected R8i modules, select the inverter unit type in parameter 95.31 Parallel
connection rating id. You can filter the list using parameter 95.30.

• Reboot the control unit either by cycling the power, or by parameter 96.08 Control board boot.

Powering up the inverter unit

Close the cabinet doors.

Make sure that it is safe to connect voltage to the drive system. Ensure that:
• nobody is working on the unit or circuits that have been wired from outside into the cabinets
• cover of the motor terminal box is on.

Close the main disconnecting device of the drive system.

WARNING! When connecting voltage to the supply unit, the DC busbars will become live,
as will all the inverters connected to the DC bus.

WARNING!
Inverter units with a DC switch-disconnector:
Some types of inverter module may be energized through a charging circuit even when the
DC switch-disconnector is open or the DC fuses are removed.
Inverter units without a DC switch-disconnector:
If the inverter unit only has DC fuses without a switch fuse, all the inverter units with the DC fuses in
place will be energized when the main breaker/contactor closes. To prevent this, remove the fuses
from the inverter units which are to remain unenergized before connecting voltage. When the main
breaker/contactor of the supply unit is closed (DC busbars are live), never remove or insert
the DC fuses of an inverter unit.
Inverter cubicles with frame R1i…R5i modules:
Before closing the main DC switch-disconnector of the cubicle, leave open the fuse disconnectors of
those inverter modules that need not be powered at this time. Do not open or close any fuse
disconnectors under load.

Inverter units equipped with DC switch-disconnector (or fuse disconnectors): Close the DC
switch/disconnector (or fuse disconnectors) of the inverter units that are to be powered up.

Inverter cubicles equipped with main DC switch-disconnector (frames R1i…R5i): Close the main DC
switch/disconnector.
174 Start-up

Tasks
WARNING! Before closing the main contactor/air circuit breaker, make sure that sufficient
inverter power is connected to the intermediate (DC) bus.
As a rule of thumb,
• the sum power of the inverters connected must be at least 30% of the sum power of all inverters
• the sum power of the inverters connected must be at least 30% of the rated power of the brake
unit (Pbr.max) (if present).
If the above-mentioned rules are not followed, the DC fuses of the connected inverter units may
blow, or the brake chopper (if present) may be damaged.

Close the main contactor (or breaker) of the supply unit.

The DC bus is now powered, along with all inverters that are connected to it.

Checks with voltage connected to the inverter unit

Complete the pending ID (motor identification) run. Refer to the firmware manual and/or start-up
guide of the control program.
WARNING! Make sure the motor can be started and rotated as required by the selected ID
run mode (parameter 99.13 ID run requested).

Check the rotation direction of the motor.

Check the operation of the pulse encoder (if present). Refer to the user manual of the pulse encoder
interface module.

Check the functioning of the emergency stop function from each operating location.

Validate the Safe torque off function. Refer to chapter The Safe torque off function, section Start-up
including acceptance test (page 316).
WARNING! The safety functions cannot be considered safe until they are validated.

Validate any other safety functions (Emergency stop, Prevention of unexpected start-up, etc.)
according to the appropriate procedures.
WARNING! The safety functions cannot be considered safe until they are validated.

Control from an overriding system

Disconnect all voltages from the drive system.

Connect the communication link between the overriding system and the inverter unit.

Power up the drive system.

Check the start/stop functions.

Check the references received from the overriding system.

Check the warning/fault words.

Check the reaction of the inverter unit in case of a communication break.

Check the updating intervals of the communication.

Check any other relevant points.

 Maintenance 175

8
Maintenance

Contents of this chapter

This chapter contains maintenance instructions.

Maintenance intervals
The table below shows the maintenance tasks which can be done by the end user. The
complete maintenance schedule is available on the Internet
(http://www.abb.com/drivesservices). For more information, consult your local ABB
Service representative (http://www.abb.com/searchchannels).

Recommended annual actions by the user

Air inlet and outlet cleaning (IP20/IP42) I

Cabinet door filter change (IP54) R

Ambient conditions (dustiness, moisture, corrosion, temperature) I

Cleaning of heatsinks I

Tightness of terminals I

Quality of supply voltage P

Air circuit breaker maintenance (if present) I

Reforming DC circuit capacitors (spare modules and spare capacitors) O

Spare parts I
176 Maintenance

Years from start-up

Cooling
3 6 9 12 15 18 21

Frame R1i…R7i inverter module main cooling fan R R R

Frame R5i auxiliary cooling fan R R R R R R R

Frame R8i inverter module speed-controlled (without option

R R
+C188) main cooling fan

Frame R8i inverter module direct-on-line (option +C188) main

R R R
cooling fan

Frame R8i circuit board compartment fan R R R

Cabinet cooling fan R R R

Batteries

Control panel battery R R

Control unit battery R R R

Symbols
I Inspection (visual inspection and maintenance action if needed)
P Performance of on/off-site work (commissioning, tests, measurements or other work)
R Replacement

Maintenance and component replacement intervals are based on the assumption that the
equipment is operated within the specified ratings and ambient conditions. ABB
recommends annual drive inspections to ensure the highest reliability and optimum
performance.
Note: Long term operation near the specified maximum ratings or ambient conditions may
require shorter maintenance intervals for certain components. Consult your local ABB
Service representative for additional maintenance recommendations.

Maintenance timers and counters

The control program has maintenance timers and counters that can be configured to
generate a warning when a pre-defined limit is reached. Each timer/counter can be set to
monitor any parameter. This feature is especially useful as a service reminder. For more
information, see the firmware manual.
 Maintenance 177

Cleaning

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

WARNING! Use a vacuum cleaner with an antistatic hose and nozzle, and wear a
grounding wristband. Otherwise an electrostatic charge might build up and
damage the circuit boards.

 Cleaning the interior of the cabinet

1. Stop the drive and disconnect it from the power line. Wait for five minutes to let the DC
capacitors discharge before opening the cabinet door. Ensure by measuring with a
multimeter (impedance at least 1 Mohm) that there is no voltage present.
2. Open the cabinet door.
3. Clean the interior of the cabinet. Use a vacuum cleaner and a soft brush.
4. Clean the air inlets and outlets of the fans.

 Cleaning the module heatsink

The module heatsink fins pick up dust from the cooling air. Inverter modules run into
overtemperature warnings and faults if the heatsink is not clean. In a “normal” environment
(neither especially dusty nor clean), the heatsink should be checked annually, in a dusty
environment more often.
1. Remove the main cooling fan of the inverter module as described under Cooling fans
elsewhere in this chapter.
2. Blow clean and dry compressed air through the module from bottom to top,
simultaneously using a vacuum cleaner at the air outlet to trap the dust.
Note: Prevent the dust from entering adjoining equipment.
3. Refit the cooling fan.
178 Maintenance

 Cleaning the door air inlets

Follow the instructions of the manufacturer of the cabinet system. The cleaning
instructions for the inlet kits specified in Ordering information (starting page 203) are given
below.

Cleaning the door air inlets (IP20)

Use a vacuum cleaner and brush to clean the grating.

Cleaning the door air inlets (IP42)

1. Remove the fasteners at the top of the grating.
2. Lift the grating and pull it away from the door.
3. Vacuum clean or wash the grating on both sides.
4. Reinstall the grating in reverse order.

3 5
 Maintenance 179

Cleaning the door air inlets (IP54)

1. Remove the fasteners at the top of the grating.
2. Lift the grating and pull it away from the door.
3. Remove the air filter mat.
4. Place the new filter mat in the grating the metal wire side facing the door.
5. Reinstall the grating in reverse order.

2 3

4
180 Maintenance

Cooling fans
 Replacing the module cooling fans
The lifespan of the cooling fans of the drive depend on the running time of the fan, ambient
temperature and dust concentration. See the firmware manual for the actual signal which
indicates the running time of the cooling fan. For resetting the running time signal after a
fan replacement, please contact ABB.
Replacement fans are available from ABB. Do not use other than ABB specified spare
parts.

Frames R1i and R2i

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Detach the power cable clamp plate and terminal blocks.

2. Release the retaining clips (arrowed) carefully using a screwdriver.
3. Pull the fan holder out.
4. Disconnect the fan cable.
5. Carefully bend the clips on the fan holder to free the fan.
6. Install new fan in reverse order.
Note: The airflow direction is bottom-to-top. Install the fan so that the arrow on it points up.

Airflow direct
ion
 Maintenance 181

Frames R3i and R4i

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. To remove the fan, release the retaining clip (arrowed) carefully using a screwdriver.
2. Pull the fan holder out.
3. Disconnect the fan cable.
4. Carefully bend the clips on the fan holder to free the fan.
5. Install new fan in reverse order.
Note: The airflow direction is bottom-to-top. Install the fan so that the airflow arrow points
up.

Airflow direct
io n
182 Maintenance

Frame R5i – Main cooling fan

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Disconnect the drive from the power line. Lock the main disconnecting device and
ensure by measuring that there is no voltage.
2. Lift the fan mounting plate by the front edge.
3. Unplug the power supply wires.
4. Lift the fan assembly off.
5. Install the new fan assembly in reverse order. Make sure that the fan blows upwards.

2 4

3
 Maintenance 183

Frame R5i – Auxiliary cooling fan

Frame R5i modules have an auxiliary fan located at the top front of the module.

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Unplug the fan from the control unit. Make note of the connector the plug is connected
to.
2. Push the two locking tabs gently inwards to release the fan.
3. Remove the fan.
Install new fan in reverse order. Make sure that the fan blows upwards (the arrows on the
fan frame and the fan holder point in the same direction).

2
184 Maintenance

Frames R6i and R7i

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

Frame R6i modules have one fan, R7i modules have two.
1. Stop the drive and disconnect it from the AC power line. Obey the instructions in
section Electrical safety precautions (page 146).
2. Open the door. Remove any shrouding in front of the fan unit.
3. Remove the front plate.
4. Remove the two screws that lock the fan unit.
5. Unplug the power supply wire(s) of the fan(s).
6. To free the fan holder, pull it slightly outwards (about 5 mm), then downwards.
7. Detach the fan(s) from the fan holder.
8. Install new fan(s) in reverse order. Note: The airflow direction is bottom-to-top. Install
the fan(s) so that the airflow direction arrow points up.

6
4

8
 Maintenance 185

Frame R8i – Main cooling fan (modules without option +C188)

If the inverter module is equipped with a direct-on-line cooling fan (option +C188), see
page 187.

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Stop the drive and disconnect it from the AC power line. Obey the instructions in
section Electrical safety precautions (page 146).
2. Open the cubicle door.
3. Remove the shroud in front of the fan (if any).
4. Remove the cover panel in front of the fan.
5. Unplug the wiring of the fan.
6. Remove the fan control box.
7. Undo the screws of the fan unit.
8. Pull the fan unit out.
9. Install the new fan in reverse order.
186 Maintenance

5
4
8

6
 Maintenance 187

Frame R8i – Direct-on-line main cooling fan (option +C188)

If the inverter module is not equipped with a direct-on-line cooling fan (option +C188), see
page 185.

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Stop the drive and disconnect it from the AC power line. Obey the instructions in
section Electrical safety precautions (page 146).
2. Open the door.
3. Remove the shroud in front of the fan (if any).
4. Remove the cover panel.
5. Remove the bracket.
6. Unplug the wiring of the fan assembly.
7. Undo the screws of the fan assembly.
8. Pull out the fan assembly.
9. Unplug fan wire from the fan assembly.
10. Undo the screws of the fan.
11. Install a new fan in reverse order.
188 Maintenance

10

10
6
 Maintenance 189

Frame R8i – Circuit board compartment fan

The R8i module is equipped with a fan blowing air through the circuit board compartment.
The fan is accessible from the front of the module.

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Open the door of the module cubicle.

2. Remove the two M4×12 (T20) screws which lock the fan holder.
3. Pull the fan holder out of the module.
4. Disconnect the fan cable.

4
3

5. Remove the four M3 (5.5 mm) nuts which hold the fan.
6. Remove the fan from the fan holder.

6
190 Maintenance

7. Put the fan onto the threaded studs on the fan holder with the airflow direction arrow
pointing towards the fan holder.
8. Install and tighten the four nuts removed earlier.

9. Connect the fan cable.

10. Align and push the fan holder into the module.
11. Install and tighten the two M4×12 (T20) screws.

9
10

11
 Maintenance 191

 Replacing the cabinet cooling fans

Cabinets with ABB air outlet kits

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Stop the drive and disconnect it from the AC power line. Obey the instructions in
section Electrical safety precautions (page 146).
2. The instruction mentioned at each air outlet kit in chapter Ordering information
contains an exploded view of the outlet. Remove all gratings and filters, and finally
remove the plate on top of the outlet. Unscrew all necessary screws securing the fan
and remove it.
3. Install new fan in reverse order.

Cabinets with other fan types

Follow the instructions of the manufacturer of the air outlet or enclosure system.

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.
192 Maintenance

Replacing a frame R6i/R7i inverter module

The following procedure describes the replacement of a frame R6i or R7i inverter module.
The procedure applies to the design presented in this manual (see page 99).

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.
• Do not leave the module standing unattended in a vertical position. The module can
cause damage or physical injury if it topples over.
• Keep your fingers away from the edges of the module when inserting the module into
the cubicle.
• Only lift the module by its lifting eyes (see drawing on page 32). A lifting device that
can be attached to the cubicle is available from ABB; see page 243.

Refer to the drawings below.

1. Disconnect the drive system from the AC power line.
2. Open the cubicle door.
3. Remove the shrouds. Also remove the mounting brackets of the middle shroud (3a) on
the left.
4. Remove the two screws holding the fan unit (arrowed). Remove the fan unit by pulling
it slightly outwards, then downwards.
5. Remove the mounting screws (arrowed) of the front air baffle. Remove the baffle.
6. Disconnect all control cabling coming to the control unit at the front of the module.
Move the cabling aside and tie it out of the way.
7. Disconnect the DC busbars.
8. Disconnect the AC busbars.
9. Pull out the module until the lifting device (or a suitable hoist) can be attached to the
lifting eyes at the top of the module (arrowed).
10. Make sure the lifting device is carrying the weight of the module, and pull the module
out completely.
Install the module in reverse order to the above.
 Maintenance 193

3 4

3a

5
194 Maintenance

8
7

9
 Maintenance 195

Replacing a frame R8i inverter module

WARNING! Only qualified electricians are allowed to do the work described

below. Read the complete safety instructions given in Safety instructions for
ACS880 multidrive cabinets and modules [3AUA0000102301 (English)] before
you service the drive. Ignoring the instructions can cause physical injury or death, or
damage to the equipment.

WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment:

• Use extreme caution when maneuvering the module. The module is heavy and has a
high center of gravity. It topples over easily if handled carelessly.
• When removing the module, pull the module carefully out of the cubicle along the
ramp. While pulling on the handle, keep a constant pressure with one foot on the base
of the module to prevent the module from falling on its back.
• When replacing the module, push the module up the ramp and back into the cubicle.
Keep your fingers away from the edge of the module front plate to avoid pinching them
between the module and the cubicle. Also, keep a constant pressure with one foot on
the base of the module to prevent the module from falling on its back.
• Do not tilt the module. Do not leave the module unattended on a sloping floor.
• Do not use the module pull-out ramp with plinth heights over 100 mm. The ramp is
designed for a plinth height of 100 mm (the standard plinth height of Rittal TS 8
cabinets).
196 Maintenance

1. Stop the drive and disconnect it from the AC power line. Obey the instructions in
section Electrical safety precautions on page 146. Open the main switch-disconnector
or main breaker. If the disconnecting equipment is located outside the cabinet, make
sure that it is in the disconnected position.
2. Open the cubicle door.
3. Remove the shrouds (if any).
4. Unplug the wiring on the front of the module. Unplug the connector (X50) at the top of
the module. Move the wires aside.
5. Use a module pull out ramp or other lifting device to remove the module from the
cabinet. If the ramp designed for Rittal TS 8 is used, install it by placing the hooks of
the ramp between the bottom plate and enclosure frame.
6. Remove the module fastening screws on the top part of the module.
7. Remove the module fastening screws on the lower part of the module.
8. Pull the module carefully out of the cabinet along the ramp, or use another lifting
device to remove the module.
9. Replace the module:
• Push the module back in and fasten. Be careful not to break the locking screws:
tighten the fastening screws of the module to 22 N·m (16.2 lbf.ft) and fastening
bolts of the DC input busbars to 70 N·m (51.6 lbf.ft).
• Reconnect connector X50 at the top of the module.
• Reconnect the wiring and fiber optic cables to their respective terminals on the
front of the module.
• Remove the module pull-out ramp, attach the shrouds (if any) and close the
cabinet doors.
 Maintenance 197

7
198 Maintenance

Capacitors
The DC circuit of an inverter module contains several electrolytic capacitors. Their lifespan
depends on the operating time, loading and ambient temperature. Capacitor life can be
prolonged by lowering the ambient temperature.
Capacitor failure is usually followed by damage to the unit and an input fuse failure, or a
fault trip. Contact an ABB service representative for spare parts and repair services.

 Reforming the capacitors

The DC circuit capacitors must be reformed if the inverter module has been stored for a
year or more. See section Type designation label (page 44) for information on finding out
the manufacturing date. For information on reforming the capacitors, see Converter
module capacitor reforming instructions (3BFE64059629 [English]).

Memory unit
After replacing an inverter control unit, the existing parameter settings can be retained by
transferring the memory unit from the defective unit to the new unit.

WARNING! Do not remove or insert the memory unit when the control unit is
powered.

To remove the memory unit, undo the fastening screw and pull the memory unit out.

ZCU-14 BCU
 Maintenance 199

Control panel
 Replacing the control panel battery
1. Turn the lid on the back of the panel counter-clockwise until the lid opens.
2. Replace the battery with a new CR2032 battery.
3. Put the lid back and tighten it by turning it clockwise.
4. Dispose of the old battery according to local disposal rules or applicable laws.
200 Maintenance

LED indications
Warnings and faults reported by the control program are displayed on the control panel or
in the Drive composer PC tool. For further information, see the firmware manual of the
inverter control program.
The ACS-AP-x control panel has a status LED. The control panel holder (frames R1i…R4i)
or door mounting kit DPMP-xx has two status LEDs. Frame R8i inverter modules have
three LEDs. The indications of all these LEDs are shown in the table below.

Location LED Indication

ACS-AP-x control panel Continuous green The inverter unit is functioning normally.
(status LED)

Flickering green Data is being transferred between the PC and the

module through the USB connection of the control
panel.

Blinking green There is an active warning in the inverter unit.

Continuous red There is an active fault in the inverter unit.

Blinking red There is a fault that requires the stopping and

restarting of the inverter unit.

Blinking blue The Bluetooth interface is enabled, in discoverable

(ACS-AP-W only) mode, and ready for pairing.

Flickering blue Data is being transferred through the Bluetooth

(ACS-AP-W only) interface of the control panel.

Control panel holder or Red There is an active fault in the inverter unit.
door mounting kit
Green Power supply of the inverter control unit is OK.

R8i inverter module FAULT There is an active fault in the module.

(continuous red)

ENABLE / STO The module is ready for use.

(continuous green)

ENABLE / STO XSTO connectors are de-energized.

(continuous yellow)

POWER OK Supply voltage of the internal circuit boards is OK

(continuous green) (> 21 V).
 Maintenance 201

Reduced run
A “reduced run” function is available for inverter units consisting of parallel-connected
inverter modules. The function makes it possible to continue operation with limited current
even if one (or more) module is out of service, for example, because of maintenance work.
In principle, reduced run is possible with only one module, but the physical requirements of
operating the motor still apply; for example, the modules remaining in use must be able to
provide the motor with enough magnetizing current.
The wiring accessories needed during the procedure are available from ABB (see page
251).

 Starting reduced run operation

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. If the inverter control unit is powered from the faulty module, connect the control unit to
another 24 V DC power supply. We strongly recommend using an external power
supply with inverter units consisting of parallel-connected modules.
2. Remove the module to be serviced from its bay.
3. If the STO (Safe torque off) function is in use, install the STO jumper wire set in place
of the missing module (unless the module was the last on the chain).
4. Install an air baffle to the top module guide to block the airflow through the empty
module bay.
5. In case the inverter unit has a DC switch with a charging circuit, disable the
appropriate channel on the charging monitoring unit.
6. Switch on the power to the inverter unit.
7. Enter the number of inverter modules present into parameter 95.13 Reduced run
mode.
8. Reset all faults and start the inverter unit. The maximum current is now automatically
limited according to the new inverter configuration. A mismatch between the number
of detected modules (95.14) and the value set in 95.13 will generate a fault.
9. If the STO function is in use, validate it as described in chapter The Safe torque off
function (page 316).
202 Maintenance

 Resuming normal operation

WARNING! Repeat the steps described in section Electrical safety

precautions on page 146. The complete safety instructions are given in
Safety instructions for ACS880 multidrive cabinets and modules
(3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

1. Remove the STO (Safe torque off) jumper wire set (if present).
2. Remove the air baffle from the module bay.
3. Reinstall the module into its bay.
4. Reconnect the STO wiring (if used) to the module.
5. In case the inverter unit has a DC switch with a charging circuit, re-enable all channels
on the charging monitoring unit.
6. Switch on the power to the inverter unit.
7. Enter “0” into parameter 95.13 Reduced run mode.
8. If the STO function is in use, validate it as described in chapter The Safe torque off
function (page 316).
 Ordering information 203

9
Ordering information

Contents of this chapter

This chapter lists the types and ordering codes of ACS880-104 inverter unit components.
Notes:
• This chapter only lists the installation accessories available from ABB. All other parts
must be sourced from a third party (such as Rittal) by the system integrator. For a
listing, refer to the kit-specific installation instructions available at
https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content. For access,
contact your local ABB representative.
• Parts that are labeled suitable for generic enclosures are not designed for any specific
enclosure system. These parts are intended as a basis for further engineering, and
may require additional parts to be fully usable.
Installation accessories designed for generic enclosures are in fact designed for an
inside width of 50 mm less than the nominal width of the enclosure. For example, a
mechanical kit intended for 800 mm wide generic enclosure is designed for an inside
width of 750 mm, and will not fit a 800 mm wide Rittal TS 8 enclosure.
204 Ordering information

Kit code key

The kit codes shown in this chapter break down as follows.
The format of the kit code is A-w-s-xxx, for example, A-4-X-022 where:
• A = air-cooled
• w = cabinet width in mm/100, for example 6 = 600 mm
• s = module frame size / sizes
• 1 = R1i
• 2 = R2i
• 3 = R3i
• 4 = R4i
• 5 = R5i
• 6 = R6i
• 7 = R7i
• 8 = R8i
• X = any, or not defined.
• xxx = consecutive numbering
• 001…099 = Kits related to cabinets, for example, air inlets and outlets
001…019 Common AC- and DC-related kits
020…039 Air inlets
040…059 Air outlets
060…070 Air outlets with fan

• 100…199 = Kits related to AC connection, for example, busbars

100…129 Kits with connection to AC
130…149 Kits with connection to module
150…199 Other kits related to AC connection

• 200…299 = Kits related to DC connection, for example, busbars

200…229 Kits with connection to common DC
230…249 Kits with connection to module
250…299 Other kits related to DC connection

• 300…399 = Kits related to module installation, for example, mechanical supports

300…330 Module supporting kits, basic mechanical support
350…379 Shroud kits

• 400…499 = Other kits

420…439 Air guides

• 500…599 = Marine kits

 Ordering information 205

Frames R1i…R4i
 Inverter modules
As standard, frame R1i to R4i inverter modules come with a cover that also acts as a
control panel holder. The cover is fitted with a panel interface board (ZDPI-01) which
enables the construction of a panel bus. The panel bus makes it possible to control several
inverter units from a single control panel (see page 167).
The modules can be ordered without the cover by specifying option code +0J414. (If
desired, the panel bus can be constructed using FDPI-02 modules which are available
separately.)
206 Ordering information

Ordering code Contents

[Module type] • Inverter module (1) with ZCU control unit (1a)
For example, • ZMU memory unit (2) with ACS880 primary control program. For
ACS880-104-008A0-3 availability of other control programs, contact your local ABB
representative.
• Module cover with control panel holder (3)
• ZDPI-01 panel interface board (4)
• Cable from ZDPI-01 to control unit (5)
• Control cable grounding/strain relief plate (6) with adapter (6a)
• Two power cable grounding/strain relief plates (7a, 7b)
• Module air temperature sensor (8) with mounting plate (8a)
• Cabinet cooling fan wire (connector with a stretch of wire).
[Module type] +0J414 • Inverter module (1) with ZCU control unit (1a)
For example, • ZMU memory unit (2) with ACS880 primary control program. For
ACS880-104-008A0-3 +0J414 availability of other control programs, contact your local ABB
representative.
• Control cable grounding/strain relief plate (6) with adapter (6a)
• Two power cable grounding/strain relief plates (7a, 7b)
• Module air temperature sensor (8) with mounting plate (8a)
• Cabinet cooling fan wire (connector with a stretch of wire).
[Module type] +N8010 • ACS880 primary control program with application programmability using
For example, function blocks based on the IEC 61131-3 standard. For more
ACS880-104-008A0-3 +N8010 information, see Programming manual: Drive application programming
(IEC 61131-3) (3AUA0000127808 [English]).
ACS880-104-008A0-3 +0J414
+N8010

For module types, see Ratings (page 277).

 Ordering information 207

ACS-AP-x control panel

The control panel is not included with the inverter module but must be ordered separately.
One control panel is required for the commissioning of an ACS880 drive system, even if
the Drive composer PC tool is used.
For more information on the control panel, see ACX-AP-x assistant control panels user’s
manual (3AUA0000085685 [English]). See also sections The ACS-AP-x control panel
(page 43) and Panel bus (Control of several inverter units from one control panel) (page
167).
The control panel can be flush mounted on the cabinet door with the help of a door
mounting kit.
Type Description Ordering code Illustration

Control panel with

ACS-AP-W 3AXD50000025965
Bluetooth

ACS-AP-I Control panel 3AUA0000088311

Door mounting kit

DPMP-01 3AUA0000108878
(IP55)
208 Ordering information

 DC-side components
Frame R1i…R4i inverter modules are connected to the DC bus through individual fuses.
The fuses are installed on fuse bases that can be opened under no load. Microswitches
are used for monitoring the open/closed state of the fuse bases. The fuse bases specified
for frame sizes R3i and R4i include the microswitches as standard; the microswitches
must be ordered separately for R1i and R2i fuse bases.
A main DC switch/disconnector and DC fuses for all the modules in the same enclosure
can optionally be added. The main DC fuses are typically used to protect against short-
circuits in the DC path to the module fuses when a high-power supply unit is used.

DC bus installation parts

The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat-
PLS DC bus and ensure its correct placement and alignment inside the cabinet line-up.
Enclosure width Qty Kit code Ordering code Illustration

400 mm
600 mm 1 A-468-X-001 3AUA0000115906
800 mm

Instruction code: 3AUA0000115891

Module-specific DC fuses (IEC, UL)

Module type Fuse
Qty Ordering code
ACS880-104-… Type Data
004A8-3 003A6-5
Bussmann FWP-10A14F* 10 A, 660 V 2 3AUA0000089115
006A0-3 004A8-5
008A0-3 006A0-5 Bussmann FWP-15A14F* 15 A, 660 V 2 3AUA0000089116
0011A-3 008A0-5 Bussmann FWP-20A14F* 20 A, 660 V 2 3AUA0000089117
0014A-3 0011A-5 Bussmann FWP-25A14F* 25 A, 660 V 2 3AUA0000089118
0018A-3 0014A-5
Bussmann FWP-32A14F* 32 A, 660 V 2 3AUA0000089119
0018A-5
0025A-3 0025A-5 Mersen 6,921 CP URQ 27x60/50** 50 A, 690 V 2 3AXD50000000189
0035A-3 0030A-5 Mersen 6,921 CP URQ 27x60/63** 63 A, 690 V 2 3AXD50000000211
0044A-3 0035A-5 Mersen 6,921 CP URQ 27x60/80** 80 A, 690 V 2 3AXD50000000213
0050A-3 0050A-5 Mersen 6,921 CP URQ 27x60/100** 100 A, 690 V 2 3AXD50000000215
0061A-3 0061A-5 Mersen 6,921 CP URQ 27x60/125** 125 A, 690 V 2 3AXD50000000217
0078A-3 0078A-5 Mersen 6,921 CP URQ 27x60/160** 160 A, 690 V 2 3AXD50000000219
0094A-3 0094A-5
Mersen 6,921 CP URQ 27x60/200** 200 A, 690 V 2 3AXD50000000221
0100A-3
*Size: 14 × 51 mm
**Size: 27 × 60 mm
 Ordering information 209

Module-specific DC fuse bases (IEC, UL)

Module type Fuse base
Qty Ordering code
ACS880-104-… Type Data
004A8-3 003A6-5 2 3AUA0000089224 (fuse base)
… … Mersen US141 14 × 51 mm
(Z331153F) 50 A, 690 V 2 3AUA0000089228 (microswitch)
0018A-3 0018A-5
0025A-3 0025A-5
… … Mersen US271MI 27 × 60 mm 3AUA0000089227
2
(R227600C) 150 A, 800 V (microswitch included)
0100A-3 0094A-5

Main DC switch/disconnector kits

IEC
DC switch/disconnector
Enclosure width Qty Ordering code
Type Data
400 mm ABB OT400E11 2-pole, 400 A 1 3AXD50000000891
600 mm ABB OT630E11 2-pole, 630 A 1 3AXD50000000892
800 mm ABB OT400E22 4-pole, 400 A 1 3AXD50000000893

UL
DC switch/disconnector
Enclosure width Qty Ordering code
Type Data
400 mm ABB OT400U11 2-pole, 400 A 1 3AXD50000002764
600 mm ABB OT600U11 2-pole, 600 A 1 3AXD50000002765
800 mm ABB OT400U22 4-pole, 400 A 1 3AXD50000002767

Kit contents:
• DC switch/disconnector
• Shaft (12 × 325 mm)
• OHB___J12 handle with off/on indication
• OA1G10 normally-open auxiliary contact block.

Main DC fuses (IEC, UL)

Fuse
Enclosure width Qty Ordering code
Type Data Size
400 mm Bussmann 170M4413 450 A, 690 V 1 2 68731623
600 mm Bussmann 170M4418 800 A, 690 V 1 2 3AXD50000000250
800 mm Bussmann 170M4413 450 A, 690 V 1 4 68731623
210 Ordering information

Busbars between main DC switch/disconnector and fuses

IEC
Enclosure width Qty Kit code Ordering code Illustration

400 mm 1 A-4-1234-272 3AUA0000114423

Instruction code: 3AUA0000114418

600 mm 1 A-6-1234-271 3AUA0000114079

Instruction code: 3AUA0000114054

800 mm 1 A-8-1234-273 3AUA0000114426

Instruction code: 3AUA0000114413

 Ordering information 211

UL
Enclosure width Qty Kit code Ordering code Illustration

400 mm 1 A-4-1234-274 3AXD50000003918

Instruction code: 3AXD50000003895

600 mm 1 A-6-1234-271 3AUA0000114079

Instruction code: 3AUA0000114054

800 mm 1 A-8-1234-275 3AXD50000003919

Instruction code: 3AXD50000003875

212 Ordering information

 AC-side components
Output (du/dt) filters
For information on the usage of output (du/dt) filters, see document ACS880 multidrive
cabinets and modules electrical planning instructions (3AUA0000102324 [English]).
Module type Filter
Qty Ordering code
ACS880-104-… Type Data
004A8-3 003A6-5
006A0-3 004A8-5 IRMS: 15 A
008A0-3 006A0-5 L: 150 µH
0011A-3 008A0-5 NOCH0016-60 Power loss: 110 W 1 58982784
0014A-3 0011A-5 Cable size: 0.2 … 10 mm2
0018A-3 0014A-5 Connection: M5
0018A-5
0025A-3 0025A-5 IRMS: 28 A
0035A-3 0030A-5 L: 140 µH
0035A-5 NOCH0030-60 Power loss: 167 W 1 58982792
Cable size: 0.5 … 16 mm2
Connection: M5
0044A-3 0050A-5 IRMS: 65 A
0050A-3 0061A-5
L: 115 µH
0061A-3 0078A-5
NOCH0070-60 Power loss: 210 W 1 58982806
0078A-3 0094A-5
0094A-3 Cable size: 10…35 mm2
0100A-3 Connection: M6
 Ordering information 213

 Mechanical installation accessories

These kits include parts that are required for installing the inverter module in the
enclosure.

Mounting plate shroud kits

The plates are installed in front of the main DC switch and fuses. The module-specific fuse
disconnectors are installed onto this plate.
Enclosure width Qty Kit code Ordering code Illustration

400 mm 1 A-4-1234-403 3AUA0000114448

Instruction code: 3AUA0000114444

600 mm 1 A-6-1234-402 3AUA0000114436

Instruction code: 3AUA0000114434

800 mm 1 A-8-1234-404 3AUA0000114450

Instruction code: 3AUA0000114419

Air guide kits

The air guide directs the hot air exiting the inverter module into the hot area at the rear of
the cubicle.
Frame size Qty Kit code Ordering code Illustration

R1i 1 A-468-1-422 3AUA0000114398

R2i 1 A-468-2-423 3AUA0000114330

R3i 1 A-468-3-424 3AUA0000114404

R4i 1 A-468-4-425 3AUA0000114405 Instruction code: 3AUA0000114397

214 Ordering information

 Cabinet ventilation
Air inlet kits
Mounting screws are included.
Enclosure width /
Kit code Ordering code Illustration
Degree of protection

400 mm / IP20 A-4-X-021 3AUA0000117002

Instruction code: 3AUA0000116879

400 mm / IP42 A-4-X-024 3AUA0000117007

Instruction code: 3AUA0000116873

400 mm / IP54 A-4-X-027 3AXD50000009184

Instruction code: 3AXD50000009989

 Ordering information 215

Enclosure width /
Kit code Ordering code Illustration
Degree of protection

600 mm / IP20 A-6-X-022 3AUA0000117003

Instruction code: 3AUA0000116880

600 mm / IP42 A-6-X-025 3AUA0000117008

Instruction code: 3AUA0000116874

600 mm / IP54 A-6-X-028 3AXD50000009185

Instruction code: 3AXD50000009990

800 mm / IP20 A-8-X-023 3AUA0000117005

Instruction code: 3AUA0000116887

216 Ordering information

Enclosure width /
Kit code Ordering code Illustration
Degree of protection

800 mm / IP42 A-8-X-026 3AUA0000117009

Instruction code: 3AUA0000116875

800 mm / IP54 A-8-X-029 3AXD50000009186

Instruction code: 3AXD50000010001

Air outlet kits

Note: The fan is to be ordered separately.
Enclosure width /
Qty Kit code Ordering code Illustration
Degree of protection

400 mm / IP20 1

A-4-X-062 3AUA0000125201

800 mm / IP20 2
Instruction code: 3AXD50000001982
Note: Fan to be ordered separately

600 mm / IP20 1 A-6-X-063 3AUA0000125202

Instruction code: 3AXD50000001980

Note: Fan to be ordered separately
 Ordering information 217

Enclosure width /
Qty Kit code Ordering code Illustration
Degree of protection

400 mm / IP42 1

A-4-X-060 3AUA0000114967

800 mm / IP42 2
Instruction code: 3AUA0000115290
Note: Fan to be ordered separately

600 mm / IP42 1 A-6-X-061 3AUA0000114971

Instruction code: 3AUA0000115152

Note: Fan to be ordered separately

400 mm / IP54
1
(IEC)

A-4-X-064 3AXD50000009187

800 mm / IP54
2
(IEC)

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately

400 mm / IP54
1
(UL)

A-4-X-067 3AXD50000010362

800 mm / IP54
2
(UL)

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately
218 Ordering information

Enclosure width /
Qty Kit code Ordering code Illustration
Degree of protection

600 mm / IP54
1 A-6-X-065 3AXD50000009189
(IEC)

Instruction code: 3AXD50000010004

Note: Fan to be ordered separately

600 mm / IP54
1 A-6-X-066 3AXD50000010327
(UL)

Instruction code: 3AXD50000010004

Note: Fan to be ordered separately

Cooling fans
One or two cooling fans are to be installed inside the air outlet compartment to ensure
sufficient cooling of the cabinet.
IEC
Enclosure width / Component
Degree of protection Qty Ordering code
(Auxiliary voltage) Name Data

400 mm, 600 mm / Fan R3G225-RH17-23 1 3AXD50000000592

IP20, IP42 Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
(230 V 50/60 Hz) Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RB4C-355/170 1 3AXD50000006934
400 mm / IP54 Capacitor MSB MKP 6/603/E1679 1 3AXD50000006959
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan CRBB/4-400/188 1 3AXD50000006111
600 mm / IP54 Capacitor MSB MKP 12/603/E1679 1 3AXD50000006885
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
 Ordering information 219

IEC
Enclosure width / Component
Degree of protection Qty Ordering code
(Auxiliary voltage) Name Data

800 mm / Fan R3G225-RH17-23 2 3AXD50000000592

IP20, IP42 Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
(230 V 50/60 Hz) Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724
Fan RB4C-355/170 2 3AXD50000006934
800 mm / IP54 Capacitor MSB MKP 6/603/E1679 2 3AXD50000006959
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724

UL
Enclosure width / Component
Degree of protection Qty Ordering code
(Auxiliary voltage) Name Data
Fan R2E225-RA92-17 1 3AXD50000000514
400 mm, 600 mm / Capacitor MSB MKP 3,5/603/E1679 1 3AXD50000000882
IP20, IP42
Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
(230 V 50/60 Hz)
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan R2E225-BD40-65 1 68502926
400 mm, 600 mm / Capacitor KO230F, mod. 345 1 58915211
IP20, IP42
Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
(115 V 60 Hz)
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RB4C-355/170 1 3AXD50000006934
400 mm / IP54 Capacitor MSB MKP 6/603/E1679 1 3AXD50000006959
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RH35M-4EK.4F.1R 1 64750062
400 mm / IP54 Capacitor 25 µF, 220 V 1 68713188
(115 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan CRBB/4-400/188 1 3AXD50000006111
600 mm / IP54 Capacitor MSB MKP 12/603/E1679 1 3AXD50000006885
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RH40M-4EK.4I.1R 1 64750038
600 mm / IP54 Capacitor 25 µF, 220 V 1 68713188
(115 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan R2E225-RA92-17 2 3AXD50000000514
800 mm / Capacitor MSB MKP 3,5/603/E1679 2 3AXD50000000882
IP20, IP42
Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
(230 V 50/60 Hz)
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724
Fan R2E225-BD40-65 2 68502926
800 mm / IP20, IP42 Capacitor KO230F, mod. 345 2 58915211
(115 V 60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724
Fan RB4C-355/170 2 3AXD50000006934
800 mm / IP54 Capacitor MSB MKP 6/603/E1679 2 3AXD50000006959
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724
220 Ordering information

UL
Enclosure width / Component
Degree of protection Qty Ordering code
(Auxiliary voltage) Name Data
Fan RH35M-4EK.4F.1R 2 64750062
800 mm / IP54 Capacitor 25 µF, 220 V 2 68713188
(115 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724

The wiring diagram examples (starting on page 379) show a cabinet cooling fan circuit that
energizes the fan when at least one inverter module installed in the cabinet is running. The
fan will continue to run for 20 minutes after all inverter modules have been stopped.
The following parts (or equivalent) are used to implement the circuit. These parts are to be
sourced by the customer.
• Phoenix Contact ST 2,5-DIO/L-R - 3036262 spring cage component terminal block
with a 1N4007 diode
• Relpol PI84-24DC-M41G relay
• Rated load (capacity): 8 A / 24 V DC
• Rated power consumption: 0.4 … 0.48 W DC
• GZT80 relay socket
• 600 mm of AWG24, 300 V, UL1569 (or equivalent material, valid for PVC insulation
only) wire
• Favier SEP-4 light brown 4 kV fiberglass sleeving.
 Ordering information 221

Frame R5i
 Inverter module
As standard, frame R5i inverter modules come with a two-part front cover, the top part of
which also acts as a control panel holder. The holder is fitted with a panel interface board
(ZDPI-01) which enables the construction of a panel bus. The panel bus makes it possible
to control several inverter units from a single control panel (see page 167).
The modules can be ordered without the front covers by specifying option code +0J414. (If
desired, the panel bus can be constructed using FDPI-02 modules which are available
separately.)
222 Ordering information

Ordering code Contents

[Module type] • Inverter module (1) with ZCU-12 control unit (2)
For example, • ZMU memory unit (3) with ACS880 primary control program. For
ACS880-104-007A3-7 availability of other control programs, contact your local ABB
representative.
• Module front cover, top (4) including
• Control panel holder
• ZDPI-01 panel interface board
• Cable from ZDPI-01 to control unit
• Module front cover, bottom (5)
• Cabinet cooling fan wire (connector with a stretch of wire).
[Module type] +C132 • Marine type approval. For more information, see ACS880 +C132 marine
For example, type-approved drive modules and module packages supplement
ACS880-104-007A3-7 +C132 (3AXD50000037752 [English]).
ACS880-104-007A3-7 +C132
+0J414
[Module type] +0J414 • Inverter module (1) with ZCU-12 control unit (2)
For example, • ZMU memory unit (3) with ACS880 primary control program. For
ACS880-104-007A3-7 +0J414 availability of other control programs, contact your local ABB
representative.
• Cabinet cooling fan wire (connector with a stretch of wire).
[Module type] +N8010 • ACS880 primary control program with application programmability using
For example, function blocks based on the IEC 61131-3 standard. For more
ACS880-104-007A3-7 +N8010 information, see Programming manual: Drive application programming
(IEC 61131-3) (3AUA0000127808 [English]).
ACS880-104-007A3-7 +0J414
+N8010

3
2 1

For module types, see Ratings (page 277).

 Ordering information 223

ACS-AP-x control panel

The control panel is not included with the inverter module but must be ordered separately.
One control panel is required for the commissioning of an ACS880 drive system, even if
the Drive composer PC tool is used.
For more information on the control panel, see ACX-AP-x assistant control panels user’s
manual (3AUA0000085685 [English]). See also sections The ACS-AP-x control panel
(page 43) and Panel bus (Control of several inverter units from one control panel) (page
167).
The control panel can be flush mounted on the cabinet door with the help of a door
mounting kit.
Type Description Ordering code Illustration

Control panel with

ACS-AP-W 3AXD50000025965
Bluetooth

ACS-AP-I Control panel 3AUA0000088311

Door mounting kit

DPMP-01 3AUA0000108878
(IP55)

 DC-side components
Frame R5i inverter modules are connected to the DC bus through individual fuses. The
fuses are installed on fuse bases that can be opened under no load. Microswitches are
224 Ordering information

used for monitoring the open/closed state of the fuse bases. The fuse bases listed below
include the microswitches as standard.
A main DC switch/disconnector and DC fuses for all the modules in the same enclosure
can optionally be added. The main DC fuses are typically used to protect against short-
circuits in the DC path to the module fuses when a high-power supply unit is used.

DC bus installation parts

The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat-
PLS DC bus and ensure its correct placement and alignment inside the cabinet line-up.
Enclosure width Qty Kit code Ordering code Illustration

400 mm
1 A-468-X-001 3AUA0000115906
600 mm

Instruction code: 3AUA0000115891

Module-specific DC fuses (IEC, UL)

Module type Fuse
Qty Ordering code
ACS880-104-… Type Data
007A3-7
009A8-7
Mersen 1021 CP URB 27x60/40* 40 A, 1000 V 2 3AUA0000089197
014A2-7
0018A-7
0022A-7
0027A-7
0035A-7 Mersen 1021 CP URB 27x60/100* 100 A, 1000 V 2 3AUA0000089211
0042A-7
0052A-7
*Size: 27 × 60 mm

Module-specific DC fuse bases (IEC, UL)

Module type Fuse base
Qty Ordering code
ACS880-104-… Type Data
007A3-7
009A8-7
014A2-7
0018A-7
Mersen PS272PREMCPS 27 × 60 mm 3AXD50000012958
0022A-7 1
(N220076) 250 A, 1250 V DC (microswitch included)
0027A-7
0035A-7
0042A-7
0052A-7
 Ordering information 225

Main DC switch/disconnector kits

IEC

Enclosure Qty of DC switch/disconnector

Qty Ordering code
width modules Type Data
400 mm 2 × R5i ABB OT200E11 2-pole, 200 A 1 3AXD50000015608
600 mm 4 × R5i ABB OT400E11 2-pole, 400 A 1 3AXD50000000891

UL

Enclosure Qty of DC switch/disconnector

Qty Ordering code
width modules Type Data
400 mm 2 × R5i ABB OT200U11 2-pole, 200 A 1 3AXD50000024411
600 mm 4 × R5i ABB OT400U11 2-pole, 400 A 1 3AXD50000002764

Kit contents:
• DC switch/disconnector
• Shaft (6 × 210 mm for OT200_, 12 × 325 mm for OT400_)
• OHB65J6 (OT200_) or OHB125J12 (OT400_) handle with off/on indication
• OA1G10 normally-open auxiliary contact block.

Main DC fuses (IEC, UL)

Enclosure Qty of Fuse

Qty Ordering code
width modules Type Data Size
400 mm 2 × R5i Bussmann 170M4389 200 A, 1250 V 1 2 3AXD50000010195
600 mm 4 × R5i Bussmann 170M4393 400 A, 1250 V 1 2 3AUA0000076327

DC busbars (IEC, UL)

Enclosure width Qty Kit code Ordering code Illustration

400 mm 1 A-4-5-276 3AXD50000013505

Instruction code: 3AXD50000013532

600 mm 1 A-6-5-277 3AXD50000013506

Instruction code: 3AXD50000013496

226 Ordering information

 AC-side components
Output (du/dt) filters
For information on the usage of output (du/dt) filters, see document ACS880 multidrive
cabinets and modules electrical planning instructions (3AUA0000102324 [English]).
Module type Filter
Qty Ordering code
ACS880-104-… Type Data
IRMS: 15 A
007A3-7 L: 150 µH
009A8-7 NOCH0016-60 Power loss: 110 W 1 58982784
014A2-7 Cable size: 0.2 … 10 mm2
Connection: M5
IRMS: 28 A
0018A-7 L: 140 µH
0022A-7 NOCH0030-60 Power loss: 167 W 1 58982792
0027A-7 Cable size: 0.5 … 16 mm2
Connection: M5
IRMS: 65 A
0035A-7 L: 115 µH
0042A-7 NOCH0070-60 Power loss: 210 W 1 58982806
0052A-7 Cable size: 10…35 mm2
Connection: M6

 Mechanical installation accessories

These kits include parts that are required for installing the inverter module in the
enclosure.

Mounting plate shroud kits

The shrouds are to be attached to the Rittal partial mounting plate mounted in front of the
DC switch. The module-specific fuse disconnectors are to be installed onto the vertical
plate.
Enclosure width Qty Kit code Ordering code Illustration

400 mm 1 A-4-1234-403 3AUA0000114448

Instruction code: 3AUA0000114444

600 mm 1 A-6-1234-402 3AUA0000114436

Instruction code: 3AUA0000114434

 Ordering information 227

Fuse base shroud kit

IP20 protection of the DC fuse bases requires shrouding both above and below. One
shroud kit contains the shrouds for each dual fuse base.
Used with… Qty Kit code Ordering code Illustration

R5i modules installed in

1 per
400 or 600 mm wide A-X-5-356 3AXD50000015328
module
cubicles

Instruction code: 3AXD50000015303

 Cabinet ventilation
Air inlet kits
Mounting screws are included.
Enclosure width /
Kit code Ordering code Illustration
Degree of protection

400 mm / IP20 A-4-X-021 3AUA0000117002

Instruction code: 3AUA0000116879

400 mm / IP42 A-4-X-024 3AUA0000117007

Instruction code: 3AUA0000116873

228 Ordering information

Enclosure width /
Kit code Ordering code Illustration
Degree of protection

400 mm / IP54 A-4-X-027 3AXD50000009184

Instruction code: 3AXD50000009989

600 mm / IP20 A-6-X-022 3AUA0000117003

Instruction code: 3AUA0000116880

600 mm / IP42 A-6-X-025 3AUA0000117008

Instruction code: 3AUA0000116874

600 mm / IP54 A-6-X-028 3AXD50000009185

Instruction code: 3AXD50000009990

 Ordering information 229

Air outlet kits

Note: The fan is to be ordered separately.
Enclosure width /
Qty Kit code Ordering code Illustration
Degree of protection

400 mm / IP20 1 A-4-X-062 3AUA0000125201

Instruction code: 3AXD50000001982

Note: Fan to be ordered separately

600 mm / IP20 1 A-6-X-063 3AUA0000125202

Instruction code: 3AXD50000001980

Note: Fan to be ordered separately

400 mm / IP42 1 A-4-X-060 3AUA0000114967

Instruction code: 3AUA0000115290

Note: Fan to be ordered separately

600 mm / IP42 1 A-6-X-061 3AUA0000114971

Instruction code: 3AUA0000115152

Note: Fan to be ordered separately
230 Ordering information

Enclosure width /
Qty Kit code Ordering code Illustration
Degree of protection

400 mm / IP54
1 A-4-X-064 3AXD50000009187
(IEC)

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately

400 mm / IP54
1 A-4-X-067 3AXD50000010362
(UL)

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately
 Ordering information 231

Enclosure width /
Qty Kit code Ordering code Illustration
Degree of protection

600 mm / IP54
1 A-6-X-065 3AXD50000009189
(IEC)

Instruction code: 3AXD50000010004

Note: Fan to be ordered separately

600 mm / IP54
1 A-6-X-066 3AXD50000010327
(UL)

Instruction code: 3AXD50000010004

Note: Fan to be ordered separately
232 Ordering information

Cooling fan
A cooling fan is to be installed inside the air outlet compartment to ensure sufficient cooling
of the cabinet.
IEC
Enclosure width / Component
Degree of protection Qty Ordering code
(Auxiliary voltage) Name Data

400 mm, 600 mm / Fan R3G225-RH17-23 1 3AXD50000000592

IP20, IP42 Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
(230 V 50/60 Hz) Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RB4C-355/170 1 3AXD50000006934
400 mm / IP54 Capacitor MSB MKP 6/603/E1679 1 3AXD50000006959
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan CRBB/4-400/188 1 3AXD50000006111
600 mm / IP54 Capacitor MSB MKP 12/603/E1679 1 3AXD50000006885
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724

UL
Enclosure width / Component
Degree of protection Qty Ordering code
(Auxiliary voltage) Name Data
Fan R2E225-RA92-17 1 3AXD50000000514
400 mm, 600 mm / Capacitor MSB MKP 3,5/603/E1679 1 3AXD50000000882
IP20, IP42
Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
(230 V 50/60 Hz)
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan R2E225-BD40-65 1 68502926
400 mm, 600 mm / Capacitor KO230F, mod. 345 1 58915211
IP20, IP42
Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
(115 V 60 Hz)
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RB4C-355/170 1 3AXD50000006934
400 mm / IP54 Capacitor MSB MKP 6/603/E1679 1 3AXD50000006959
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RH35M-4EK.4F.1R 1 64750062
400 mm / IP54 Capacitor 25 µF, 220 V 1 68713188
(115 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan CRBB/4-400/188 1 3AXD50000006111
600 mm / IP54 Capacitor MSB MKP 12/603/E1679 1 3AXD50000006885
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RH40M-4EK.4I.1R 1 64750038
600 mm / IP54 Capacitor 25 µF, 220 V 1 68713188
(115 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724

The wiring diagram examples (starting on page 386) show a cabinet cooling fan circuit that
energizes the fan when at least one inverter module installed in the cabinet is running. The
fan will continue to run for 20 minutes after all inverter modules have been stopped.
 Ordering information 233

The following parts (or equivalent) are used to implement the circuit. These parts are to be
sourced by the customer.
• Phoenix Contact ST 2,5-DIO/L-R - 3036262 spring cage component terminal block
with a 1N4007 diode
• Relpol PI84-24DC-M41G relay
• Rated load (capacity): 8 A / 24 V DC
• Rated power consumption: 0.4 … 0.48 W DC
• GZT80 relay socket
• 600 mm of AWG24, 300 V, UL1569 (or equivalent material, valid for PVC insulation
only) wire
• Favier SEP-4 light brown 4 kV fiberglass sleeving.
234 Ordering information

Frames R6i and R7i

 Inverter modules
Deliveries of frame R6i and R7i inverter modules include the following items:
Ordering code Contents
[Module type] • Inverter module with ZCU control unit
For example, • ZMU memory unit with ACS880 primary control program. For availability
ACS880-104-0210A-3 of other control programs, contact your local ABB representative.
[Module type] +C132 • Marine type approval. For more information, see ACS880 +C132 marine
For example, type-approved drive modules and module packages supplement
ACS880-104-0210A-3 +C132 (3AXD50000037752 [English]).
ACS880-104-0210A-3 +C132
+F272
[Module type] +F272 • Inverter module with ZCU control unit and internal charging circuit (note
For example, that R7i requires additional external components – see page 235)
ACS880-104-0210A-3 +F272 • ZMU memory unit with ACS880 primary control program. For availability
of other control programs, contact your local ABB representative.
[Module type] +N8010 • ACS880 primary control program with application programmability using
For example, function blocks based on the IEC 61131-3 standard. For more
ACS880-104-0210A-3 +N8010 information, see Programming manual: Drive application programming
(IEC 61131-3) (3AUA0000127808 [English]).
ACS880-104-0210A-3 +F272
+N8010
For module types, see Ratings (page 277).

Note: The following components are also required to construct a working unit and must be
ordered separately:
• An ACS-AP-W or ACS-AP-I control panel is required for the commissioning of an
ACS880 drive system, even if the Drive composer PC tool is used. See section ACS-
AP-x control panel below
• Common mode filters – see page 240.
The other parts listed in this chapter for these frame sizes
• may be required by the application (such as a DC switch/disconnector), or
• make the installation or use of the module easier.

ACS-AP-x control panel

The control panel is not included with the inverter module but must be ordered separately.
One control panel is required for the commissioning of an ACS880 drive system, even if
the Drive composer PC tool is used.
For more information on the control panel, see ACX-AP-x assistant control panels user’s
manual (3AUA0000085685 [English]). See also sections The ACS-AP-x control panel
(page 43) and Panel bus (Control of several inverter units from one control panel) (page
167).
 Ordering information 235

The control panel can be flush mounted on the cabinet door with the help of a door
mounting kit.
Type Description Ordering code Illustration

Control panel with

ACS-AP-W 3AXD50000025965
Bluetooth

ACS-AP-I Control panel 3AUA0000088311

Door mounting kit

DPMP-01 3AUA0000108878
(IP55)

 DC-side components
Frame R6i and R7i inverter modules are connected to the DC bus through fuses. The
design presented in this manual has flush-end fuse blocks bolted to the DC busbars.
A DC switch/disconnector can be installed if quick isolation of the module from the DC bus
is required. One of the auxiliary contacts of the switch is used for monitoring the
open/closed state of the switch.
A capacitor charging circuit must be fitted if
• the inverter module is connected to the DC bus through a DC switch/disconnector, or
• the inverter unit is directly connected to the DC bus and the supply unit of the system
does not have a charging capability.
236 Ordering information

If a charging circuit is required, the inverter module is to be ordered using option code
+F272. With frame R6i, all charging components are built into the module. R7i modules
with option code +F272 require an external charging contactor and resistors, which are
included in the DC connection kit (see page 238) for frame R7i.
The common mode filters (see page 240) are mounted onto the busbars that connect to
the DC input of the inverter module.

DC bus installation parts (for Rittal TS 8 enclosures)

The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat-
PLS DC bus and ensure its correct placement and alignment inside the cabinet line-up.
Enclosure width Qty Ordering code Kit code Illustration

400 mm 1 3AUA0000115906 A-468-X-001

Instruction code: 3AUA0000115891

DC fuses (IEC, UL)

Fuse
Module type
Type Qty Ordering code
ACS880-104-… Data Size
(Bussmann)
0110A-5 170M4409 250 A, 690 V 1 2 3AUA0000066038
0140A-3 0140A-5 170M4410 315 A, 690 V 1 2 3AXD50000000234
0170A-3 0170A-5
170M4412 400 A, 690 V 1 2 3AXD50000000238
0200A-5
0210A-3 170M4413 450 A, 690 V 1 2 68731623
0250A-3 0240A-5 170M4414 500 A, 690 V 1 2 3AXD50000000242
0300A-3 0300A-5 170M4416 630 A, 690 V 1 2 3AXD50000000246
0350A-3 0340A-5 170M4417 700 A, 690 V 1 2 64607383
0062A-7 170M3392 125 A, 1250 V 1* 2 3AXD50000010198
0082A-7 170M4388 160 A, 1250 V 1 2 3AUA0000114934
0100A-7 170M4389 200 A, 1250 V 1 2 3AXD50000010195
0130A-7 170M4390 250 A, 1250 V 1 2 3AUA0000114933
0140A-7 170M4391 315 A, 1250 V 1 2 3AXD50000010196
0190A-7 170M4392 350 A, 1250 V 1 2 3AXD50000010197
0220A-7 170M4393 400 A, 1250 V 1 2 3AUA0000076327
0270A-7 170M4395 500 A, 1100 V 1 2 3AUA0000114932
 Ordering information 237

DC switch/disconnector kits
IEC
Module type DC switch/disconnector
Qty Ordering code
ACS880-104-… Type Data
0140A-3 0110A-5 0062A-7
0170A-3 0140A-5 0082A-7
0210A-3 0170A-5 0100A-7
0250A-3 0200A-5 0130A-7
ABB OT400E11 2-pole, 400 A 1 3AXD50000001306
0240A-5 0140A-7
0190A-7
0220A-7
0270A-7
0300A-3 0300A-5
ABB OT630E11 2-pole, 630 A 1 3AXD50000001307
0350A-3 0340A-5

UL
Module type DC switch/disconnector
Qty Ordering code
ACS880-104-… Type Data
0140A-3 0110A-5 0062A-7
0170A-3 0140A-5 0082A-7
0210A-3 0170A-5 0100A-7
0250A-3 0200A-5 0130A-7
ABB OT400U11 2-pole, 400 A 1 3AXD50000002791
0240A-5 0140A-7
0190A-7
0220A-7
0270A-7
0300A-3 0300A-5
ABB OT600U11 2-pole, 600 A 1 3AXD50000002792
0350A-3 0340A-5

Kit contents:
• DC switch/disconnector
• Shaft (12 × 395 mm)
• OHB___J12 handle with off/on indication
• OA1G10 normally-open auxiliary contact block.

Charging kit (R7i only)

Module type
Qty Ordering code
ACS880-104-…

0300A-3 0300A-5
1 3AXD50000001328
0350A-3 0340A-5
0220A-7
1 3AXD50000018982
0270A-7

Kit contents:
• ABB AF190-30-22-13 charging contactor (3AXD50000012146)
• 2 pcs Danotherm CAV 120 C (36 ohm, 55 W) charging resistor (3AUA0000088634)
• Wire set (3AXD50000001360 for 400 and 500 V types, 3AXD50000005981 for 690 V).
238 Ordering information

DC connection kit (for Rittal TS 8 enclosures)

This kit contains the busbars from the DC bus towards the module as well as an air guide,
mounting plate, insulators and screws. The assembly incorporates the electrical
components (such as DC fuses, DC switch/disconnector, and charging components)
whenever required; note that the electrical parts are to be ordered separately as detailed
above.

Item Explanation
1 DC switch/disconnector (obscured by mounting plate)
2 DC fuses
1 3 Charging contactor (R7i only)
4 Charging resistors (R7i only; 400/500 V units have
2 two resistors, 690 V units have three)
5 Air guide
6 Connection to DC busbars (see DC busbars with
common mode filter holder (for Rittal TS 8
5 enclosures) on page 240)
3

Used with… Qty Kit code Ordering code Illustration

Frame R6i without DC

1 A-4-67-283 3AUA0000122202
switch/disconnector

Instruction code: 3AUA0000123371

Frame size R6i with DC

switch/disconnector 1 A-4-6-281 3AUA0000122201
(IEC)

Instruction code: 3AUA0000123369

 Ordering information 239

Used with… Qty Kit code Ordering code Illustration

Frame size R6i with DC

switch/disconnector 1 A-4-6-285 3AXD50000004381
(UL)

Instruction code: 3AXD50000004422

Frame R7i without DC

switch/disconnector or 1 A-4-67-283 3AUA0000122202
charging circuit

Instruction code: 3AUA0000123371

Frame size R7i without

DC switch/disconnector, 1 A-4-7-282 3AUA0000122237
with charging circuit

Instruction code: 3AUA0000123372

Frame size R7i with DC

switch/disconnector and 1 A-4-7-280 3AXD50000008846
charging circuit

Instruction code: 3AUA0000117112

240 Ordering information

DC busbars with common mode filter holder (for Rittal TS 8 enclosures)

This kit contains the busbars that connect to the DC input of the inverter module. The
busbars have a holder for the common mode filters; note that the filters shown in the
illustration are not included in the kit.
Module frame size Qty Kit code Ordering code Illustration

R6i
1 A-4-67-241 3AUA0000122152
R7i

Instruction code: 3AUA0000123359

Note: Filters to be ordered separately

DC busbars with fuse and common mode filter holders (for generic enclosures)
This kit contains the busbars that connect to the DC input of the inverter module. The kit is
mounted onto the module. It has screws for cable lug connection as well as a holder for
the DC fuses and common mode filters. Note that the fuses and filters are not included in
the kit.
Module frame size Qty Kit code Ordering code Illustration

R6i
1 A-0-67-244 3AXD50000023329
R7i

Instruction code: 3AXD50000023500

Note: Fuses and filters to be ordered
separately

Common mode filters

Common mode filtering reduces bearing currents and is required for electromagnetic
compatibility (EMC). The filtering is implemented by installing two toroidal cores onto the
DC input busbars.
DC busbar kits 3AUA0000122152 and 3AXD50000023329 contain a holder for the filters.
Module frame size Qty Kit code Ordering code Illustration

R6i
2 - 3AUA0000032859
R7i

Instruction code: 3AUA0000123359

 Ordering information 241

 AC-side components
AC busbar kit
This kit contains the busbars for connection of the motor cable. Note that the output (du/dt)
filters (if required) are to be ordered separately (see further below).
Module frame size Qty Kit code Ordering code Illustration

R6i, R7i
1 A-4-67-181 3AUA0000122145
(without output filters)

Instruction code: 3AUA0000117543

R6i, R7i
1 A-4-67-186 3AXD50000010037
(with output filters)

Instruction code: 3AXD50000010077

Note: Filters to be ordered separately

Output (du/dt) filters

For information on the usage of output (du/dt) filters, see document ACS880 multidrive
cabinets and modules electrical planning instructions (3AUA0000102324 [English]).
Module frame size Qty Ordering code Illustration Filter type

R6i
1 3AXD50000018892 BOCH-350A-7
R7i

Instruction code: 3AXD50000018989,

3AXD50000027070
242 Ordering information

 Mechanical installation accessories and tools

These kits include parts that are used for installing the inverter module in the Rittal TS 8
enclosure.

Inverter module mounting parts

This kit contains the rails on which the inverter module rests, and provides air baffles for
blocking unwanted air flow along the sides of the module.
Module frame size Qty Kit code Ordering code Illustration

R6i
1 A-4-67-302 3AUA0000117090
R7i

Instruction code: 3AUA0000117085

Shrouding
This kit contains three shrouds with the necessary brackets and screws.
Frame size Qty Kit code Ordering code Illustration

R6i
1 A-4-67-350 3AUA0000114215
R7i

Instruction code: 3AUA0000114211

 Ordering information 243

Lifting device
The lifting device is designed for maneuvering a frame R6i/R7i module when installing it
into (or extracting it from) the Rittal TS 8 enclosure. See also section Replacing a frame
R6i/R7i inverter module (page 192).
Frame size Qty Kit code Ordering code Illustration

R6i
1 A-46-67-440 3AXD50000004182
R7i

Instruction code: 3AXD50000004591

244 Ordering information

 Cabinet ventilation

Air inlet kits

Degree of protection Kit code Ordering code Illustration

IP20 A-4-X-021 3AUA0000117002

Instruction code: 3AUA0000116879

IP42 A-4-X-024 3AUA0000117007

Instruction code: 3AUA0000116873

400 mm / IP54 A-4-X-027 3AXD50000009184

Instruction code: 3AXD50000009989

 Ordering information 245

Air outlet kits

Note: The IP54 kits require a cooling fan that must be ordered separately.
Degree of protection Qty Kit code Ordering code Illustration

IP20 1 A-4-X-042 3AUA0000125203

Instruction code: 3AXD50000001983

IP42 1 A-4-X-040 3AUA0000114968

Instruction code: 3AUA0000115292

400 mm / IP54
1 A-4-X-064 3AXD50000009187
(IEC)

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately
246 Ordering information

Degree of protection Qty Kit code Ordering code Illustration

400 mm / IP54
1 A-4-X-067 3AXD50000010362
(UL)

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately

Cooling fan for IP54 air outlets

A cooling fan is to be installed inside the IP54 air outlet compartment to ensure sufficient
cooling of the cabinet.
Enclosure width / Component
Degree of protection Qty Ordering code
(Auxiliary voltage) Name Data
Fan RB4C-355/170 1 3AXD50000006934
400 mm / IP54 Capacitor MSB MKP 6/603/E1679 1 3AXD50000006959
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RH35M-4EK.4F.1R 1 64750062
400 mm / IP54 Capacitor 25 µF, 220 V 1 68713188
(115 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
 Ordering information 247

Frame R8i and multiples

 Inverter modules
Inverter units consisting of frame R8i inverter modules are to be ordered as separate
modules. For inverter unit ratings, see page 277.
Inverter unit Modules used
Ordering code
Type Frame size Qty
(for options, see below)
UN = 400 V
ACS880-104-0470A-3 R8i 1 ACS880-104-0470A-3
ACS880-104-0640A-3 R8i 1 ACS880-104-0640A-3
ACS880-104-0760A-3 R8i 1 ACS880-104-0760A-3
ACS880-104-0900A-3 R8i 1 ACS880-104-0900A-3
ACS880-104-1250A-3 2×R8i 2 ACS880-104-0640A-3 +E205
ACS880-104-1480A-3 2×R8i 2 ACS880-104-0760A-3 +E205
ACS880-104-1760A-3 2×R8i 2 ACS880-104-0900A-3 +E205
ACS880-104-2210A-3 3×R8i 3 ACS880-104-0760A-3 +E205
ACS880-104-2610A-3 3×R8i 3 ACS880-104-0900A-3 +E205
ACS880-104-3450A-3 4×R8i 4 ACS880-104-0900A-3 +E205
ACS880-104-4290A-3 5×R8i 5 ACS880-104-0900A-3 +E205
ACS880-104-5130A-3 6×R8i 6 ACS880-104-0900A-3 +E205
UN = 500 V
ACS880-104-0440A-5 R8i 1 ACS880-104-0440A-5
ACS880-104-0590A-5 R8i 1 ACS880-104-0590A-5
ACS880-104-0740A-5 R8i 1 ACS880-104-0740A-5
ACS880-104-0810A-5 R8i 1 ACS880-104-0810A-5
ACS880-104-1150A-5 2×R8i 2 ACS880-104-0590A-5 +E205
ACS880-104-1450A-5 2×R8i 2 ACS880-104-0740A-5 +E205
ACS880-104-1580A-5 2×R8i 2 ACS880-104-0810A-5 +E205
ACS880-104-2150A-5 3×R8i 3 ACS880-104-0740A-5 +E205
ACS880-104-2350A-5 3×R8i 3 ACS880-104-0810A-5 +E205
ACS880-104-3110A-5 4×R8i 4 ACS880-104-0810A-5 +E205
ACS880-104-3860A-5 5×R8i 5 ACS880-104-0810A-5 +E205
ACS880-104-4610A-5 6×R8i 6 ACS880-104-0810A-5 +E205
UN = 690 V
ACS880-104-0340A-7 R8i 1 ACS880-104-0340A-7 +E205
ACS880-104-0410A-7 R8i 1 ACS880-104-0410A-7 +E205
ACS880-104-0530A-7 R8i 1 ACS880-104-0530A-7 +E205
ACS880-104-0600A-7 R8i 1 ACS880-104-0600A-7 +E205
ACS880-104-0800A-7 2×R8i 2 ACS880-104-0410A-7 +E205
ACS880-104-1030A-7 2×R8i 2 ACS880-104-0530A-7 +E205
ACS880-104-1170A-7 2×R8i 2 ACS880-104-0600A-7 +E205
ACS880-104-1540A-7 3×R8i 3 ACS880-104-0530A-7 +E205
ACS880-104-1740A-7 3×R8i 3 ACS880-104-0600A-7 +E205
ACS880-104-2300A-7 4×R8i 4 ACS880-104-0600A-7 +E205
ACS880-104-2860A-7 5×R8i 5 ACS880-104-0600A-7 +E205
ACS880-104-3420A-7 6×R8i 6 ACS880-104-0600A-7 +E205
248 Ordering information

Ordering code format Option codes

[Module type] +code [+code] … +C132: Marine type approval. For more information, see ACS880 +C132
For example, marine type-approved drive modules and module packages supplement
ACS880-104-0470A-3 +E205 (3AXD50000037752 [English]).
+C183: Heating element mounted to module base
+C188: Direct-on-line (DOL) cooling fan
+E205: Internal du/dt filtering. Standard with 690 V modules, required with
parallel-connected modules for all nominal voltages
+G304: 115 V AC auxiliary voltage supply
+P942: Retrofit version (mechanically compatible with ACS800 R8i). See
also pages 156 and 345.

Note: The following components are also required to construct a working inverter unit and
must be ordered separately:
• An ACS-AP-W or ACS-AP-I control panel is required for the commissioning of an
ACS880 drive system, even if the Drive composer PC tool is used. See section ACS-
AP-x control panel below.
• Inverter control unit (see section Inverter control unit below)
• Fiber optic cabling from control unit to each inverter module (see section Fiber optic
cables below)
• Common mode filters – see page 257
• Control circuit plug connectors – see page 250
• Quick connector – see page 264.
The other parts listed in this chapter for this frame size
• may be required by the application (such as a DC switch/disconnector), or
• make the installation or use of the module easier.
 Ordering information 249

ACS-AP-x control panel

The control panel is not included with the inverter module but must be ordered separately.
One control panel is required for the commissioning of an ACS880 drive system, even if
the Drive composer PC tool is used.
For more information on the control panel, see ACX-AP-x assistant control panels user’s
manual (3AUA0000085685 [English]). See also sections The ACS-AP-x control panel
(page 43) and Panel bus (Control of several inverter units from one control panel) (page
167).
The control panel can be flush mounted on the cabinet door with the help of a door
mounting kit.

Type Description Ordering code Illustration

Control panel with

ACS-AP-W 3AXD50000025965
Bluetooth

ACS-AP-I Control panel 3AUA0000088311

Door mounting kit

DPMP-01 3AUA0000108878
(IP55)
250 Ordering information

 Control electronics
Inverter control unit
One BCU-0x control unit is required per inverter unit. The type of the control unit depends
on the number of inverter modules as shown below. The control unit is delivered with a
memory unit containing the ACS880 primary control program, optionally with application
programmability. For availability of other control programs, contact your local ABB
representative.
Application
Frame size Control unit type Ordering code
programmability
No 3AXD50000003417
R8i, 2×R8i BCU-02
*Yes 3AXD50000011540
No 3AXD50000006340
3×R8i…6×R8i BCU-12
*Yes 3AXD50000011541
*Application programmability using function blocks based on the IEC 61131-3 standard. For more information,
see Programming manual: Drive application programming (IEC 61131-3) (3AUA0000127808 [English]).

Fiber optic cables

Each frame R8i module is connected to the inverter control unit with a pair of fiber optic
cables.
If the inverter unit is equipped with a DC switch/disconnector, each inverter module is also
connected to the charging controller by a pair of fiber optic cables.
The following kits, each consisting of a pair of plastic fiber optic cables, are available from
ABB:
Length (m) Kit type designation Ordering code
2m NLWC-02 58988821
3m NLWC-03 58948233
5m NLWC-05 58948250
7m NLWC-07 58948268
10 m NLWC-10 58948276

Control circuit plug connectors

The control circuit plug for connector X50 is not included in the module kit and you must
order it separately.
Note: Plug connectors for X51, X52 and X53 are included in the module kit.
Connector Qty Ordering code Illustration Data

STV S 9 SB
X50 1 per module 3AUA0000059813
500 V, 32 A, 9-pole
 Ordering information 251

Wire sets for use with the reduced run function

A “reduced run” function (for inverter unit frame sizes 3×R8i and above) makes it possible
to continue operation with limited current even if some modules of the inverter unit are out
of service. For more information, see chapter Maintenance (page 201). The wire set for the
STO connection is available as shown below.
Use Qty Ordering code Data

STO wiring in place of 3AXD50000022694 PVC insulation

removed inverter 1 per module
module 3AXD50000022695 Halogen-free insulation

 DC-side components
Frame R8i modules are connected to the DC bus through fuses. The design presented in
this manual has flush-end fuse blocks bolted to the DC busbars.
A DC switch/disconnector can be installed if quick isolation of the module from the DC bus
is required. One of the auxiliary contacts of the switch is used for monitoring the
open/closed state of the switch. A capacitor charging circuit is to be installed with the DC
switch/disconnector.
Note: A separate capacitor charging circuit must be designed and installed by the
customer if the inverter unit is directly connected to the DC bus and the supply unit of the
system does not have a charging capability.
The common mode filters (see page 257) are mounted onto the busbars that connect to
the DC input of the inverter module.

DC bus installation parts (for Rittal TS 8 enclosures)

The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat-
PLS DC bus and ensure its correct placement and alignment inside the cabinet line-up.
Note: The designs presented in this manual for Rittal TS 8 enclosures employ the Rittal
Flat-PLS busbar system. Make sure that the current carrying capability of the busbars is
not exceeded at any point of the drive system.
Enclosure width Qty Kit code Ordering code Illustration

400 mm (TS 8)
1 A-468-X-001 3AUA0000115906
600 mm (TS 8)

Instruction code: 3AUA0000115891

252 Ordering information

DC connection parts 1 of 2 (for Rittal TS 8 enclosures)

These parts connect the Flat-PLS busbars to the DC fuses, and provide the mounting
base for the charging components if required.
Used with… Qty Kit code Ordering code Illustration

400/600 mm TS 8
enclosure
1 per
without DC A-46-8-206 3AXD50000004411
module
switch/disconnector and
charging

Instruction code: 3AXD50000004851

400 mm TS 8 enclosure
without DC
1 A-4-8-252 3AXD50000004416
switch/disconnector and
charging

Instruction code: 3AXD50000004851

600 mm TS 8 enclosure
without DC
1 A-6-8-255 3AXD50000005053
switch/disconnector and
charging

Instruction code: 3AXD50000004860

400/600 mm TS 8
enclosure
1 per
with DC A-46-8-207 3AXD50000004412
module
switch/disconnector and
charging

Instruction code: 3AXD50000004834

 Ordering information 253

Used with… Qty Kit code Ordering code Illustration

1 A-4-8-288 3AXD50000044554

400 mm TS 8 enclosure
with DC Instruction code: 3AXD50000043516
switch/disconnector and
charging

1 A-4-8-290 3AXD50000044557

Instruction code: 3AXD50000043504

1 A-6-8-289 3AXD50000044555

600 mm TS 8 enclosure
with DC Instruction code: 3AXD50000043542
switch/disconnector and
charging

1 A-6-8-291 3AXD50000044558

Instruction code: 3AXD50000043555

254 Ordering information

DC connection parts 1 of 2 (for generic enclosures)

These parts provide the DC connection between the input busbars and the DC fuses
(including a mounting base for the charging components if required).
Used with… Qty Kit code Ordering code Illustration

400 mm generic
enclosure without DC
1 A-4-8-256 3AXD50000006418
switch/disconnector and
charging

Instruction code: 3AXD50000006441

600 mm generic
enclosure without DC
1 A-6-8-257 3AXD50000006444
switch/disconnector and
charging

Instruction code: 3AXD50000006447

800 mm generic
enclosure without DC
1 A-8-8-258 3AXD50000006450
switch/disconnector and
charging

Instruction code: 3AXD50000006455

1 A-4-8-292 3AXD50000044559

400 mm generic
enclosure with DC Instruction code: 3AXD50000043644
switch/disconnector and
charging

1 A-4-8-295 3AXD50000044582

Instruction code: 3AXD50000043686

 Ordering information 255

Used with… Qty Kit code Ordering code Illustration

1 A-6-8-293 3AXD50000044560

600 mm generic
enclosure with DC Instruction code: 3AXD50000043784
switch/disconnector and
charging

1 A-6-8-296 3AXD50000044583

Instruction code: 3AXD50000043737

1 A-8-8-294 3AXD50000044581

800 mm generic
enclosure with DC Instruction code: 3AXD50000044586
switch/disconnector and
charging

1 A-8-8-297 3AXD50000044584

Instruction code: 3AXD50000044574

256 Ordering information

DC connection parts 2 of 2 (for Rittal TS 8 or generic enclosures)

These parts connect the DC fuses to the inverter module.
Used with… Qty Kit code Ordering code Illustration

1 per
A-468-8-235 3AXD50000028401
module

All TS 8 and generic

enclosures without DC Instruction code: 3AXD50000028418
switch/disconnector and Note: Filters to be ordered separately
charging

1 per
A-468-8-246 3AXD50000028403
module

Instruction code: 3AXD50000028384

1 per
A-468-8-247 3AXD50000044551
module

All TS 8 and generic

enclosures with DC Instruction code: 3AXD50000043411
Note: Filters to be ordered separately
switch/disconnector and
charging

1 per
A-468-8-248 3AXD50000044553
module

Instruction code: 3AXD50000043466

 Ordering information 257

Common mode filters

Common mode filtering reduces bearing currents and is required for electromagnetic
compatibility (EMC). The filtering is implemented by installing two toroidal cores onto the
DC busbars.
Kits 3AXD50000028401 and 3AXD50000044551 (see above) contain a holder for the
filters.
Used with… Qty Kit code Ordering code Illustration

2 per
All enclosure types - 3AUA0000032859
module

Instruction code: 3AXD50000005734

258 Ordering information

DC fuses (IEC, UL)

Unit type Fuse
ACS880-104-… Qty Ordering code Type Data Size
0470A-3 2 3AXD50000000148 Bussmann 170M6413 900 A, 690 V 3
0640A-3 2 68244463 Bussmann 170M6416 1250 A, 690 V 3
0760A-3 2 3AXD50000000150 Bussmann 170M6417 1400 A, 690 V 3
0900A-3 2 68393108 Bussmann 170M6419 1600 A, 690 V 3*
1250A-3 4 68244463 Bussmann 170M6416 1250 A, 690 V 3
1480A-3 4 3AXD50000000150 Bussmann 170M6417 1400 A, 690 V 3
1760A-3 4 68393108 Bussmann 170M6419 1600 A, 690 V 3*
2210A-3 6 3AXD50000000150 Bussmann 170M6417 1400 A, 690 V 3
2610A-3 6
3450A-3 8
68393108 Bussmann 170M6419 1600 A, 690 V 3*
4290A-3 10
5130A-3 12
0440A-5 2 3AXD50000000148 Bussmann 170M6413 900 A, 690 V 3
0590A-5 2 68731658 Bussmann 170M6415 1100 A, 690 V 3
0740A-5
2 3AXD50000000150 Bussmann 170M6417 1400 A, 690 V 3
0810A-5
1150A-5 4 68731658 Bussmann 170M6415 1100 A, 690 V 3
1450A-5
4
1580A-5
2150A-5
6
2350A-5 3AXD50000000150 Bussmann 170M6417 1400 A, 690 V 3
3110A-5 8
3860A-5 10
4610A-5 12
0340A-7 2 63903167 Bussmann 170M6544 630 A, 1250 V 3
0410A-7 2 68736005 Bussmann 170M6546 800 A, 1250 V 3
0530A-7 2 63916749 Bussmann 170M6548 1000 A, 1100 V 3
0600A-7 2 68736021 Bussmann 170M6549 1100 A, 1000 V 3
0800A-7 4 68736005 Bussmann 170M6546 800 A, 1250 V 3
1030A-7 4 63916749 Bussmann 170M6548 1000 A, 1100 V 3
1170A-7 4 68736021 Bussmann 170M6549 1100 A, 1000 V 3
1540A-7 6 63916749 Bussmann 170M6548 1000 A, 1100 V 3
1740A-7 6
2300A-7 8
68736021 Bussmann 170M6549 1100 A, 1000 V 3
2860A-7 10
3420A-7 12
 Ordering information 259

DC switch/disconnector kits
IEC – 230 V 50 Hz
Unit type
Enclosure type Qty Ordering code Switch type
ACS880-104-…
0470A-3 0440A-5 0340A-7
0640A-3 0590A-5 0410A-7
Rittal TS 8 or generic 1 3AXD50000009534 ABB OT1600E11
0760A-3 0740A-5 0530A-7
0900A-3 0810A-5 0600A-7
1250A-3 1150A-5 0800A-7
1480A-3 1450A-5 1030A-7 Rittal TS 8 or generic 1 3AXD50000009535 ABB OT1600E22
1760A-3 1580A-5 1170A-7
1 3AXD50000009534 ABB OT1600E11
2210A-3 2150A-5 1540A-7 Rittal TS 8
1 3AXD50000009535 ABB OT1600E22
2610A-3 2350A-5 1740A-7
Generic 1 3AXD50000009536 ABB OT2500E22
3450A-3 3110A-5 2300A-7 Rittal TS 8 or generic 2 3AXD50000009535 ABB OT1600E22
1 3AXD50000009534 ABB OT1600E11
Rittal TS 8
2 3AXD50000009535 ABB OT1600E22
4290A-3 3860A-5 2860A-7
1 3AXD50000009535 ABB OT1600E22
Generic
1 3AXD50000009536 ABB OT2500E22
Rittal TS 8 3 3AXD50000009535 ABB OT1600E22
5130A-3 4610A-5 3420A-7
Generic 2 3AXD50000009536 ABB OT2500E22

IEC – 240 V 60 Hz
Unit type
Enclosure type Qty Ordering code Switch type
ACS880-104-…
0470A-3 0440A-5 0340A-7
0640A-3 0590A-5 0410A-7
Rittal TS 8 or generic 1 3AXD50000026854 ABB OT1600E11
0760A-3 0740A-5 0530A-7
0900A-3 0810A-5 0600A-7
1250A-3 1150A-5 0800A-7
1480A-3 1450A-5 1030A-7 Rittal TS 8 or generic 1 3AXD50000026857 ABB OT1600E22
1760A-3 1580A-5 1170A-7
1 3AXD50000026854 ABB OT1600E11
2210A-3 2150A-5 1540A-7 Rittal TS 8
1 3AXD50000026857 ABB OT1600E22
2610A-3 2350A-5 1740A-7
Generic 1 3AXD50000026860 ABB OT2500E22
3450A-3 3110A-5 2300A-7 Rittal TS 8 or generic 2 3AXD50000026857 ABB OT1600E22
1 3AXD50000026854 ABB OT1600E11
Rittal TS 8
2 3AXD50000026857 ABB OT1600E22
4290A-3 3860A-5 2860A-7
1 3AXD50000026857 ABB OT1600E22
Generic
1 3AXD50000026860 ABB OT2500E22
Rittal TS 8 3 3AXD50000026857 ABB OT1600E22
5130A-3 4610A-5 3420A-7
Generic 2 3AXD50000026860 ABB OT2500E22
260 Ordering information

UL – 115 V 60 Hz
Unit type
Enclosure type Qty Ordering code Switch type
ACS880-104-…
0470A-3 0440A-5 0340A-7
0640A-3 0590A-5 0410A-7
Rittal TS 8 or generic 1 3AXD50000009540 ABB OT1200U11
0760A-3 0740A-5 0530A-7
0900A-3 0810A-5 0600A-7
1250A-3 1150A-5 0800A-7
1480A-3 1450A-5 1030A-7 Rittal TS 8 or generic 1 3AXD50000009541 ABB OT1200U22
1760A-3 1580A-5 1170A-7
2210A-3 2150A-5 1540A-7 1 3AXD50000009540 ABB OT1200U11
Rittal TS 8 or generic
2610A-3 2350A-5 1740A-7 1 3AXD50000009541 ABB OT1200U22
3450A-3 3110A-5 2300A-7 Rittal TS 8 or generic 2 3AXD50000009541 ABB OT1200U22
1 3AXD50000009540 ABB OT1200U11
4290A-3 3860A-5 2860A-7 Rittal TS 8 or generic
2 3AXD50000009541 ABB OT1200U22
5130A-3 4610A-5 3420A-7 Rittal TS 8 or generic 3 3AXD50000009541 ABB OT1200U22

Kit contents:
• DC switch/disconnector(s)
• Shaft (12 × 395 mm)
• OHB150J12P (switch types …11) or OHB274J12 (switch types …22) handle with
off/on indication
• Interlock kit OTZT4A with PDAL2 coil
• One normally-open (OA1G10) and one normally-closed (OA3G01) auxiliary contact
block.
 Ordering information 261

Charging kits
The charging kit contains the main parts of the charging circuit, such as the charging
switch (with shaft, handle, terminal shrouds and a set of auxiliary contacts), fuses,
connectors and the charging controller. Note that the charging resistors or fiber optic
cables are not included in the kit and must be ordered separately.
IEC
Unit type
Enclosure type Qty Ordering code
ACS880-104-…
0470A-3 0440A-5 0340A-7
0640A-3 0590A-5 0410A-7
0760A-3 0740A-5 0530A-7
0900A-3 0810A-5 0600A-7 Rittal TS 8 or generic 1 3AXD50000009537
1250A-3 1150A-5 0800A-7
1480A-3 1450A-5 1030A-7
1760A-3 1580A-5 1170A-7
2210A-3 2150A-5 1540A-7 Rittal TS 8 2 3AXD50000009537
2610A-3 2350A-5 1740A-7 Generic 1 3AXD50000009539
3450A-3 3110A-5 2300A-7 Rittal TS 8 or generic 2 3AXD50000009537
Rittal TS 8 3 3AXD50000009537
4290A-3 3860A-5 2860A-7 1 3AXD50000009537
Generic
1 3AXD50000009539
Rittal TS 8 3 3AXD50000009537
5130A-3 4610A-5 3420A-7
Generic 2 3AXD50000009539

UL
Unit type
Enclosure type Qty Ordering code
ACS880-104-…
0470A-3 0440A-5 0340A-7
0640A-3 0590A-5 0410A-7
0760A-3 0740A-5 0530A-7
0900A-3 0810A-5 0600A-7 Rittal TS 8 or generic 1 3AXD50000009538
1250A-3 1150A-5 0800A-7
1480A-3 1450A-5 1030A-7
1760A-3 1580A-5 1170A-7
2210A-3 2150A-5 1540A-7
2610A-3 2350A-5 1740A-7 Rittal TS 8 or generic 2 3AXD50000009538
3450A-3 3110A-5 2300A-7
4290A-3 3860A-5 2860A-7
Rittal TS 8 or generic 3 3AXD50000009538
5130A-3 4610A-5 3420A-7
262 Ordering information

Kit contents:
Ordering code Contents
Switch fuse (OS160GD04F) with terminal shrouds (OSS160GT1S/4); shaft
3AXD50000009537 (6 × 161 mm); OHB65J6 handle; one normally-closed auxiliary contact (OA3G01);
170M2676 fuses; charging controller
Switch fuse (OS100GJ04FP) with terminal shrouds (OSS160GT1S/4); shaft
3AXD50000009538 (6 × 161 mm); OHB65J6 handle; one normally-closed auxiliary contact (OA3G01);
FWJ30A fuses and fuse holder modification parts; charging controller
Switch fuse (OS200DZ22F) with terminal shrouds (OSS200G1S/4); shaft
3AXD50000009539 (6 × 210 mm); OHB65J6 handle; one normally-closed auxiliary contact (OA3G01);
170M2676 fuses; charging controller
• Charging resistors are not included and must be ordered separately. See below.
• The charging controller connects to each inverter module by a pair of fiber optic cables. The cables are not
included and must be ordered separately. See section Fiber optic cables, page 250.

Charging resistors
IEC
Unit type
Enclosure type Qty Ordering code Data
ACS880-104-…
0470A-3 0440A-5
0640A-3 0590A-5
Rittal TS 8 or generic 4 10037531 ZRF 30/165 S 24R
0760A-3 0740A-5
0900A-3 0810A-5
1250A-3 1150A-5
1480A-3 1450A-5 Rittal TS 8 or generic 6 10037531 ZRF 30/165 S 24R
1760A-3 1580A-5
2210A-3 2150A-5 Rittal TS 8 10
10037531 ZRF 30/165 S 24R
2610A-3 2350A-5 Generic 8
3450A-3 3110A-5 Rittal TS 8 or generic 12 10037531 ZRF 30/165 S 24R
Rittal TS 8 16
4290A-3 3860A-5 10037531 ZRF 30/165 S 24R
Generic 14
Rittal TS 8 18
5130A-3 4610A-5 10037531 ZRF 30/165 S 24R
Generic 16
0340A-7
0410A-7
Rittal TS 8 or generic 4 10028531 ZRF 30/165 S 33R
0530A-7
0600A-7
0800A-7
1030A-7 Rittal TS 8 or generic 6 10028531 ZRF 30/165 S 33R
1170A-7
1540A-7 Rittal TS 8 10
10028531 ZRF 30/165 S 33R
1740A-7 Generic 8
2300A-7 Rittal TS 8 or generic 12 10028531 ZRF 30/165 S 33R
Rittal TS 8 16
2860A-7 10028531 ZRF 30/165 S 33R
Generic 14
Rittal TS 8 18
3420A-7 10028531 ZRF 30/165 S 33R
Generic 16
 Ordering information 263

UL
Unit type
Enclosure type Qty Ordering code Data
ACS880-104-…
0470A-3 0440A-5
0640A-3 0590A-5
Rittal TS 8 or generic 4 10037531 ZRF 30/165 S 24R
0760A-3 0740A-5
0900A-3 0810A-5
1250A-3 1150A-5
1480A-3 1450A-5 Rittal TS 8 or generic 6 10037531 ZRF 30/165 S 24R
1760A-3 1580A-5
2210A-3 2150A-5
Rittal TS 8 or generic 10 10037531 ZRF 30/165 S 24R
2610A-3 2350A-5
3450A-3 3110A-5 Rittal TS 8 or generic 12 10037531 ZRF 30/165 S 24R
4290A-3 3860A-5 Rittal TS 8 or generic 16 10037531 ZRF 30/165 S 24R
5130A-3 4610A-5 Rittal TS 8 or generic 18 10037531 ZRF 30/165 S 24R
0340A-7
0410A-7
Rittal TS 8 or generic 4 10028531 ZRF 30/165 S 33R
0530A-7
0600A-7
0800A-7
1030A-7 Rittal TS 8 or generic 6 10028531 ZRF 30/165 S 33R
1170A-7
1540A-7
Rittal TS 8 or generic 10 10028531 ZRF 30/165 S 33R
1740A-7
2300A-7 Rittal TS 8 or generic 12 10028531 ZRF 30/165 S 33R
2860A-7 Rittal TS 8 or generic 16 10028531 ZRF 30/165 S 33R
3420A-7 Rittal TS 8 or generic 18 10028531 ZRF 30/165 S 33R
264 Ordering information

 AC-side components
Quick connector
Used with… Qty Kit code Ordering code Illustration

1 per
All enclosure types A-468-8-100 3AUA0000119227
module

Instruction code: 3AUA0000118667

Output busbars/shrouds kit

This kit contains the busbars that connect to the quick connector(s), the busbars for the
motor cable connection, and shrouding.
The following types of kits are available:
1. Kits with cable connections (all enclosure types).
Each inverter module has its own motor cable connections. If the inverter unit consists
of parallel-connected modules, each module must be separately (and identically)
cabled to the motor.
2. Kits with bridging busbars (600 mm TS 8 or generic enclosures, 800 mm generic
enclosures).
These kits connect the outputs of the modules in the same cubicle so that, for
example, a single thicker cable can be used instead of separate cables for each
module.

WARNING! The bridging can carry the nominal output of one inverter module. In
case of three parallel modules, ensure that the load capacity of the bridging is not
exceeded. For example, if the cabling connects to the output busbars at one
module only, use the module in the middle.
If the inverter unit consists of modules installed in different cubicles, make sure that the
load is distributed evenly between the modules:
• In case of two inverter cubicles of two modules, connect the same number of
cables to each cubicle.
• In case of one inverter cubicle with three modules and another with two, each
cubicle requires a number of cables proportional to the number of modules within.
For example, connect three out of five (or six out of ten, etc.) cables to the cubicle
with three modules, the remaining two out of five (four out of ten) cables to the
cubicle with two modules.

3. Kits with common AC output busbars (400 and 600 mm wide TS 8 enclosures).
These kits have connection points for busbars that join the outputs of inverter modules
whether the modules are located in the same cubicle or not. Using these kits, it is
possible to construct a common output cubicle where all motor cables connect to.
 Ordering information 265

Used with… Qty Kit code Ordering code Illustration

400 mm TS 8 enclosure
1 A-4-8-132 3AXD50000004414
(cable connection)

Instruction code: 3AXD50000004838

400 mm TS 8 enclosure
(common AC output 1 A-4-8-140 3AXD50000008705
busbar connection)

Instruction code: 3AXD50000010278

600 mm TS 8 enclosure
1 A-6-8-133 3AXD50000005051
(cable connection)

Instruction code: 3AXD50000004594

600 mm TS 8 enclosure
(cable connection with 1 A-6-8-134 3AXD50000005244
bridging busbars)

Instruction code: 3AXD50000005189

600 mm TS 8 enclosure
(common AC output 1 A-6-8-141 3AXD50000008707
busbar connection)

Instruction code: 3AXD50000008157

266 Ordering information

Used with… Qty Kit code Ordering code Illustration

400 mm generic
enclosure (cable 1 A-4-8-135 3AXD50000006435
connection)

Instruction code: 3AXD50000006497

600 mm generic
enclosure (cable 1 A-6-8-136 3AXD50000006491
connection)

Instruction code: 3AXD50000006489

600 mm generic
enclosure
1 A-6-8-138 3AXD50000006493
(cable connection with
bridging busbars)

Instruction code: 3AXD50000006505

800 mm generic
enclosure 1 A-8-8-137 3AXD50000006492
(cable connection)

Instruction code: 3AXD50000006503

800 mm generic
enclosure
1 A-8-8-139 3AXD50000006494
(cable connection with
bridging busbars)

Instruction code: 3AXD50000006498

 Ordering information 267

Lead-through kit
This kit, to be installed on the bottom plate of the enclosure, contains four lead-throughs
for motor cables with grommets, wire meshing for 360° grounding, and a strain relief
bracket.
Used with… Qty Kit code Ordering code Illustration

1 per
All enclosure types A-468-8-441 3AXD50000004385
module

Instruction code: 3AXD50000004817

 Mechanical installation accessories

These kits include parts that are used for installing the inverter module in the enclosure.

Inverter module top/bottom guides

This kit contains the rails that guide the inverter module at the top and the bottom.
Used with… Qty Kit code Ordering code Illustration

400 mm Rittal TS 8
1 A-4-8-310 3AXD50000004415
enclosure

Instruction code: 3AXD50000004842

600 mm Rittal TS 8
1 A-6-8-309 3AXD50000005052
enclosure

Instruction code: 3AXD50000004859

268 Ordering information

Used with… Qty Kit code Ordering code Illustration

400 mm generic
1 A-4-8-315 3AXD50000005875
enclosure

Instruction code: 3AXD50000005874

600 mm generic
1 A-6-8-311 3AXD50000005876
enclosure

Instruction code: 3AXD50000005864

800 mm generic
1 A-8-8-312 3AXD50000005877
enclosure

Instruction code: 3AXD50000005848

Ramp (for Rittal TS 8 enclosures)

The ramp can be used when installing or removing an R8i module.
Note: Do not use the ramp with plinth heights over 100 mm. The ramp is designed for a
plinth height of 100 mm (the standard plinth height of Rittal TS 8 enclosures).
Used with… Qty Kit code Ordering code Illustration

All TS 8 enclosures 1 A-468-8-304 3AUA0000120467

 Ordering information 269

Shrouding
This kit contains the shroud for the top part of the cubicle with the necessary brackets and
screws.
Frame size Qty Kit code Ordering code Illustration

400 mm Rittal TS 8
1 A-4-8-359 3AXD50000045738
enclosure

Instruction code: 3AXD50000045749

600 mm Rittal TS 8
1 A-6-8-360 3AXD50000045779
enclosure

Instruction code: 3AXD50000045798

 Cabinet ventilation

Air inlet kits

Enclosure width /
Kit code Ordering code Illustration
Degree of protection

400 mm / IP20 A-4-X-021 3AUA0000117002

Instruction code: 3AUA0000116879

270 Ordering information

Enclosure width /
Kit code Ordering code Illustration
Degree of protection

400 mm / IP42 A-4-X-024 3AUA0000117007

Instruction code: 3AUA0000116873

400 mm / IP54 A-4-X-027 3AXD50000009184

Instruction code: 3AXD50000009989

600 mm / IP20 A-6-X-022 3AUA0000117003

Instruction code: 3AUA0000116880

 Ordering information 271

Enclosure width /
Kit code Ordering code Illustration
Degree of protection

600 mm / IP42 A-6-X-025 3AUA0000117008

Instruction code: 3AUA0000116874

600 mm / IP54 A-6-X-028 3AXD50000009185

Instruction code: 3AXD50000009990

800 mm / IP20 A-8-X-023 3AUA0000117005

Instruction code: 3AUA0000116887

800 mm / IP42 A-8-X-026 3AUA0000117009

Instruction code: 3AUA0000116875

272 Ordering information

Enclosure width /
Kit code Ordering code Illustration
Degree of protection

800 mm / IP54 A-8-X-029 3AXD50000009186

Instruction code: 3AXD50000010001

Air outlet kits

Note: The IP54 kits require a cooling fan that must be ordered separately.
Enclosure width /
Qty Kit code Ordering code Illustration
Degree of protection

400 mm / IP20 1

A-4-X-042 3AUA0000125203

800 mm / IP20 2

Instruction code: 3AXD50000001983

600 mm / IP20 1 A-6-X-043 3AUA0000125204

Instruction code: 3AXD50000001981

400 mm / IP42 1

A-4-X-040 3AUA0000114968

800 mm / IP42 2

Instruction code: 3AUA0000115292

 Ordering information 273

Enclosure width /
Qty Kit code Ordering code Illustration
Degree of protection

600 mm / IP42 1 A-6-X-041 3AUA0000114789

Instruction code: 3AUA0000115166

400 mm / IP54
1
(IEC)

A-4-X-064 3AXD50000009187

800 mm / IP54
2
(IEC)

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately

400 mm / IP54
1
(UL)

A-4-X-067 3AXD50000010362

800 mm / IP54
2
(UL)

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately
274 Ordering information

Enclosure width /
Qty Kit code Ordering code Illustration
Degree of protection

600 mm / IP54
1 A-6-X-065 3AXD50000009189
(IEC)

Instruction code: 3AXD50000010004

Note: Fan to be ordered separately

600 mm / IP54
1 A-6-X-066 3AXD50000010327
(UL)

Instruction code: 3AXD50000010004

Note: Fan to be ordered separately

Cooling fans for IP54 air outlets

One or two cooling fans are to be installed inside the air outlet compartment to ensure
sufficient cooling of the cabinet.
Enclosure width / Component
Degree of protection Qty Ordering code
(Auxiliary voltage) Name Data
Fan RB4C-355/170 1 3AXD50000006934
400 mm / IP54 Capacitor MSB MKP 6/603/E1679 1 3AXD50000006959
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RH35M-4EK.4F.1R 1 64750062
400 mm / IP54 Capacitor 25 µF, 220 V 1 68713188
(115 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan CRBB/4-400/188 1 3AXD50000006111
600 mm / IP54 Capacitor MSB MKP 12/603/E1679 1 3AXD50000006885
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
 Ordering information 275

Fan RH40M-4EK.4I.1R 1 64750038

600 mm / IP54 Capacitor 25 µF, 220 V 1 68713188
(115 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 1 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 1 3AXD50000000724
Fan RB4C-355/170 2 3AXD50000006934
800 mm / IP54 Capacitor MSB MKP 6/603/E1679 2 3AXD50000006959
(230 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724
Fan RH35M-4EK.4F.1R 2 64750062
800 mm / IP54 Capacitor 25 µF, 220 V 2 68713188
(115 V 50/60 Hz) Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724
276 Ordering information
 Technical data 277

10
Technical data

Contents of this chapter

This chapter contains the technical specifications of the inverter modules and associated
components.

Ratings
Output ratings
Inverter unit Input
Light-overload
type Frame ratings No-overload use Heavy-duty use
use
ACS880-104- size IInput Imax IN PN SN ILd PLd IHd PHd
…
A A A kW kVA A kW A kW
UN = 400 V
004A8-3 R1i 5.8 7.0 4.8 1.5 3.3 4.5 1.5 4.0 1.5
006A0-3 R1i 7.2 8.8 6.0 2.2 4.2 5.5 2.2 5.0 1.5
008A0-3 R1i 9.6 10.5 8.0 3.0 5.5 7.6 3.0 6.0 2.2
0011A-3 R2i 12.6 13.5 10.5 4.0 7.3 9.7 4.0 9.0 3.0
0014A-3 R2i 16.8 16.5 14.0 5.5 9.7 13.0 5.5 11.0 4.0
0018A-3 R2i 21.6 21 18.0 7.5 12.5 16.8 7.5 14.0 5.5
0025A-3 R3i 30 33 25 11.0 17 23 11.0 19.0 7.5
0035A-3 R3i 42 44 35 15.0 24 32 15.0 29 11.0
0044A-3 R3i 53 53 44 18.5 30 41 18.5 35 15.0
0050A-3 R3i 60 66 50 22 35 46 22 44 22
0061A-3 R4i 73 78 61 30 42 57 30 52 22
0078A-3 R4i 94 100 78 37 54 74 37 69 30
0094A-3 R4i 113 124 94 45 65 90 45 75 37
0100A-3 R4i 125 125 104 55 72 100 55 78 37
0140A-3 R6i 169 183 141 75 98 135 75 105 55
0170A-3 R6i 203 220 169 90 117 162 90 126 55
0210A-3 R6i 247 268 206 110 143 198 110 154 75
0250A-3 R6i 295 320 246 132 170 236 132 184 90
0300A-3 R7i 360 390 300 160 208 288 160 224 110
0350A-3 R7i 420 455 350 200 242 336 160 262 132
278 Technical data

Output ratings
Inverter unit Input
Light-overload
type Frame ratings No-overload use Heavy-duty use
use
ACS880-104- size
IInput Imax IN PN SN ILd PLd IHd PHd
…
A A A kW kVA A kW A kW
0470A-3 R8i 529 620 470 250 326 451 250 352 160
0640A-3 R8i 720 840 640 355 443 614 315 479 250
0760A-3 R8i 855 990 760 400 527 730 400 568 315
0900A-3 R8i 1013 1080 900 500 624 864 450 673 355
1250A-3 2×R8i 1406 1630 1250 630 866 1200 630 935 500
1480A-3 2×R8i 1665 1930 1480 800 1025 1421 800 1107 630
1760A-3 2×R8i 1980 2120 1760 1000 1219 1690 900 1316 710
2210A-3 3×R8i 2486 2880 2210 1200 1531 2122 1200 1653 900
2610A-3 3×R8i 2936 3140 2610 1400 1808 2506 1400 1952 1000
3450A-3 4×R8i 3881 4140 3450 1800 2390 3312 1800 2581 1400
4290A-3 5×R8i 4826 5150 4290 2400 2972 4118 2000 3209 1800
5130A-3 6×R8i 5771 6160 5130 2800 3554 4925 2400 3837 2000
UN = 500 V
003A6-5 R1i 4.3 5.3 3.6 1.5 3.1 3.4 1.5 3.0 1.5
004A8-5 R1i 5.8 7.0 4.8 2.2 4.2 4.5 2.2 4.0 1.5
006A0-5 R1i 7.2 8.8 6.0 3.0 5.2 5.5 3.0 5.0 2.2
008A0-5 R1i 9.6 10.5 8.0 4.0 6.9 7.6 4.0 6.0 3.0
0011A-5 R2i 12.6 13.5 10.5 5.5 9.1 9.7 5.5 9.0 4.0
0014A-5 R2i 16.8 16.5 14.0 7.5 12.1 13.0 7.5 11.0 5.5
0018A-5 R2i 21.6 21 18.0 11.0 16 16.8 11.0 14.0 7.5
0025A-5 R3i 30 33 25 15.0 22 23 15.0 19.0 11.0
0030A-5 R3i 36 36 30 18.5 26 28 18.5 24 15.0
0035A-5 R3i 42 44 35 22 30 32 22 29 18.5
0050A-5 R3i 60 66 50 30 43 46 30 44 22
0061A-5 R4i 73 78 61 37 53 57 37 52 30
0078A-5 R4i 94 100 78 45 68 74 45 69 45
0094A-5 R4i 113 124 94 55 81 90 55 75 45
0110A-5 R6i 136 147 113 75 98 108 75 85 55
0140A-5 R6i 163 177 136 90 118 131 90 102 55
0170A-5 R6i 198 215 165 110 143 158 110 123 75
0200A-5 R6i 236 256 197 132 171 189 132 147 90
0240A-5 R6i 288 312 240 160 208 230 160 180 110
0300A-5 R7i 362 393 302 200 262 290 200 226 132
0340A-5 R7i 408 442 340 250 294 326 200 254 160
0440A-5 R8i 495 580 440 250 381 422 250 329 200
0590A-5 R8i 664 770 590 400 511 566 355 441 250
0740A-5 R8i 833 970 740 500 641 710 450 554 355
0810A-5 R8i 911 1060 810 560 701 778 500 606 400
1150A-5 2×R8i 1294 1500 1150 800 996 1104 710 860 560
1450A-5 2×R8i 1631 1890 1450 1000 1256 1392 900 1085 710
1580A-5 2×R8i 1778 2060 1580 1100 1368 1517 1000 1182 800
2150A-5 3×R8i 2419 2800 2150 1500 1862 2064 1400 1608 1100
2350A-5 3×R8i 2644 3060 2350 1600 2035 2256 1500 1758 1200
3110A-5 4×R8i 3499 4050 3110 2000 2693 2986 2000 2326 1600
3860A-5 5×R8i 4343 5020 3860 2400 3343 3706 2400 2887 2000
4610A-5 6×R8i 5186 6000 4610 3200 3992 4426 2800 3448 2400
UN = 690 V
007A3-7 R5i 8.8 9.5 7.3 5.5 8.7 6.9 5.5 5.6 4.0
009A8-7 R5i 11.8 12.7 9.8 7.5 11.7 9.3 7.5 7.3 5.5
014A2-7 R5i 17.0 18.5 14.2 11.0 17.0 13.5 11.0 9.8 7.5
0018A-7 R5i 22 23 18.0 15.0 21.5 17.1 15.0 14.2 11.0
0022A-7 R5i 26 29 22 18.5 26 21 18.5 18.0 15.0
0027A-7 R5i 32 35 27 22 32 26 22 22 18.5
0035A-7 R5i 42 46 35 30 42 33 30 27 22
0042A-7 R5i 50 55 42 37 50 40 37 35 30
0052A-7 R5i 62 68 52 45 62 49 45 42 37
 Technical data 279

Output ratings
Inverter unit Input
Light-overload
type Frame ratings No-overload use Heavy-duty use
use
ACS880-104- size
IInput Imax IN PN SN ILd PLd IHd PHd
…
A A A kW kVA A kW A kW
0062A-7 R6i 74 81 62 55 74 60 55 46 45
0082A-7 R6i 98 107 82 75 98 79 75 61 55
0100A-7 R6i 119 129 99 90 118 95 90 74 75
0130A-7 R6i 150 163 125 110 149 120 110 94 75
0140A-7 R6i 173 187 144 132 172 138 132 108 90
0190A-7 R6i 230 250 192 160 229 184 160 144 132
0220A-7 R7i 260 282 217 200 259 208 200 162 160
0270A-7 R7i 324 351 270 250 323 259 250 202 200
0340A-7 R8i 383 510 340 315 406 326 250 254 200
0410A-7 R8i 461 620 410 400 490 394 355 307 250
0530A-7 R8i 596 800 530 500 633 509 450 396 355
0600A-7 R8i 675 900 600 560 717 576 560 449 400
0800A-7 2×R8i 900 1200 800 800 956 768 710 598 560
1030A-7 2×R8i 1159 1550 1030 1000 1231 989 900 770 710
1170A-7 2×R8i 1316 1760 1170 1100 1398 1123 1000 875 800
1540A-7 3×R8i 1733 2310 1540 1400 1840 1478 1400 1152 1100
1740A-7 3×R8i 1958 2610 1740 1600 2080 1670 1600 1302 1200
2300A-7 4×R8i 2588 3450 2300 2000 2749 2208 2000 1720 1600
2860A-7 5×R8i 3218 4290 2860 2800 3418 2746 2400 2139 2000
3420A-7 6×R8i 3848 5130 3420 3200 4087 3283 3200 2558 2400

Definitions

UN Nominal AC supply voltage of drive system

IInput Nominal rms input current
IN Nominal output current (available continuously with no over-loading)
PN Typical motor power in no-overload use
SN Apparent power in no-overload use
ILd Continuous rms output current allowing 10% overload for 1 minute every 5 minutes
PLd Typical motor power in light-overload use
Imax Maximum output current. Available for 10 seconds at start; otherwise as long as allowed by drive
temperature.
IHd Continuous rms output current allowing 50% overload for 1 minute every 5 minutes
PHd Typical motor power in heavy-duty use
Notes:
• The ratings apply at an ambient temperature of 40 °C (104 °F).
• The ratings apply to units without option +C132 (marine type approval). For ratings of units with option
+C132, see ACS880 +C132 marine type-approved drive modules and module packages supplement
(3AXD50000037752 [English])
• To achieve the rated motor power given in the table, the rated current of the drive must be higher than or
equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for
selecting the drive, motor and gear combination.
280 Technical data

Derating
 Ambient temperature derating
In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated
by 1% for every added 1 °C (1.8 °F). The output current can be calculated by multiplying
the current given in the rating table by the derating factor (k):
k

1.00

0.90

0.80
T
+40 °C +50 °C
+104 °F +122 °F

 Altitude derating
At altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the continuous output
currents given above must be derated 1% for every 100 m (328 ft). For a more accurate
derating, use the DriveSize PC tool.

 Switching frequency derating

Switching frequencies other than default can require output current derating. Contact ABB
for more information.

 Output frequency derating

Motor operation above 150 Hz can require type-specific output current derating. Contact
ABB for more information.

Cooling characteristics, noise, DC capacitance

DC
Inverter unit type Power loss Air flow Noise level
capacitance
ACS880-104-…
W m3/h ft3/min dB(A) µF
UN = 400 V
004A8-3 70 24 14 47 280
006A0-3 80 24 14 47 280
008A0-3 90 24 14 47 280
0011A-3 110 48 28 39 435
0014A-3 140 48 28 39 865
0018A-3 170 48 28 39 865
0025A-3 200 142 84 63 785
0035A-3 300 142 84 63 785
0044A-3 350 200 118 71 1178
0050A-3 410 200 118 71 1178
0061A-3 500 290 171 70 1570
0078A-3 600 290 171 70 2355
0094A-3 740 290 171 70 2355
0100A-3 750 290 171 70 2355
0140A-3 1100 650 383 71 4500
0170A-3 1400 650 383 71 4500
0210A-3 1800 650 383 71 4500
0250A-3 2000 650 383 71 6750
 Technical data 281

DC
Inverter unit type Power loss Air flow Noise level
capacitance
ACS880-104-…
W m3/h ft3/min dB(A) µF
0300A-3 2500 940 553 72 9000
0350A-3 3100 940 553 72 9000
0470A-3 4800 1300 765 72 11250
0640A-3 6700 1300 765 72 13500
0760A-3 8600 1300 765 72 18000
0900A-3 10000 1300 765 72 18000
1250A-3 13000 2600 1530 74 27000
1480A-3 16000 2600 1530 74 36000
1760A-3 20000 2600 1530 74 36000
2210A-3 23000 3900 2295 76 54000
2610A-3 30000 3900 2295 76 54000
3450A-3 40000 5200 3060 76 72000
4290A-3 50000 6500 3825 77 90000
5130A-3 60000 7800 4590 78 108000
UN = 500 V
003A6-5 60 24 14 47 280
004A8-5 70 24 14 47 280
006A0-5 80 24 14 47 280
008A0-5 90 24 14 47 280
0011A-5 130 48 28 39 435
0014A-5 150 48 28 39 865
0018A-5 180 48 28 39 865
0025A-5 230 142 84 63 785
0030A-5 280 142 84 63 785
0035A-5 320 142 84 63 785
0050A-5 480 200 118 71 1178
0061A-5 550 290 171 70 1570
0078A-5 650 290 171 70 2355
0094A-5 800 290 171 70 2355
0110A-5 1000 650 383 71 4500
0140A-5 1200 650 383 71 4500
0170A-5 1500 650 383 71 4500
0200A-5 1800 650 383 71 4500
0240A-5 2000 650 383 71 6750
0300A-5 2700 940 553 72 9000
0340A-5 3200 940 553 72 9000
0440A-5 4700 1300 765 72 11250
0590A-5 6300 1300 765 72 13500
0740A-5 8100 1300 765 72 18000
0810A-5 9300 1300 765 72 18000
1150A-5 12000 2600 1530 74 27000
1450A-5 16000 2600 1530 74 36000
1580A-5 18000 2600 1530 74 36000
2150A-5 24000 3900 2295 76 54000
2350A-5 27000 3900 2295 76 54000
3110A-5 36000 5200 3060 76 72000
3860A-5 44000 6500 3825 77 90000
4610A-5 53000 7800 4590 78 108000
UN = 690 V
007A3-7 220 280 165 62 343
009A8-7 280 280 165 62 343
014A2-7 400 280 165 62 343
0018A-7 490 280 165 62 343
0022A-7 580 280 165 62 687
0027A-7 660 280 165 62 687
0035A-7 860 280 165 62 687
0042A-7 1000 280 165 62 687
0052A-7 1120 280 165 62 687
282 Technical data

DC
Inverter unit type Power loss Air flow Noise level
capacitance
ACS880-104-…
W m3/h ft3/min dB(A) µF
0062A-7 800 650 383 71 1500
0082A-7 1100 650 383 71 1500
0100A-7 1300 650 383 71 1500
0130A-7 1500 650 383 71 3000
0140A-7 1800 650 383 71 3000
0190A-7 2500 650 383 71 3000
0220A-7 2800 940 553 72 4500
0270A-7 3300 940 553 72 4500
0340A-7 5200 1300 765 72 6000
0410A-7 6100 1300 765 72 6000
0530A-7 7900 1300 765 72 9000
0600A-7 9000 1300 765 72 9000
0800A-7 12000 2600 1530 74 12000
1030A-7 15000 2600 1530 74 18000
1170A-7 18000 2600 1530 74 18000
1540A-7 23000 3900 2295 76 27000
1740A-7 26000 3900 2295 76 27000
2300A-7 35000 5200 3060 76 36000
2860A-7 43000 6500 3825 77 45000
3420A-7 52000 7800 4590 78 54000

Allowable mounting orientations

The modules must be mounted upright unless other orientations are expressly allowed
below.
Frames R6i…R7i: Installation on right-hand side (viewed from the front) allowed.

Frame R8i: Installation on right-hand side (viewed from the front) allowed.
 Technical data 283

Dimensions and weights

The weights of the ACS880-104 modules are shown below. For the dimensions, see
chapter Dimension drawings (page 335).
Inverter module type Weight
ACS880-104-… kg lbs
004A8-3 003A6-5
006A0-3 004A8-5
3 6.5
008A0-3 006A0-5
008A0-5
0011A-3 0011A-5
0014A-3 0014A-5 5 11
0018A-3 0018A-5
0025A-3 0025A-5
0035A-3 0030A-5
10 22
0044A-3 0035A-5
0050A-3 0050A-5
007A3-7
009A8-7
014A2-7
0018A-7
0022A-7 14 31
0027A-7
0035A-7
0042A-7
0052A-7
0061A-3 0061A-5
0078A-3 0078A-5
17 38
0094A-3 0094A-5
0100A-3
0140A-3 0110A-5 0062A-7
0170A-3 0140A-5 0082A-7
0210A-3 0170A-5 0100A-7
38 84
0250A-3 0200A-5 0130A-7
0240A-5 0140A-7
0190A-7
0300A-3 0300A-5 0220A-7
39 86
0350A-3 0340A-5 0270A-7
0470A-3 0440A-5 0340A-7
0640A-3 0590A-5 0410A-7
125 275
0760A-3 0740A-5 0530A-7
0900A-3 0810A-5 0600A-7
284 Technical data

Free space requirements

Inverter module type Above (1 Below (3 Front (4 Left/Right (5
ACS880-104-… mm inch mm inch mm inch mm inch
004A8-3 003A6-5
006A0-3 004A8-5
008A0-3 006A0-5
0011A-3 008A0-5 150 (2 5.9 (2 125 4.9 0 0.0 2.5 0.1
0014A-3 0011A-5
0018A-3 0014A-5
0018A-5
0025A-3 0025A-5
0035A-3 0030A-5
0044A-3 0035A-5 150 (2 5.9 (2 150 5.9 0 0.0 2.5 0.1
0050A-3 0050A-5
0061A-3 0061A-5
0078A-3 0078A-5
0094A-3 0094A-5 150 (2 5.9 (2 175 6.9 0 0.0 2.5 0.1
0100A-3
007A3-7
009A8-7
014A2-7
0018A-7
0022A-7 200 7.9 150 5.9 0 0.0 10 0.4
0027A-7
0035A-7
0042A-7
0052A-7
0140A-3 0110A-5 0062A-7
0170A-3 0140A-5 0082A-7
0210A-3 0170A-5 0100A-7
0250A-3 0200A-5 0130A-7
150 5.9 150 5.9 0 0.0 25 1.0
0300A-3 0240A-5 0140A-7
0350A-3 0300A-5 0190A-7
0340A-5 0220A-7
0270A-7
0470A-3 0440A-5 0340A-7
0640A-3 0590A-5 0410A-7
200 7.9 - - 10 0.4 10 0.4
0760A-3 0740A-5 0530A-7
0900A-3 0810A-5 0600A-7

1)
As required by cooling air flow or 2) air guide
3)
As required by cooling air flow and/or cabling
4) Additional free space may be required by options installed on control unit, and control wiring
5) As required for smooth installation
 Technical data 285

Input power (DC) connection

Voltage (U1) ACS880-104-xxxxx-3: 513…566 V DC. This is indicated in the type
designation label as typical input voltage level (566 V DC).
ACS880-104-xxxxx-5: 513…707 V DC. This is indicated in the type
designation label as typical input voltage levels (566/679/707 V DC).
ACS880-104-xxxxx-7: 709…976 V DC. This is indicated in the type
designation label as typical input voltage levels (742/849/976 V DC).
Drive AC supply network TN (grounded) and IT (ungrounded) systems, corner-grounded systems up
type to 600 V AC
Input terminals Frame R1i
UDC+, UDC–: 0.25…4 mm2, 0.5 … 0.6 N·m (4.4 …5.3 lbf·in)
PE: 1.5 N·m (13 lbf·in)
Frame R2i
UDC+, UDC–: 0.5 … 6 mm2, 1.2 … 1.5 N·m (10.6 … 13.3 lbf·in)
PE: 1.5 N·m (13 lbf·in)
Frames R3i, R4i and R5i
UDC+, UDC–: 6…70 mm2. Allen screw torque 15 N·m (11 lbf·ft), connection
post torque 4 N·m (30 lbf·in). Other conductor sizes can be used by
replacing the original lug with a suitable crimp ring terminal.
PE: Screw size M5, torque 3 N·m (25 lbf·in)
Connector cover screws: Torque 3 N·m (25 lbf·in)
Frames R6i and R7i
See chapter Dimension drawings (page 335), and section One R6i/R7i
module in a 400 mm wide Rittal TS 8 enclosure (page 99)
Frame R8i and multiples
M12, maximum intrusion into module 20 mm (0.8”). See also chapter
Dimension drawings (page 335), and section One R8i module in a 400 mm
wide Rittal TS 8 enclosure (page 112)

Motor (AC) connection

Motor types Asynchronous AC induction motors, permanent magnet synchronous motors
and AC induction servomotors
Voltage (U2) 0 to AC supply voltage of drive, 3-phase symmetrical, Umax at field
weakening point
Frequency 0…±598 Hz, except
0…±120 Hz for frames R1i…R5i with output (du/dt) filters
0…±200 Hz for frames R6i and R7i with output (du/dt) filters
• For higher operational output frequencies, please contact your local ABB
representative.
• Operation above 150 Hz may require type-specific derating. For more
information, contact your local ABB representative.
Current See section Ratings (page 277).
Switching frequency Frames R1i…R4i: 4.5 kHz (typical)
Frames R5i…R8i: 3 kHz (typical)
The switching frequency can vary per frame and voltage. For exact values,
please contact your local ABB representative.
Maximum motor cable Frames R1i…R2i: 150 m (492 ft)
length Frames R3i…R7i: 300 m (984 ft)
Note: Tested with 100 m (328 ft) for EMC Category C3. See standards and
markings information in Electrical planning instructions for ACS880
multidrive cabinets and modules (3AUA0000102324 [English]).
Frame R8i and multiples: 500 m (1640 ft)
286 Technical data

Output terminals Frame R1i

U2, V2, W2: 0.25…4 mm2, 0.5 … 0.6 N·m (4.4 …5.3 lbf·in)
Ground: 1.5 N·m (13 lbf·in)
Frame R2i
U2, V2, W2: 0.5 … 6 mm 2, 1.2 … 1.5 N·m (10.6 … 13.3 lbf·in)
Ground: 1.5 N·m (13 lbf·in)
Frames R3i, R4i and R5i
U2, V2, W2: 6…70 mm2. Allen screw torque 15 N·m (11 lbf·ft), connection
post torque 4 N·m (30 lbf·in). Other conductor sizes can be used by
replacing the original lug with a suitable crimp ring terminal.
Ground: Screw size M5, torque 3 N·m (25 lbf·in)
Connector cover screws: Torque 3 N·m (25 lbf·in)
Frames R6i and R7i
See chapter Dimension drawings (page 335), and section One R6i/R7i
module in a 400 mm wide Rittal TS 8 enclosure (page 99).
Frame R8i
Busbars to quick connector: M12. Torque: 50 N·m (37 lbf·ft)
Busbars to support insulators: M8. Torque: 9 N·m (6.5 lbf·ft)
Cables to busbars: M12. Torque: 70 N·m (52 lbf·ft)
See also chapter Dimension drawings (page 335), and section One R8i
module in a 400 mm wide Rittal TS 8 enclosure (page 112)

Control connections
See chapter The inverter control unit (page 293).

Efficiency
Approximately 98% at nominal power level

Degree of protection
Frames R1i…R5i: IP20
Frames R6i…R8i: IP00

Ambient conditions
Environmental limits for the drive system are given below. The drive system is to be used in a heated, indoor,
controlled environment.
Operation Storage Transportation
installed for stationary in the protective in the protective
use package package
Installation site altitude 1. 0…4000 m (13123 ft) - -
above sea level 2. 0…2000 m (6561 ft)
Output derated above
1000 m (3281 ft). See
section Altitude derating
(page 280).
1. Frames R1i…R8i: Neutral-grounded TN and TT network systems,
non-corner-grounded IT network systems
Frame R8i: Corner-grounded TN, TT and IT network systems up to 600 V
2. Frames R1i…R7i: Corner-grounded TN, TT and IT network systems up to
500 V
 Technical data 287

Air temperature 0 … +40 °C -40 to +70 °C -40 to +70 °C

(+32 … +104 °F). No (-40 to +158 °F) (-40 to +158 °F)
condensation allowed.
Output derated in the
range +40 … +50 °C
(+104 … +122 °F). See
section Ambient
temperature derating
(page 280).
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the
presence of corrosive gases.
Contamination IEC/EN 60721-3- IEC 60721-3-1 IEC 60721-3-2
3:2002: Classification of
environmental
conditions - Part 3-3:
Classification of groups
of environmental
parameters and their
severities - Stationary
use of weather
protected locations
Chemical gases Class 3C2 Class 1C2 Class 2C2
Solid particles Class 3S1. No Class 1S3 (packing Class 2S2
conductive dust allowed. must support this,
otherwise 1S2)
Vibration 10…57 Hz: max. For modules and For cabinet package:
IEC 61800-5-1 0.075 mm amplitude cabinets in packages: IEC/EN 60721-3-1:1997
58…150 Hz: 1 g IEC/EN 60721-3-1:1997 Classification of
IEC 60068-2-6:2007,
Classification of environmental
EN 60068-2-6:2008 Tested in ABB multidrive
environmental conditions - Part 3:
Environmental testing Part 2: cabinet (ACS880-x07)
conditions - Part 3: Classification of groups
Tests -Test Fc: Vibration according to:
Classification of groups of environmental
(sinusoidal) Max. 1 mm (0.04 in.) of environmental parameters and their
(5 … 13.2 Hz), parameters and their severities - Section 2:
max. 0.7 g severities - Section 1: Transportation
(13.2 … 100 Hz) Storage
sinusoidal
Shock Not allowed With packing max. With packing max.
IEC 60068-2-27:2008, 100 m/s2 (330 ft./s2) 100 m/s2 (330 ft./s2)
EN 60068-2-27:2009 11 ms 11 ms
Environmental testing - Part
2-27: Tests - Test Ea and
guidance: Shock

Materials
Module housing PC/ABS 3 mm, color NCS 1502-Y (RAL 9002 / PMS 1C Cool Gray) and RAL
9017 (frames R1i…R5i)
PC+10%GF 3.0mm, Color RAL 9017 (in frames R1i…R3i only)
Hot-dip zinc coated steel sheet 1.5 to 3.0 mm, thickness of coating 20
micrometers, color NCS 1502-Y
Package Frames R1i…R5i: Corrugated cardboard. Foam cushions: PP-E. Plastic
wrapping: PE-LD. Strapping: PP.
Frames R6i and up: Plywood base, corrugated cardboard, PET straps.
288 Technical data

Disposal The drive contains raw materials that should be recycled to preserve energy
and natural resources. The package materials are environmentally
compatible and recyclable. All metal parts can be recycled. The plastic parts
can either be recycled or burned under controlled circumstances, according
to local regulations. Most recyclable parts are marked with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and
printed circuit boards can be landfilled. Electrolytic capacitors and printed
circuit boards are classified as hazardous waste within the EU. They must be
removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling
instructions, please contact your local ABB distributor.

Standards
See Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324
[English]).

Markings
See Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324
[English]).
 Technical data 289

Auxiliary power consumptions

 Control equipment

f Icont Istart Pcont

Device UN
Hz A A W
ZCU/BCU control unit 24 V DC (+10%) - 2.0 - 48
230 V AC (+15%/-20%) 50 0.45 - 105
R8i module: internal electronics
115 V AC (+15%/-20%) 60 0.9 - 105
R8i module: heating element 230 V AC 50/60 - - 40
(option +C183) 115 V AC 60 - - 40
R8i module: direct-on-line fan 50 1.5 3.0 -
400 V AC
(option +C188) 60 1.9 3.8 -
230 V AC (+10%/-15%) 50/60 0.04 - -
Charging controller
115 V AC (+10%/-15%) 50/60 0.08 - -
230 V AC (+10%/-30%) 50 - - 6.5
PDAL2 switch/disconnector interlock coil 240 V AC (+10%/-30%) 60 - - 6.5
110 V AC (+10%/-30%) 60 - - 6.5

 Cabinet cooling fans

UN f Icont
Frame size Type
V AC Hz A
R2E225-RA92-17, 50 0.7
230
R1i…R5i (IP20/IP42 roof fan) R3G225-RD05-03 60 0.9
R2E225-BD40-65 115 60 1.8
50 1.1
RB4C-355/170 230
60 1.45
50 2.3
CRBB/4-400/188 230
60 3
R1i…R8i (IP54 roof fan)
50 3.1
RH35M-4EK.4F.1R 115
60 3.9
50 5.5
RH40M-4EK.4I.1R 115
60 6.3

 Definitions

f Supply frequency
Icont Continuous current consumption
Istart Calculated load current at start
Pcont Continuous input power
UN Voltage requirement
290 Technical data

Fuse data
 Ferrules used with 400 V and 500 V units

Power
Rating
loss at In Clearing I2t Un
Class Example
A rms W A2s V V
10 aR Bussmann FWP-10A14F 4 22 660
15 aR Bussmann FWP-15A14F 5.5 75 660
660 (IEC),
20 aR Bussmann FWP-20A14F 6 180 660
700 (UL)
25 aR Bussmann FWP-25A14F 7 320 660
32 aR Bussmann FWP-32A14F 7.6 600 660
50 aR Mersen 6,921 CP URQ 27x60/50 16 610 690
63 aR Mersen 6,921 CP URQ 27x60/63 21 860 690
80 aR Mersen 6,921 CP URQ 27x60/80 24 1880 690
100 aR Mersen 6,921 CP URQ 27x60/100 27 3210 690 690
125 aR Mersen 6,921 CP URQ 27x60/125 30 6970 690
160 aR Mersen 6,921 CP URQ 27x60/160 34 15000 690
200 aR Mersen 6,921 CP URQ 27x60/200 38 30000 690

 Ferrules used with 690 V units

Power
Rating
loss at In Clearing I2t Un
Class Example
A rms W A2s V V
40 aR Mersen 1021 CP URB 27x60/40 17 450 1000
1000
100 aR Mersen 1021 CP URB 27x60/100 27 6000 1000

 Flush-end fuse blocks used with 400 V and 500 V units

Power
Rating
loss at In Clearing I2t Un
Class Example Size
A rms W A2s V V
250 aR Bussmann 170M4409 55 21000 660
315 aR Bussmann 170M4410 58 42000 660
400 aR Bussmann 170M4412 65 91500 660
450 aR Bussmann 170M4413 70 120000 660
1
500 aR Bussmann 170M4414 72 170000 660
630 aR Bussmann 170M4416 80 350000 660
690 (IEC),
700 aR Bussmann 170M4417 85 465000 660
700 (UL)
800 aR Bussmann 170M4418 95 725000 660
900 aR Bussmann 170M6413 120 670000 660
1100 aR Bussmann 170M6415 130 1300000 660
1250 aR Bussmann 170M6416 140 1950000 660 3
1400 aR Bussmann 170M6417 155 2450000 660
1600 aR Bussmann 170M6419 160 3900000 660
 Technical data 291

 Flush-end fuse blocks used with 690 V units

Power
Rating Clearing I2t Un
Class Example loss at In Size
A rms W A2s V V
125 aR Bussmann 170M3392 35 9000 1000 1*
160 aR Bussmann 170M4388 45 11500 1000
200 aR Bussmann 170M4389 50 22500 1000
1250 (IEC),
250 aR Bussmann 170M4390 60 46000 1000
1300 (UL)
315 aR Bussmann 170M4391 65 90000 1000 1
350 aR Bussmann 170M4392 70 125000 1000
400 aR Bussmann 170M4393 75 175000 1000
500 aR Bussmann 170M4395 85 340000 1000 1100 (IEC)
630 aR Bussmann 170M6544 115 495000 1000 1250 (IEC),
800 aR Bussmann 170M6546 125 995000 1000 1300 (UL)
3
1000 aR Bussmann 170M6548 135 2150000 1000 1100 (IEC)
1100 aR Bussmann 170M6549 140 2800000 1000 1000 (IEC)

Tightening torques
 Common tightening torques for screw connections
Use the torques given in component-specific documentation.
For Rittal components, use the torques given in the Rittal assembly documentation.

 Electrical connections
Size Torque Note
M3 0.5 N·m (4.4 lbf·in) Strength class 4.6...8.8
M4 1 N·m (9 lbf·in) Strength class 4.6...8.8
M5 4 N·m (35 lbf·in) Strength class 8.8
M6 9 N·m (6.6 lbf·ft) Strength class 8.8
M8 22 N·m (16 lbf·ft) Strength class 8.8
M10 42 N·m (31 lbf·ft) Strength class 8.8
M12 70 N·m (52 lbf·ft) Strength class 8.8
M16 120 N·m (90 lbf·ft) Strength class 8.8

 Mechanical connections
Size Max. torque Note
M5 6 N·m (53 lbf·in) Strength class 8.8
M6 10 N·m (7.4 lbf·ft) Strength class 8.8
M8 24 N·m (17.7 lbf·ft) Strength class 8.8

 Insulation supports
Size Max. torque Note
M6 5 N·m (44 lbf·in) Strength class 8.8
M8 9 N·m (6.6 lbf·ft) Strength class 8.8
M10 18 N·m (13.3 lbf·ft) Strength class 8.8
M12 31 N·m (23 lbf·ft) Strength class 8.8
292 Technical data

 Cable lugs
Size Max. torque Note
M8 15 N·m (11 lbf·ft) Strength class 8.8
M10 32 N·m (23.5 lbf·ft) Strength class 8.8
M12 50 N·m (37 lbf·ft) Strength class 8.8

Disclaimers
 Generic disclaimer
The manufacturer shall have no obligation with respect to any product which (i) has been
improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident;
(iii) has been used in a manner contrary to the manufacturer’s instructions; or (iv) has
failed as a result of ordinary wear and tear.

 Cybersecurity disclaimer
This product is designed to be connected to and to communicate information and data via
a network interface. It is Customer's sole responsibility to provide and continuously ensure
a secure connection between the product and Customer network or any other network (as
the case may be). Customer shall establish and maintain any appropriate measures (such
as but not limited to the installation of firewalls, application of authentication measures,
encryption of data, installation of anti-virus programs, etc) to protect the product, the
network, its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. ABB and its
affiliates are not liable for damages and/or losses related to such security breaches, any
unauthorized access, interference, intrusion, leakage and/or theft of data or information.
 The inverter control unit 293

11
The inverter control unit

Contents of this chapter

This chapter
• describes the connections of the inverter control units used with ACS880 multidrive
modules
• contains the specifications of the inputs and outputs.

General
The ZCU-14 control unit is used with inverter module frame sizes R1i…R4i, R6i and R7i,
while the ZCU-12 unit is used with frame size R5i. Both ZCU units consist of a ZCON
control board contained in a plastic housing. The control unit is mounted on the inverter
module.
The BCU control unit is used with frame size R8i and multiples. The BCU consists of a
BCON control board (and a BIOC I/O connector board and power supply board) built in a
metal housing. The BCU is mounted separately from the inverter module(s), and
connected to the module(s) by fiber optic cables. For instructions on the mechanical
installation of the BCU, refer to BCU-02/12/22 control units hardware manual
(3AUA0000113605 [English]).
In this manual, the name “BCU” represents the control unit types BCU-02, BCU-12 and
BCU-22. These have a different number of inverter module connections (2, 7 and 12
respectively) but are otherwise similar.
294 The inverter control unit

Layout and connections

 ZCU-12 layout and connections

X13 Description
XAI Analog inputs
X202
XAO Analog outputs
X208
XDI Digital inputs
XDIO Digital input/outputs
X205 XD24 Start interlock connection (DIIL) and +24 V
output
XD2D Drive to drive link
XPOW External power input
X203 XRO1 Relay output RO1
XRO2 Relay output RO2
XRO3 Relay output RO3
X12
XSTO Safe torque off connection
X12 Connector for FSO-xx safety functions
module (optional)
X13 Control panel connection
X202 Option slot 1
X204
X203 Option slot 2

J1, J2 J3, J6 X204 Option slot 3

X205 Memory unit connection
XPOW XAI XAO XD2D XRO1 J1, J2 Voltage/Current selection jumpers (J1, J2) for
analog inputs
J3 Drive-to-drive link termination switch (J3)
XRO2
J6 Common digital input ground selection switch
(J6). See the Ground isolation diagram (ZCU)
(page 307).
XSTO XDI XDIO XD24 XRO3
 The inverter control unit 295

 ZCU-14 layout and connections

Description
X202 XPOW External power input
XRO1
XAI Analog inputs
XAO Analog outputs
XRO2
XD2D Drive to drive link
XRO1 Relay output RO1
XRO3
XRO2 Relay output RO2
XRO3 Relay output RO3
XPOW
XD24 Start interlock connection (DIIL) and +24 V output
J1, J2
XDIO Digital input/outputs
XDI Digital inputs
XAI
X203 XSTO Safe torque off connection
X12 Connector for FSO-xx safety functions module (optional)
X13 Control panel connection
XAO
X12 X202 Option slot 1
J3
X203 Option slot 2
XD2D X204 Option slot 3
X205 Memory unit connection (memory unit inserted in the
drawing)
XSTO J1, J2 Voltage/Current selection jumpers (J1, J2) for analog
inputs
J3 Drive-to-drive link termination jumper (J3)
X204
XDI J6 Common digital input ground selection jumper (J6). See
the Ground isolation diagram (ZCU) (page 307).

XDIO
J6

XD24

X13 X205
296 The inverter control unit

 BCU layout and connections

Description
I/O I/O terminals (see following diagram)

SLOT 1 I/O extension, encoder interface or

fieldbus adapter module connection.
(This is the sole location for an FDPI-02
diagnostics and panel interface.)
SLOT 2 I/O extension, encoder interface or
fieldbus adapter module connection
SLOT 3 I/O extension, encoder interface, fieldbus
adapter or FSO-xx safety functions
module connection
SLOT 4 RDCO-0x DDCS communication option
module connection

X205 Memory unit connection

BATTERY Holder for real-time clock battery
(CR 2032)

AI1 Mode selector for analog input AI1

(I = current, U = voltage)
AI2 Mode selector for analog input AI2
(I = current, U = voltage)
D2D TERM Termination switch for drive-to-drive link
(D2D)
DICOM= Ground selection. Determines whether
DIOGND DICOM is separated from DIOGND (ie.
the common reference for the digital
inputs floats). See the Ground isolation
diagram (BCU) (page 308).

7-segment display
Multicharacter indications are displayed as repeated
sequences of characters
(“U” is indicated briefly before “o”.)
Control program startup in progress

(Flashing) Firmware cannot be started.

Memory unit missing or corrupted

Firmware download from PC to control

unit in progress

At power-up, the display may show short

indications of eg. “1”, “2”, “b” or “U”.
These are normal indications immediately
after power-up. If the display ends up
showing any other value than those
described, it indicates a hardware failure.
 The inverter control unit 297

Description
XAI Analog inputs
XAO Analog outputs
XDI Digital inputs, Digital input interlock (DIIL)
XRO3 XDIO Digital input/outputs
XD24 XPOW
XD2D Drive-to-drive link
XD24 +24 V output (for digital inputs)
XRO2 XETH Ethernet port (eg. for PC communication)
XDIO XAO
XPOW External power input
XRO1 Relay output RO1
XRO1 XRO2 Relay output RO2
XRO3 Relay output RO3
XDI XAI XSTO Safe torque off connection (input signals)
X485 XSTO OUT Safe torque off connection (to inverter modules)
X12 (On the opposite side) Connection for FSO-xx
safety functions module (optional)
X13 Control panel connection
XD2D XSTO XSTO
OUT X485 Not in use

V1T/V1R, Fiber optic connection to inverter modules 1 and

V2T/V2R 2 (VxT = transmitter, VxR = receiver)
V3T/V3R Fiber optic connection to inverter modules 3…7
… (BCU-12/22 only)
V7T/V7R (VxT = transmitter, VxR = receiver)
V8T/V8R Fiber optic connection to inverter modules 8…12
… (BCU-22 only)
V12T/V12R (VxT = transmitter, VxR = receiver)

SD CARD Data logger memory card for inverter module

communication

BATT OK Real-time clock battery voltage is higher than

2.8 V. If the LED is off when the control unit is
powered, replace the battery.
FAULT The control program has generated a fault. See
the firmware manual of the inverter unit.
PWR OK Internal voltage supply is OK
WRITE Writing to memory card in progress. Do not
remove the memory card.
298 The inverter control unit

 Default I/O connection diagram (ZCU)

Relay outputs XRO1…XRO3

Ready NO 13
250 V AC / 30 V DC COM 12
2A NC 11
Running NO 23
250 V AC / 30 V DC COM 22
2A NC 21
Faulted(-1) NO 33
250 V AC / 30 V DC COM 32
Fault
2A NC 31
External power input XPOW
GND 2
24 V DC, 2 A min. (without optional modules)
+24VI 1
Reference voltage and analog inputs J1, J2, XAI
AI1: U AI2: U
AI1/AI2 current/voltage selection
AI1: I AI2: I
By default not in use. AI2- 7
0(4)…20 mA, Rin = 100 ohm 1) AI2+ 6
Speed reference AI1- 5
0(2)…10 V, Rin > 200 kohm 2) AI1+ 4
Ground AGND 3
-10 V DC, RL 1…10 kohm -VREF 2
10 V DC, RL 1…10 kohm +VREF 1
Analog outputs XAO
AGND 4
Motor current 0…20 mA, RL < 500 ohm
AO2 3
AGND 2
Motor speed rpm 0…20 mA, RL < 500 ohm
AO1 1
Drive-to-drive link XD2D
Shield 4
3) BGND 3
Drive-to-drive link
A 2
B 1
Drive-to-drive link termination 3) J3
Safe torque off XSTO
IN2 4
Safe torque off. Both circuits must be closed for IN1 3
the drive to start. 4) SGND 2
OUT 1
Digital inputs XDI
By default not in use. DI6 6
Constant speed 1 select (1 = on) 5) DI5 5
Acceleration & deceleration select 6) DI4 4
Reset DI3 3
Forward (0) / Reverse (1) DI2 2
Stop (0) / Start (1) DI1 1
Digital input/outputs XDIO
Output: Running DIO2 2
Output: Ready DIO1 1
Ground selection 7) J6
Auxiliary voltage output, digital interlock 8) XD24
Digital input/output ground DIOGND 5
+24 V DC 200 mA 9) +24VD 4
Digital input ground DICOM 3
+24 V DC 200 mA 9) +24VD 2
Run enable 8) DIIL 1
Safety functions module connection X12
Control panel connection X13
Memory unit connection X205
 The inverter control unit 299

Notes:
The wire size accepted by all screw terminals (for both stranded and solid wire) is
0.5 … 2.5 mm2 (24…12 AWG). The torque is 0.5 N·m (5 lbf·in).
1)Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input
selected by jumper J2. Change of setting requires reboot of control unit.
2)
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input
selected by jumper J1. Change of setting requires reboot of control unit.
3) See section Drive-to-drive link (page 303).
4)
See chapter The Safe torque off function (page 309).
5)
Constant speed 1 is defined by parameter 22.26.
6)
0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use.
1 = Acceleration/deceleration ramps defined by parameters 23.14/23.15 in use.
7)
Jumper/switch J6. Determines whether DICOM is separated from DIOGND (ie. common
reference for digital inputs floats; in practice, selects whether the digital inputs are used in
current sinking or sourcing mode). See Ground isolation diagram (ZCU) (page 307).
8) See section DIIL input (page 303).
9)
Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by
DIO1 and DIO2.
300 The inverter control unit

 Default I/O connection diagram (BCU)

Drive-to-drive link XD2D
B 1
A 2
Drive-to-drive link 1)
BGND 3
Shield 4
RS485 connection X485
B 5
A 6
Not in use
BGND 7
Shield 8
Relay outputs XRO1…XRO3
Ready NC 11
250 V AC / 30 V DC COM 12
2A NO 13
Running NC 21
250 V AC / 30 V DC COM 22
2A NO 23
Fault
Faulted(-1) NC 31
250 V AC / 30 V DC COM 32
2A NO 33
Safe torque off XSTO, XSTO OUT
OUT 1
Safe torque off input. Both circuits must be closed for the SGND 2
drive to start. 2) IN1 3
IN2 4
IN1 5
SGND 6
Safe torque off output to inverter modules 2) To inverter modules
IN2 7
SGND 8
Digital inputs XDI
Stop (0) / Start (1) DI1 1
Forward (0) / Reverse (1) DI2 2
Reset DI3 3
Acceleration & deceleration select 3) DI4 4
Constant speed 1 select (1 = on) 4) DI5 5
By default not in use. DI6 6
Run enable 5) DIIL 7
Digital input/outputs XDIO
Output: Ready DIO1 1
Output: Running DIO2 2
Digital input/output ground DIOGND 3
Digital input/output ground DIOGND 4
Auxiliary voltage output XD24
+24 V DC 200 mA 6) +24VD 5
Digital input ground DICOM 6
+24 V DC 200 mA 6) +24VD 7
Digital input/output ground DIOGND 8
Ground selection switch 7) DICOM=DIOGND
Analog inputs, reference voltage output AI
10 V DC, RL 1…10 kohm +VREF 1
-10 V DC, RL 1…10 kohm -VREF 2
Ground AGND 3
Speed reference AI1+ 4
0(2)…10 V, Rin > 200 kohm 8) AI1- 5
By default not in use. AI2+ 6
0(4)…20 mA, Rin = 100 ohm 9) AI2- 7
Analog outputs AO
AO1 1
Motor speed rpm 0…20 mA, RL < 500 ohm
AGND 2
AO2 3
Motor current 0…20 mA, RL < 500 ohm
AGND 4
External power input XPOW
+24VI 1
24 V DC, 2.05 A GND 2
Two supplies can be connected for redundancy. +24VI 3
GND 4
Safety functions module connection X12
Control panel connection X13
Memory unit connection X205
 The inverter control unit 301

Notes:
The wire size accepted by all screw terminals (for both stranded and solid wire) is
0.5 … 2.5 mm2 (24…12 AWG). The torque is 0.5 N·m (5 lbf·in).
1) See section Drive-to-drive link (page 303).
2) See chapter The Safe torque off function (page 309).
3)
0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use.
1 = Acceleration/deceleration ramps defined by parameters 23.14/23.15 in use.
4)
Constant speed 1 is defined by parameter 22.26.
5)
See section DIIL input (page 303).
6)
Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by
DIO1 and DIO2.
7)
Determines whether DICOM is separated from DIOGND (ie. common reference for
digital inputs floats; in practice, selects whether the digital inputs are used in current
sinking or sourcing mode). See also Ground isolation diagram (BCU) (page 308).
DICOM=DIOGND ON: DICOM connected to DIOGND. OFF: DICOM and DIOGND
separate.
8)
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input
selected by switch AI1. Change of setting requires reboot of control unit.
9)
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input
selected by switch AI2. Change of setting requires reboot of control unit.

 External power supply for the control unit (XPOW)

ZCU
By default, the ZCU control unit is powered from the power module. An external 24 V DC,
2 A power supply for the control unit can be connected to terminal block XPOW. Using an
external supply is recommended if
• the control board needs to be kept operational during input power breaks, for example,
because of uninterrupted fieldbus communication, or
• immediate restart is needed after power breaks (that is, no control board power up
delay is allowed).
See also the firmware manual, parameter 95.04.

BCU
The BCU must be powered from a 24 V DC, 2 A power supply. The power supply is
connected to terminal block XPOW. A second supply can be connected to the same
terminal block for redundancy.

 DI6 as a PTC sensor input

A PTC sensor can be connected to this input for motor temperature measurement as
follows. The sensor can alternatively be connected to FEN-xx encoder interface module.
Do not connect both ends of the cable shield directly to ground. If a capacitor cannot be
302 The inverter control unit

used at one end, leave that end of the shield unconnected. See the firmware manual for
parameter settings.

+24VD

PTC DI6
T
3.3 nF
> 630 V AC

WARNING! As the inputs pictured above are not insulated according to

IEC 60664, the connection of the motor temperature sensor requires double or
reinforced insulation between motor live parts and the sensor. If the assembly
does not fulfill the requirement, the I/O board terminals must be protected against contact
and must not be connected to other equipment or the temperature sensor must be
isolated from the I/O terminals.

 AI1 or AI2 as a Pt100, Pt1000 or KTY84 sensor input

Three Pt100/Pt1000 sensors or one KTY84 sensor for motor temperature measurement
can be connected between an analog input and output as shown below. (Alternatively, you
can connect the KTY to an FIO-11 or FAIO-01 analog /I/O extension module or FEN-xx
encoder interface module.) Do not connect both ends of the cable shields directly to
ground. If a capacitor cannot be used at one end, leave that end of the shield
unconnected.

1…3 × Pt100/Pt1000 or 1 × KTY84 XAI

AIn+ 1)
AIn-

XAO
T T T 2)
AOn
AGND

3.3 nF
> 630 V AC

1) For AI1, set input type to voltage with switch/jumper J1 (ZCU) or switch AI1 (BCU). For AI2, set input type
with J2 (ZCU) or AI2 (BCU). Set the appropriate analog input unit to V (volt) in parameter group 12 Standard
AI.
2) Select the excitation mode in parameter group 13 Standard AO.

WARNING! As the inputs pictured above are not insulated according to

IEC 60664, the connection of the motor temperature sensor requires double or
reinforced insulation between motor live parts and the sensor. If the assembly
does not fulfill the requirement, the I/O board terminals must be protected against contact
and must not be connected to other equipment or the temperature sensor must be isolated
from the I/O terminals.
 The inverter control unit 303

 DIIL input
The DIIL input can used for the connection of safety circuits. By default, the input is
parametrized to stop the unit when the input signal is lost.

 Drive-to-drive link
The drive-to-drive link is a daisy-chained RS-485 transmission line that allows basic
master/follower communication with one master drive and multiple followers.
Enable bus termination on the inverters at the ends of the drive-to-drive link. On
intermediate inverters, disable bus termination. The settings for each type of control unit
are:

Switch/jumper
Control unit type Settings
designation

ZCU-12 Termination disabled.

J3
(frame size R5i) Termination enabled.

ZCU-14 Termination enabled.

J3
(frame sizes R1i…R4i, R6i, R7i) Termination disabled.

BCU-x2 ON = Termination enabled.

D2D.TERM
(frame size R8i and multiples) OFF = Termination disabled.

Use shielded twisted-pair cable (~100 ohm, for example, PROFIBUS-compatible cable) for
the wiring. For best immunity, high quality cable is recommended. Keep the cable as short
as possible; the maximum length of the link is 50 meters (164 ft). Avoid unnecessary loops
and running the cable near power cables (such as motor cables). Ground the cable shields
as described in section Connecting the control cables – All frame sizes on page 159.
The following diagram shows the wiring of the drive-to-drive link.
XD2D

XD2D

XD2D
1
2
3
Shield 4

1
2
3
Shield 4

1
2
3
Shield 4
B
A
BGND

B
A
BGND

B
A
BGND

Termination ON Termination OFF Termination ON

 Safe torque off

For the drive to start, both connections (OUT1 to IN1 and IN2) must be closed. By default,
the terminal block has jumpers to close the circuit. Remove the jumpers before connecting
an external Safe torque off circuit to the drive.
For information on the implementation of a Safe torque off function, see chapter The Safe
torque off function (page 309).
304 The inverter control unit

 FSO-xx safety functions module connection (X12)

See ACS880 multidrive cabinets and modules electrical planning instructions
(3AUA0000102324 [English]), and FSO-12 user’s manual (3AXD50000015612 [English]).

 SDHC memory card slot (BCU-x2 only)

The BCU-x2 has an on-board data logger that collects real-time data from the inverter
module power stages to help fault tracing and analysis. The data is stored onto the SDHC
memory card inserted into the SD CARD slot and can be analyzed by ABB service
personnel.
 The inverter control unit 305

Control unit connector data

Power supply Connector pitch 5 mm, wire size 2.5 mm 2
(XPOW)
24 V (±10%) DC, 2 A
External power input. Two supplies can be connected to BCU for
redundancy.
Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm 2
(XRO1…XRO3)
250 V AC / 30 V DC, 2 A
Protected by varistors
+24 V output Connector pitch 5 mm, wire size 2.5 mm 2
(XD24:2 and XD24:4)
Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus
the power taken by DIO1 and DIO2.
Digital inputs DI1…DI6 Connector pitch 5 mm, wire size 2.5 mm 2
(XDI:1…XDI:6) 24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP (DI1…DI5), NPN (DI6)
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
DI6 (XDI:6) can alternatively be used as an input for a PTC
thermistor.
“0” > 4 kohm, “1” < 1.5 kohm
Imax: 15 mA (DI1…DI5), 5 mA (DI6)
Start interlock input DIIL Connector pitch 5 mm, wire size 2.5 mm 2
(XD24:1 [ZCU])
(XDI:7 [BCU]) 24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
Digital inputs/outputs DIO1 and DIO2 Connector pitch 5 mm, wire size 2.5 mm2
(XDIO:1 and XDIO:2)
As inputs:
Input/output mode selection by 24 V logic levels: “0” < 5 V, “1” > 15 V
parameters. Rin: 2.0 kohm
DIO1 can be configured as a frequency Filtering: 0.25 ms (ZCU), 1 ms (BCU)
input (0…16 kHz with hardware filtering As outputs:
of 4 microseconds) for 24 V level square Total output current from +24VD is limited to 200 mA
wave signal (sinusoidal or other wave
form cannot be used). DIO2 can be +24VD
configured as a 24 V level square wave
frequency output. See the firmware
manual, parameter group 11.

DIOx

RL

DIOGND

Reference voltage for analog inputs Connector pitch 5 mm, wire size 2.5 mm 2
+VREF and -VREF 10 V ±1% and –10 V ±1%, Rload 1…10 kohm
(XAI:1 and XAI:2) Maximum output current: 10 mA
Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 2.5 mm 2
(XAI:4 … XAI:7) Current input: –20…20 mA, Rin = 100 ohm
Current/voltage input mode selection by Voltage input: –10…10 V, Rin > 200 kohm
jumpers (ZCU) or switches (BCU). Differential inputs, common mode range ±30 V
Sampling interval per channel: 0.25 ms
Hardware filtering: 0.25 ms, adjustable digital filtering up to 8 ms
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
306 The inverter control unit

Analog outputs AO1 and AO2 Connector pitch 5 mm, wire size 2.5 mm2
(XAO) 0…20 mA, Rload < 500 ohm
Frequency range: 0…300 Hz (ZCU), 0…500 Hz (BCU)
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm2
(XD2D) Physical layer: RS-485
Termination by jumper (ZCU) or switch (BCU)
RS-485 connection Connector pitch 5 mm, wire size 2.5 mm2
(X485) (BCU only) Physical layer: RS-485
Safe torque off connection Connector pitch 5 mm, wire size 2.5 mm2
(XSTO)
Input voltage range: -3…30 V DC
Logic levels: “0” < 5 V, “1” > 17 V
For the drive to start, both connections must be “1”
Current consumption: 66 mA (continuous) per STO channel per
inverter module
EMC (immunity) according to IEC 61326-3-1
Safe torque off output Connector pitch 5 mm, wire size 2.5 mm2
(XSTO OUT) (BCU only)
To STO connector of inverter module. See chapter The Safe torque
off function (page 309).
Control panel connection (X13) Connector: RJ-45
Cable length < 3 m
Ethernet connection Connector: RJ-45
(XETH) (BCU only)
SDHC memory card slot Memory card type: SDHC
(SD CARD) (BCU only) Maximum memory size: 4 GB
The terminals of the control unit fulfil the Protective Extra Low Voltage (PELV) requirements. The PELV
requirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output.
 The inverter control unit 307

Ground isolation diagram (ZCU)

XPOW
+24VI 1
GND 2
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5 Common mode voltage between
AI2+ 6 channels +30 V
AI2- 7
XAO
AO1 1
AGND 2
AO2 3
AGND 4
XD2D
B 1
A 2
BGND 3
XRO1, XRO2, XRO3
NC 1
COM 2
NO 3
NC 1
COM 2
NO 3
NC 1
COM 2
NO 3
XD24
DIIL 1
+24VD 2
DICOM 3
+24VD 4
DIOGND 5
XDIO
DIO1 1
DIO2 2
XDI
DI1 1 *
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
XSTO
OUT1 1
GND 2
IN1 3
IN2 4

Ground

*Ground selector (J6) settings

(ZCU-12)
(ZCU-14)
All digital inputs share a common ground (DICOM connected to DIOGND). This is the default setting.

(ZCU-12)
(ZCU-14)
Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from DIO signal ground (DIOGND).
Isolation voltage 50 V.
308 The inverter control unit

Ground isolation diagram (BCU)

XPOW
+24VI 1
GND 2
+24VI 3
GND 4
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5 Common mode voltage between
AI2+ 6 each AI input and AGND is
AI2- 7 +30 V
XAO
AO1 1
AGND 2
AO2 3
AGND 4
XD2D
B 1
A 2
BGND 3
SHIELD 4
XRO1, XRO2, XRO3
NC 11
COM 12
NO 13
NC 21
COM 22
NO 23
NC 31
COM 32
NO 33
XD24
+24VD 5
DICOM 6
+24VD 7
DIOGND 8
XDIO
DIO1 1
DIO2 2
DIOGND 3
DIOGND 4
XDI
DI1 1 *
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
DIIL 7
XSTO
OUT 1
SGND 2
IN1 3
IN2 4
XSTO OUT
IN1 5
SGND 6
IN2 7
Ground
SGND 8

*Ground selector (DICOM=DIOGND) settings

DICOM=DIOGND: ON
All digital inputs share a common ground (DICOM connected to DIOGND). This is the default setting.

DICOM=DIOGND: OFF
Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from DIO signal ground (DIOGND).
Isolation voltage 50 V.
 The Safe torque off function 309

12
The Safe torque off function

Contents of this chapter

This chapter describes the Safe torque off (STO) function of the inverter and gives
instructions for its use.

Description
The Safe torque off function can be used, for example, to construct safety or supervision
circuits that stop the inverter in case of danger (such as an emergency stop circuit).
Another possible application is a prevention of unexpected start-up switch that enables
short-time maintenance operations like cleaning or work on non-electrical parts of the
machinery without switching off the power supply to the inverter.
When activated, the Safe torque off function disables the control voltage of the power
semiconductors of the inverter output stage (A, see diagram below), thus preventing the
inverter from generating the torque required to rotate the motor. If the motor is running
when Safe torque off is activated, it coasts to a stop.
The Safe torque off function has a redundant architecture, that is, both channels must be
used in the safety function implementation. The safety data given in this manual is
calculated for redundant use, and does not apply if both channels are not used.
The Safe torque off function of the inverter complies with these standards:

Standard Name

EN 60204-1:2006 + AC:2010 Safety of machinery – Electrical equipment of machines – Part 1: General

requirements

IEC 61326-3-1:2008 Electrical equipment for measurement, control and laboratory use – EMC
requirements – Part 3-1: Immunity requirements for safety-related
systems and for equipment intended to perform safety-related functions
(functional safety) – General industrial applications
310 The Safe torque off function

Standard Name

IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety-

related systems – Part 1: General requirements

IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic safety-

related systems – Part 2: Requirements for
electrical/electronic/programmable electronic safety-related systems

IEC 61511-1:2016 Functional safety – Safety instrumented systems for the process industry
sector

IEC 61800-5-2:2016 Adjustable speed electrical power drive systems –

EN 61800-5-2:2007 Part 5-2: Safety requirements – Functional

IEC 62061:2015 Safety of machinery – Functional safety of safety-related electrical,

EN 62061:2005 electronic and programmable electronic control systems
+AC:2010+A1:2013+A2:2015

EN ISO 13849-1:2015 Safety of machinery – Safety-related parts of control systems – Part 1:

General principles for design

EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of control systems – Part 2:

Validation

The function also corresponds to Prevention of unexpected start-up as specified by

EN 1037:1995 + A1:2008 and Uncontrolled stop (stop category 0) as specified in
EN 60204-1:2006 + AC:2010.

 Compliance with the European Machinery Directive

See Electrical planning instructions for ACS880 multidrive cabinets and modules
(3AUA0000102324 [English]).

Wiring
The following diagrams present examples of Safe torque off wiring for
• a single inverter unit (page 312)
• a frame n×R8i inverter unit (page 313)
• multiple inverter units (page 314)
• multiple inverter units when an external 24 V DC power supply is used (page 315).
For information on the specifications of the STO input, see chapter The inverter control
unit (page 293).

 Activation switch
In the wiring diagrams below, the activation switch has the designation [K]. This represents
a component such as a manually operated switch, an emergency stop push button switch,
or the contacts of a safety relay or safety PLC.
• In case a manually operated activation switch is used, the switch must be of a type
that can be locked out to the open position.
• The contacts of the switch or relay must open/close within 200 ms of each other.
• An FSO-xx safety functions module or an FPTC-0x thermistor protection module can
also be used. For more information, see the module documentation.
 The Safe torque off function 311

 Cable types and lengths

• Double-shielded twisted-pair cable is recommended.
• Maximum cable lengths:
• 30 m (100 ft) between activation switch [K] and inverter control unit.
• 60 m (200 ft) between multiple inverter units
• 60 m (200 ft) between external power supply and first inverter unit
• With frame n×R8i inverter units: 30 m (100 ft) between BCU control unit and last
inverter module in the chain.
Note: The voltage at the INx terminals of each inverter control unit (or frame R8i inverter
module) must be at least 17 V DC to be interpreted as “1”.

 Grounding of protective shields

• Ground the shield in the cabling between the activation switch and the control unit at
the control unit.
• Ground the shield in the cabling between two control units at one control unit only.
• For frame R8i and multiples: Do not ground the shield in the cabling between BCU and
R8i module, or between R8i modules.
312 The Safe torque off function

 Single inverter unit (internal power supply)

Dual-channel connection

Inverter unit

Control unit OUT1

+24 V
SGND K

IN1
Control logic IN2

UDC+

A T1/U, T2/V, T3/W

UDC–

Single-channel connection

Inverter unit
K
Control unit OUT1
+24 V
SGND

IN1
IN2

Notes:
• Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL
classification is given.
• Pay special attention to avoiding any potential failure modes for the wiring. For example, use shielded
cable. For measures for fault exclusion of wiring, see eg. EN ISO 13849-2:2012, table D.4.
 The Safe torque off function 313

 Frame n×R8i inverter unit (internal power supply)

WARNING! Frame R8i inverter modules are as standard delivered with a jumper
wire set that supplies 24 V from connector X53 to connector X52. The jumper wire
set must be removed before wiring the Safe torque off circuit.

Control unit
XSTO
+24 V OUT1

SGND K

IN1
IN2

Inverter module
XSTO OUT STO IN (X52)
IN1 24VDC CH1
SGND GND CH1
IN2 24VDC CH2
SGND GND CH2
FE
Inverter module
STO IN (X52) STO OUT (X51)
24VDC CH1 24VDC CH1
GND CH1 GND CH1
24VDC CH2 24VDC CH2
GND CH2 GND CH2
FE FE

STO OUT (X51)

24VDC CH1
GND CH1
To next
24VDC CH2 inverter module
GND CH2
FE
314 The Safe torque off function

 Multiple inverter units (internal power supply)

Inverter unit
Control unit XSTO

+24 V OUT1

SGND K

IN1
IN2

Inverter unit
Control unit XSTO
OUT1
SGND

IN1
IN2

Inverter unit
Control unit XSTO
OUT1
SGND

IN1
IN2
 The Safe torque off function 315

 Multiple inverter units (external power supply)

Inverter unit 24 V DC
– +
Control unit XSTO
+24 V OUT1
SGND

IN1
IN2

Inverter unit
Control unit XSTO
OUT1
SGND

IN1
IN2

Inverter unit
Control unit XSTO
OUT1
SGND

IN1
IN2
316 The Safe torque off function

Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay contacts
open).
2. The STO inputs on the inverter control unit de-energize.
3. The control unit cuts off the control voltage from the inverter IGBTs.
4. The control program generates an indication as defined by parameter 31.22 (refer to
the firmware manual of the inverter).
5. Motor coasts to a stop (if running). The inverter cannot restart while the activation
switch or safety relay contacts are open. After the contacts close, a new start
command is required to start the drive.

Start-up including acceptance test

To ensure the safe operation of a safety function, validation is required. The final
assembler of the machine must validate the function by performing an acceptance test.
The acceptance test must be performed
• at initial start-up of the safety function
• after any changes related to the safety function (circuit boards, wiring, components,
settings, etc.)
• after any maintenance work related to the safety function.

 Competence
The acceptance test of the safety function must be carried out by a competent person with
adequate expertise and knowledge of the safety function as well as functional safety, as
required by IEC 61508-1 clause 6. The test procedures and report must be documented
and signed by this person.

 Acceptance test reports

Signed acceptance test reports must be stored in the logbook of the machine. The report
shall include documentation of start-up activities and test results, references to failure
reports and resolution of failures. Any new acceptance tests performed due to changes or
maintenance shall be logged into the logbook.

 Acceptance test procedure

After wiring the Safe torque off function, validate its operation as follows.
Notes:
• If an FSO-xx safety functions module or an FPTC-0x module is installed, refer to its
documentation.
• All inverter modules must be powered and connected to the STO circuit during the
acceptance test.

Action

WARNING! Follow the safety instructions given in Safety instructions for ACS880 multidrive
cabinets and modules (3AUA0000102301 [English]). Ignoring the instructions can cause
physical injury or death, or damage to the equipment.

Ensure that the inverter can be run and stopped freely during start-up.
 The Safe torque off function 317

Action

Stop the inverter (if running), switch the input power off and isolate the inverter from the power line by
a disconnector.

Check the Safe torque off circuit connections against the wiring diagram.

Close the disconnector and switch the power on.

Test the operation of the STO function when the motor is stopped.
• Give a stop command for the inverter (if running) and wait until the motor shaft is at a standstill.
Ensure that the inverter operates as follows:
• Open the STO circuit. The inverter generates an indication if one is defined for ‘stopped’ state in
parameter 31.22 (see the firmware manual).
• Give a start command to verify that the STO function blocks the inverter’s operation. The motor
should not start.
• Close the STO circuit.
• Reset any active faults. Restart the inverter and check that the motor runs normally.

Test the operation of the STO function when the motor is running.
• Start the inverter and ensure the motor is running.
• Open the STO circuit. The motor should stop. The inverter generates an indication if one is defined
for ‘running’ state in parameter 31.22 (see the firmware manual).
• Reset any active faults and try to start the inverter.
• Ensure that the motor stays at a standstill and the inverter operates as described above in testing
the operation when the motor is stopped.
• Close the STO circuit.
• Reset any active faults. Restart the inverter and check that the motor runs normally.

Test the operation of the failure detection of the inverter. The motor can be stopped or running.
• Open the 1st channel of the STO circuit (wire coming to IN1). If the motor was running, it should
coast to a stop. The inverter generates a FA81 Safe Torque Off 1 loss fault indication (see the
firmware manual).
• Give a start command to verify that the STO function blocks the inverter’s operation. The motor
should not start.
• Close the STO circuit.
• Reset any active faults. Restart the inverter and check that the motor runs normally.
• Open the 2nd channel of the STO circuit (wire coming to IN2). If the motor was running, it should
coast to a stop. The inverter generates a FA82 Safe Torque Off 2 loss fault indication (see the
firmware manual).
• Give a start command to verify that the STO function blocks the inverter’s operation. The motor
should not start.
• Close the STO circuit.
• Reset any active faults. Restart the inverter and check that the motor runs normally.

Document and sign the acceptance test report which verifies that the safety function is safe and
accepted for operation.
318 The Safe torque off function

Use
1. Open the activation switch, or activate the safety functionality that is wired to the STO
connection.
2. STO inputs on the inverter control unit de-energize, and the inverter control unit cuts
off the control voltage from the inverter IGBTs.
3. The control program generates an indication as defined by parameter 31.22 (refer to
the firmware manual of the inverter).
4. The motor coasts to a stop (if running). The inverter will not restart while the activation
switch or safety relay contacts are open.
5. Deactivate the STO by closing the activation switch, or reseting the safety functionality
that is wired to the STO connection.
6. Reset any faults before restarting.

WARNING! The Safe torque off function does not disconnect the voltage of the
main and auxiliary circuits from the inverter. Therefore maintenance work on
electrical parts of the inverter or the motor can only be carried out after isolating
the inverter from the main supply.

WARNING! The Safe torque off functionality is only achieved through the XSTO
connector of the inverter control unit. True Safe torque off functionality is not
achieved through the XSTO connectors of other control units (such as the supply
control unit or the brake control unit).
The Safe torque off function is supported by any ACS880 inverter or drive firmware. It is
not supported by supply or brake firmware.

WARNING! (With permanent magnet or synchronous reluctance [SynRM] motors

only) In case of a multiple IGBT power semiconductor failure, the inverter system
can produce an alignment torque which maximally rotates the motor shaft by
180/p (with permanent magnet motors) or 180/2p (with synchronous reluctance [SynRM]
motors) degrees regardless of the activation of the Safe torque off function. p denotes the
number of pole pairs.

Notes:
• If a running inverter is stopped by using the Safe torque off function, the inverter will
cut off the motor supply voltage and the motor will coast to a stop. If this causes
danger or is not otherwise acceptable, stop the inverter and machinery using the
appropriate stop mode before activating the Safe torque off function.
• The Safe torque off function overrides all other functions of the inverter unit.
• The Safe torque off function is ineffective against deliberate sabotage or misuse.
• The Safe torque off function has been designed to reduce the recognized hazardous
conditions. In spite of this, it is not always possible to eliminate all potential hazards.
The assembler of the machine must inform the final user about the residual risks.
 The Safe torque off function 319

Maintenance
After the operation of the circuit is validated at start-up, the STO function shall be
maintained by periodic proof testing. In high demand mode of operation, the maximum
proof test interval is 20 years. In low demand mode of operation, the maximum proof test
interval is 5 or 2 years; see section Safety data (page 320). It is assumed that all
dangerous failures of the STO circuit are detected by the proof test. To perform the proof
test, do the Acceptance test procedure (page 316).
Note: See also the Recommendation of Use CNB/M/11.050 (published by the European
co-ordination of Notified Bodies) concerning dual-channel safety-related systems with
electromechanical outputs:
• When the safety integrity requirement for the safety function is SIL 3 or PL e (cat. 3 or
4), the proof test for the function must be performed at least every month.
• When the safety integrity requirement for the safety function is SIL 2 (HFT = 1) or PL d
(cat. 3), the proof test for the function must be performed at least every 12 months.
The STO function of the drive does not contain any electromechanical components.
In addition to proof testing, it is a good practice to check the operation of the function when
other maintenance procedures are carried out on the machinery.
Include the Safe torque off operation test described above in the routine maintenance
program of the machinery that the inverter runs.
If any wiring or component change is needed after start up, or the parameters are restored,
follow the test given in section Acceptance test procedure (page 316).
Use only ABB approved spare parts.
Record all maintenance and proof test activities in the machine logbook.

 Competence
The maintenance and proof test activities of the safety function must be carried out by a
competent person with adequate expertise and knowledge of the safety function as well as
functional safety, as required by IEC 61508-1 clause 6.

Fault tracing
The indications given during the normal operation of the Safe torque off function are
selected by inverter parameter 31.22.
The diagnostics of the Safe torque off function cross-compare the status of the two STO
channels. In case the channels are not in the same state, a fault reaction function is
performed and the inverter trips on an “STO hardware failure” fault. An attempt to use the
STO in a non-redundant manner, for example activating only one channel, will trigger the
same reaction.
See the inverter firmware manual for the indications generated by the inverter, and for
details on directing fault and warning indications to an output on the control unit for
external diagnostics.
Any failures of the Safe torque off function must be reported to ABB.
320 The Safe torque off function

Safety data
The safety data for the Safe torque off function is given below.
Note: The safety data is calculated for redundant use, and does not apply if both STO
channels are not used.
PFH
Frame SIL/ SFF (T1 = 20 PFDavg PFDavg MTTFD DC Lifetime
SC PL a) Cat. HFT CCF
size SILCL (T1 = 2 a) (T1 = 5 a)
(%) (1/h) (a) (%) (a)
R1i
R2i >90
3 3 e 98.8 3.23E-09 2.83E-05 7.08E-05 24293 3 1 80 20
R3i
R4i
R5i 3 3 e 96.9 3.36E-09 2.03E-05 5.07E-05 17021 >90 3 1 80 20
R6i >90
3 3 e 98.7 3.55E-09 3.38E-05 8.45E-05 9041 3 1 80 20
R7i
R8i 3 3 e >99 4.74E-11 4.23E-07 1.04E-06 27325 >90 3 1 80 20
2×R8i 3 3 e >99 5.57E-11 4.98E-07 1.22E-06 19607 >90 3 1 80 20
3×R8i 3 3 e >99 6.39E-11 5.74E-07 1.41E-06 15295 >90 3 1 80 20
4×R8i 3 3 e >99 7.22E-11 6.49E-07 1.59E-06 12540 >90 3 1 80 20
5×R8i 3 3 e >99 8.05E-11 7.24E-07 1.78E-06 10626 >90 3 1 80 20
6×R8i 3 3 e >99 8.87E-11 7.99E-07 1.96E-06 9220 >90 3 1 80 20

• The following temperature profile is used in safety value calculations:

• 670 on/off cycles per year with T = 71.66 °C
• 1340 on/off cycles per year with T = 61.66 °C
• 30 on/off cycles per year with T = 10.0 °C
• 32 °C board temperature at 2.0% of time
• 60 °C board temperature at 1.5% of time
• 85 °C board temperature at 2.3% of time.
• The STO is a type A safety component as defined in IEC 61508-2, except for frame
size R8i (and multiples) in which the STO is type B.
• Relevant failure modes:
• The STO trips spuriously (safe failure)
• The STO does not activate when requested
A fault exclusion on the failure mode “short circuit on printed circuit board” has been
made (EN 13849-2, table D.5). The analysis is based on an assumption that one
failure occurs at one time. No accumulated failures have been analyzed.
• STO reaction time (shortest detectable break): 1 ms
• STO response time:
• Frame sizes R1i…R7i: 2 ms (typical), 5 ms (maximum)
• Frame sizes 1×R8i…6×R8i: 2 ms (typical), 25 ms (maximum)
• Fault detection time: Channels in different states for longer than 200 ms
• Fault reaction time: Fault detection time + 10 ms
• STO fault indication (parameter 31.22) delay: < 500 ms
• STO warning indication (parameter 31.22) delay: < 1000 ms
 The Safe torque off function 321

 Abbreviations
Abbr. Reference Description
Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in respect
of their resistance to faults and their subsequent behavior in the fault
condition, and which is achieved by the structural arrangement of the
parts, fault detection and/or by their reliability. The categories are: B, 1,
2, 3 and 4.
CCF EN ISO 13849-1 Common cause failure (%)
DC EN ISO 13849-1 Diagnostic coverage
FIT IEC 61508 Failure in time: 1E-9 hours
HFT IEC 61508 Hardware fault tolerance
MTTFD EN ISO 13849-1 Mean time to dangerous failure: (The total number of life units) / (the
number of dangerous, undetected failures) during a particular
measurement interval under stated conditions
PFDavg IEC 61508 Average probability of dangerous failure on demand
PFH IEC 61508 Average frequency of dangerous failures per hour
PL EN ISO 13849-1 Performance level. Levels a…e correspond to SIL
SC IEC 61508 Systematic capability
SFF IEC 61508 Safe failure fraction (%)
SIL IEC 61508 Safety integrity level (1…3)
SILCL IEC/EN 62061 Maximum SIL (level 1…3) that can be claimed for a safety function or
subsystem
SS1 IEC/EN 61800-5-2 Safe stop 1
STO IEC/EN 61800-5-2 Safe torque off
T1 IEC 61508-6 Proof test interval. T1 is a parameter used to define the probabilistic
failure rate (PFH or PFD) for the safety function or subsystem.
Performing a proof test at a maximum interval of T1 is required to keep
the SIL capability valid. The same interval must be followed to keep the
PL capability (EN ISO 13849) valid. Note that any T1 values given
cannot be regarded as a guarantee or warranty.
See also section Maintenance (page 319).
322 The Safe torque off function

 Declaration of conformity
The Safe torque off function 323
324 The Safe torque off function
 Resistor braking using frame R1i…R4i inverter modules 325

13
Resistor braking using frame
R1i…R4i inverter modules

Contents of this chapter

This chapter deals with using the internal brake choppers of frame R1i…R4i inverter
modules.

Using R1i…R4i modules for resistor braking

The internal brake choppers of frame R1i…R4i inverter modules can be used for resistor
braking of other modules. Brake resistors are available from ABB as add-on kits and must
be installed in separate cubicles; contact your local ABB representative for details.
326 Resistor braking using frame R1i…R4i inverter modules

Planning the braking system

• The continuous and maximum braking power ratings of individual inverter modules are
listed on page 331.
The total continuous braking power of parallel-connected modules is calculated with
the formula
Pbrcont = Pbrcont1 + 0.8 × (Pbrcont2 + Pbrcont3 + …)
where Pbrcont1, Pbrcont2, etc. are the Pbrcont values of the connected modules from
largest to smallest.
The total maximum braking power of parallel-connected modules is calculated with the
formula
Pbrmax = Pbrmax1 + 0.7 × (Pbrmax2 + Pbrmax3 + …)
where Pbrmax1, Pbrmax2, etc. are the Pbrmax values of the connected modules from
largest to smallest.
• The resistance of the resistor must not be lower than Rmin. The energy transferred by
any inverter module to its resistor must not exceed the heat dissipation capacity (ER)
of the resistor.

 Restrictions
• Internal brake choppers are only available for frame R1i…R4i, ACS880-104-xxxxx-3
and ACS880-104-xxxxx-5 inverter module types.
• The maximum number of modules doing the braking is 12 frame R1i…R2i modules or
6 frame R3i…R4i modules, ie. the number of modules that can be mounted into a
800 mm wide Rittal TS 8 cubicle.
• Each inverter module must have its own resistor(s).
• In case the braking power of the modules is not sufficient, a separate brake chopper
must be used. It is not allowed to use the internal brake choppers simultaneously with
a separate brake chopper.
• The cubicle with the braking modules must be next in the line-up to the inverter that
needs to be braked.
• The internal brake choppers cannot be used if the system has an IGBT (regenerative)
supply unit.
 Resistor braking using frame R1i…R4i inverter modules 327

 Selecting the brake resistor

The ratings table (page 331) lists an example brake resistor for each inverter type. These
resistors are available from ABB.
When sourcing a resistor from a third party, make sure that:
1. The resistance of the custom resistor is greater or equal than the minimum allowed
resistance:
R > Rmin

where
R Resistance of the custom resistor.
WARNING! Never use a brake resistor with a resistance smaller than Rmin. The
inverter module and the chopper are not able to handle the overcurrent caused by
the low resistance.
Rmin Minimum allowed resistance of the brake resistor. See Ratings (page 331).

2. The load capacity of the custom resistor is higher than the instantaneous maximum
power consumption of the resistor when it is connected to the DC link voltage by the
chopper:
2
U DC
Pr >
R
where
Pr Load capacity of the custom resistor
UDC Drive DC link voltage.
1.35 · 1.25 · 415 V DC (when supply voltage is 380 to 415 V AC) or
1.35 · 1.25 · 500 V DC (when supply voltage is 440 to 500 V AC)
R Resistance of the custom resistor

 Selecting and routing the brake resistor cables

Use the same cable type for resistor as for inverter input cabling to ensure that the inverter
DC fuses also protect the resistor cable.

Minimizing electromagnetic interference

Follow these rules in order to minimize electromagnetic interference caused by the rapid
current changes in the resistor cable.
• Shield the braking power line completely, either by using shielded cable or a metallic
enclosure. Unshielded single-core cable can only be used if it is routed inside a
cabinet that efficiently suppresses the radiated emissions.
• Install the cables away from other cable routes.
• Avoid long parallel runs with other cables. The minimum parallel cabling separation
distance is 0.3 meters (1 ft).
• Cross other cables at right angles.
• Keep the cable as short as possible. The longer the cable, the higher the radiated
emissions, inductive load, and voltage peaks over the IGBT semiconductors of the
brake chopper.

Maximum cable length

The maximum cable length of the resistor cable is 10 m (33 ft).
328 Resistor braking using frame R1i…R4i inverter modules

EMC compliance of the complete installation

Note: ABB has not verified that the EMC requirements are fulfilled with external user-
defined brake resistors and cabling. The EMC compliance of the complete installation
must be considered by the customer.

 Placing the brake resistor

Install the resistor outside the inverter cubicle where they will be able to cool.
Arrange the cooling of the resistor in a way that
• no danger of overheating is caused to the resistor or nearby materials
• the temperature of the room the resistor is located in does not exceed the allowed
maximum.
Supply the resistor with cooling air or coolant according to the manufacturer’s instructions.

WARNING! The materials near the brake resistor must be non-flammable. The
surface temperature of the resistor is high. Air flowing from the resistor is of
hundreds of degrees Celsius. If the exhaust vents are connected to a ventilation
system, ensure that the material withstands high temperatures. Protect the resistor against
contact.

 Protecting the system against thermal overload

The inverter module protects itself and the resistor cable against thermal overload when
the cable is correctly dimensioned. The inverter control program includes a resistor and
resistor cable thermal protection function which can be tuned by the user. See the
firmware manual.
Equipping the drive system with a main contactor or breaker is highly recommended for
safety reasons. Wire the contactor or breaker so that it opens in case the resistor
overheats. This is essential for safety since the inverter module may not be able to break
the current if the chopper remains conductive in a fault situation. An example wiring
diagram is shown below. ABB resistors are equipped with a thermal switch (1) inside the
resistor assembly as standard. The switch indicates overtemperature and overload.
We recommend that you also wire the thermal switch to a digital input of the inverter
module.

L1 L2 L3

OFF
2

1 3 5 13 3

ON
2 4 6 14 4

 1 ACS880-104
L1 L2 L3
+24VD x
Drive system
DIx x
K1
 Resistor braking using frame R1i…R4i inverter modules 329

 Protecting the resistor cable against short circuit

The DC fuses of the inverter module will also protect the resistor cable if the cable is
identical with the inverter input cable.

Mechanical installation
All brake resistors must be installed outside the drive. Follow the resistor manufacturer’s
instructions.

Electrical installation
 Checking the insulation of the brake resistor assembly
Check the insulation of each brake resistor assembly as follows:
1. Check that the resistor cable is connected to the resistor, and disconnected from the
inverter module terminals R+ and R-.
2. At the inverter end, connect the R+ and R- conductors of the resistor cable together.
Measure the insulation resistance between the combined conductors and the
Protective Earth (PE) conductor by using a measuring voltage of 1000 V DC. The
insulation resistance must be higher than 1 Mohm.

R+

R-
ohm
PE

 Connection procedure
1. Connect the resistor cable to the R+ and R- terminals in the same way as the other
power cables. Use the same cable type as with the DC input cable. If a shielded three-
conductor cable is used, cut the third conductor, insulate it, and ground the twisted
shield of the cable (protective earth conductor of the resistor assembly) at both ends.
2. Connect the thermal switch of the brake resistor as described above under Protecting
the system against thermal overload.
330 Resistor braking using frame R1i…R4i inverter modules

Start-up
Note: New brake resistors may be coated with storage grease. As the brake chopper
operates for the first time, the grease burns off and may produce some smoke. Make sure
there is proper ventilation.
Set the following inverter control program parameters (ACS880 primary control program)
in each braking inverter:
• Disable the overvoltage control (parameter 30.30).
• Set parameter 31.01 to point to the digital input to which the thermal switch of the
brake resistor is wired.
• Set parameter 31.02 so that the event generates a fault.
• Enable the brake chopper by parameter 43.06 Brake chopper enable. If you select
Enabled with thermal model, also set the brake resistor overload protection
parameters 43.08 and 43.09 according to the application.
• Check the value of parameter 43.10 Brake resistance.
• Adjust other brake-related settings as necessary in parameter group 43.
• Match the brake chopper operating limits of all braking inverters. You will need to enter
a service-level pass code into parameter 96.02 to access the limit parameters. To
obtain the pass code, contact your local ABB representative.
• Stop all inverters of the drive system (even those not used for braking) if any are
running.
• Monitor the DC voltage (parameter 01.11) on each braking inverter for a period of
time. Calculate the average of the readings separately for each inverter.
• Select one braking inverter as reference. On this inverter, enter the nominal AC
supply voltage into parameter 95.37. Multiply this value by the number shown in
the table below to get the value of 95.36.
Supply voltage range [V AC] (see parameter 95.01)
208…240 380…415 440…480 500
[95.36]= [95.37] × 0.867 0.916 0.917 1.000

For example, with a 380…415 V inverter, the value of 95.36 should be 0.916 times
the value of 95.37.
• For each of the remaining braking inverters, divide the average DC voltage value
of the inverter by that of the reference inverter. Multiply the result with the nominal
supply voltage, and enter the result into parameter 95.37. Further multiply the
value of 95.37 by the factor shown in the above table to get the value of 95.36.
• On all braking inverters, enable custom supply voltage limits using parameter
95.35.
With these parameter settings, a resistor overtemperature situation will trip the inverter
which will then coast to a stop.

WARNING! Connect the brake resistor to the inverter module before enabling the
brake chopper. On the other hand, if the chopper is disabled, the resistor must be
disconnected.

For settings with other control programs, see the appropriate firmware manual.
 Resistor braking using frame R1i…R4i inverter modules 331

Technical data
 Ratings
Output ratings Brake resistor example
Inverter unit type
Pbrcont Pbrmax Rmin R Pn ER
ACS880-104-… Type
kW kW ohm ohm W kJ
UN = 400 V
004A8-3 1.8 3.3 120
JBR-01 (Danotherm
006A0-3 1.9 3.3 120 120 105 22
CAR 155 D T 414 120R)
008A0-3 1.9 3.3 120
JBR-03 (Danotherm
0011A-3 2.8 50 80 80 135 40
CAR 200 D T 415 80R)
0014A-3 5.7 10.0 40 JBR-04 (Danotherm
40 360 73
0018A-3 5.7 10.0 40 CBR-V 210 D T 415 40R)
0025A-3 11.4 20.0 20 JBR-05 (Danotherm
20 570 77
0035A-3 11.4 20.0 20 CBR-V 330 D T 415 20R)
0044A-3 17.5 30.8 13
0050A-3 17.5 30.8 13
0061A-3 17.5 30.8 13 JBR-06 (Danotherm
13 790 132
0078A-3 17.5 30.8 13 CBR-V 460 D HT 415 13R)
0094A-3 17.5 30.8 13
0100A-3 17.5 30.8 13
UN = 500 V
003A6-5 1.3 5.5 120
004A8-5 1.8 5.5 120 JBR-01 (Danotherm
120 105 22
006A0-5 1.9 5.5 120 CAR 155 D T 414 120R)
008A0-5 1.9 5.5 120
JBR-03 (Danotherm
0011A-5 2.8 7.9 80 80 135 40
CAR 200 D T 415 80R)
0014A-5 5.7 14.6 40 JBR-04 (Danotherm
40 360 73
0018A-5 5.7 14.6 40 CBR-V 210 D T 415 40R)
0025A-5 11.4 30.7 20
JBR-05 (Danotherm
0030A-5 11.4 30.7 20 20 570 77
CBR-V 330 D T 415 20R)
0035A-5 11.4 30.7 20
0050A-5 17.5 43.9 13
0061A-5 17.5 43.9 13 JBR-06 (Danotherm
13 790 132
0078A-5 17.5 43.9 13 CBR-V 460 D HT 415 13R)
0094A-5 17.5 43.9 13

Definitions

Pbrcont Maximum continuous braking power. The braking is considered continuous if the braking time
exceeds 30 seconds.
Pbrmax Maximum braking power of the inverter module and its internal brake chopper. The inverter and
chopper will withstand this braking power for 1 second within every 10 seconds.
Note: The listed resistors will withstand this braking power for 1 second within every 120
seconds.
Rmin Minimum allowed resistance of the brake resistor.
R Resistance of the listed resistor.
Pn Continuous power (heat) dissipation of the listed resistor when placed correctly.
ER Short energy pulse that the listed resistor will withstand every 400 seconds.

The ratings apply at an ambient temperature of 40 °C (104 °F).

The listed brake resistors are protected to IP20. Refer to page 332 for dimensions, wire
sizes and tightening torques for the resistors.
332 Resistor braking using frame R1i…R4i inverter modules

 Resistor dimensions
 Resistor braking using frame R1i…R4i inverter modules 333

Resistor type
Parameter
JBR-01 JBR-03 JBR-04 JBR-05 JBR-06
Dim. A mm (in.) 295 (11.61) 340 (13.39) – – –
Dim. B mm (in.) 155 (6.10) 200 (7.87) – – –
Dim. C mm (in.) 125 (4.92) 170 (6.69) – – –
Dim. D mm (in.) – – 345 (13.58) 465 (18.31) 595 (23.43)
Dim. E mm (in.) – – 210 (8.27) 330 (12.99) 460 (18.11)
Dim. F mm (in.) – – 110 (4.33) 230 (9.06) 360 (14.17)
Weight kg (lbs) 0.75 (1.7) 0.8 (1.8) 1.8 (4.0) 3.0 (6.6) 3.9 (8.6)
Max. wire size –
10 mm 2 (AWG6)
Main terminals
Tightening torque –
1.5 … 1.8 N·m (13 … 16 lbf·in)
Main terminals
Max. wire size – Thermal
4 mm2 (AWG12)
switch terminals
Tightening torque – Thermal
0.6 … 0.8 N·m (5.3 … 7.1 lbf·in)
switch terminals

 Resistor connectors on inverter modules

R+ and R- terminals Frame R1i
U2, V2, W2: 0.25…4 mm2, 0.5 … 0.6 N·m (4.4 …5.3 lbf·in)
Ground: 1.5 N·m (13 lbf·in)
Frame R2i
U2, V2, W2: 0.5 … 6 mm2, 1.2 … 1.5 N·m (10.6 … 13.3 lbf·in)
Ground: 1.5 N·m (13 lbf·in)
Frames R3i and R4i
U2, V2, W2: 6…70 mm 2. Allen screw torque 15 N·m (11 lbf·ft), connection
post torque 4 N·m (30 lbf·in). Other conductor sizes can be used by
replacing the original lug with a suitable crimp ring terminal.
Ground: Screw size M5, torque 3 N·m (25 lbf·in)
Connector cover screws: Torque 3 N·m (25 lbf·in)
334 Resistor braking using frame R1i…R4i inverter modules
 Dimension drawings 335

14
Dimension drawings

Contents of this chapter

This chapter contains dimension drawings of the ACS880-104 inverter modules as well as
auxiliary components. Dimensional drawings of most installation accessories are available
from ABB on request.
336 Dimension drawings

Frame R1i
 Dimension drawings 337

Frame R2i
338 Dimension drawings

Frame R3i
 Dimension drawings 339

Frame R4i
340 Dimension drawings

Frame R5i
 Dimension drawings 341

Frame R6i
342 Dimension drawings

Frame R7i
 Dimension drawings 343

Frame R8i
344 Dimension drawings
 Dimension drawings 345

Frame R8i with option +P942 (ACS800 retrofit)

346 Dimension drawings
Dimension drawings 347
348 Dimension drawings

Control electronics
 ZCU-14 control unit
Note: The control cable grounding plate can be attached to either top or bottom edge of
the control unit.
 Dimension drawings 349

 BCU control unit

110 [4.33”]

115 [4.53”]
350 Dimension drawings

 DPMP-01 door mounting kit

11 [0.43]
Aperture size:
109 × 223 mm (4.29” × 8.78”)
Plate thickness:
1.5 … 2.5 mm (0.059…0.098”)

36.4 [1.43]
86.5 [3.41]
122.3 [4.81]

261.8 [10.31]

259.2 [10.20]
239.8 [9.44]

123.1 [4.85]
11 [0.43]
125 [4.92]
 Dimension drawings 351

DC fuses and fuse bases

 Fuse, 14 × 51 mm

14.3 mm
50.8 mm (2.000”) (0.563”)

15.5 mm
(0.610”)

 Mersen US141 (Z331153F) fuse disconnector (for 14 × 51 mm fuses)

352 Dimension drawings

 Fuse, 27 × 60 mm

60,3
60,3
77mm
indicator
travel
Ø 27

4 27 Ø5mm
4 5

 Mersen US271MI (R227600C) fuse disconnector (for 27 × 60 mm

fuses)
117

Fixation Fixation 87
5.25 40 40 8

Fixation 75 35
130
146 118 25.5

6.5 57
3
40
80
120
 Dimension drawings 353

 Mersen PS272PREMCPS (N220076) fuse disconnector (for R5i,

27 × 60 mm fuses)

Twin terminal covers

PS 27
Part #: A 220087
Weight: 30g
Packaging: 3 twins

Y

14
6

MC PS 

180
107

4
71

2
1
57
46
24

2.5 7.5 ø11.5 2

ø6.5 1

V
W 35 15
W'
Z
14
Z'
20

V: 93 Connecting distance between centers

W: 150 Without terminals cover length
W’: 240 With terminals cover length
Y: 196 Space factor with a 90° fuse carrier position
Z: 284 Without terminal cover, space factor with a 180° fuse carrier position
Z’: 279 With terminal cover, space factor with a 180° fuse carrier position
354 Dimension drawings

 DC fuse blocks for frames R5i…R8i (Bussmann)

B
A

F
H

D
E

690 V fuses (as used with 400 and 500 V units)

Size A (mm) B (mm) D (mm) E (mm) F G (mm) H (mm)

1 50 51 69 53 M8 8 20

3 51 53 92 76 M12 10 30

3* 51 65 92 76 M12 10 30

1000…1250 V fuses (as used with 690 V units)

Size A (mm) B (mm) D (mm) E (mm) F G (mm) H (mm)

1* 74 75 59 45 M8 5 17

1 74 75 69 53 M8 8 20

3 81 83 92 76 M12 10 30
 Dimension drawings 355

Switchgear and charging components

 OS_ switch fuses
OS100GJ04FP

mm 138...205 (OXP 6x161)

in 33,4 45
53,3/2,10 1,31 5,35...8,07 1,77
17,5 81/3,19
0,69 20
8,5 0,79
0,33 60/2,36 69/2,72
95,5 11
3,76 0,43 2,5
0,10
46
1,81
6
220 36 0,24
8,66 1,42 125,5
ON
4,94
172
0

138,5
' O
'
T

6,77 5,45
65
2,56
38
M5 1,50
min 14
0,55
46 35
1,81 1,38 104,5/4,11
A

10 A1 B1 C1 mm (in)
17,5 25
0,39 0,69 0,98
A 181.5 (7.15)

A1 160 (6.30)
114 ON
110 ON

84 ON

4,49 4,33 3,31

0 0 0
' O ' O ' O
' ' '
T T T

B1 175 (6.89)

C1 190 (7.48)
356 Dimension drawings

OS160GD04F

138...205 (OXP 6x161)

33,4 81
95,5 53,3 20 45
17,5 8,5 7,2 38
5,5 2,5
43
2,5 24
114,5 C
ON 6
0
' O
Back 46
connection
'
T

types:
140 65
M5
Ø9

46 35 10 14 min

A 20 B

mm

A 181.5
10 17,5 25
B 130

ON ON ON
C 100
114 0
' O 110 0
' O 84 0
' O

A1 160
' ' '
T T T

B1 175
A1 B1 C1 C1 190
 Dimension drawings 357

OS200DZ22F
p
75
20
G OS 200:110/46 40,5
I K OS 250:116/46 3
M5
L
J
33,5 C
*) 6
45
72 5,5
0,22
D
144 M B
126
65

10,5
*) 14 min
8,6
8,4 A
N F
E 189...254
*) OS_N3: H (OXP 6X210)

A2
OS200
[mm] D22
A 149
144 B 199
C 36,5
D 144,5
A1 E 135,5
F 43,5
B2
G 20
H 219
I 40
138,5 J 10
K 8,4
L 8,6
B1 M 165
N 80
C2
A1 191
A2 95,5
B1 210
108
B2 105
C1 227
C2 113,5
C1
358 Dimension drawings

 OT_ switch/disconnectors
OT200E11

a) The shaft must extend into the switch at least 14 mm (0.55”).

 Dimension drawings 359

OT200U11

a) The shaft must extend into the switch at least 14 mm (0.55”).

360 Dimension drawings

OT400E11

a) The shaft must extend into the switch at least 20 mm (0.79”).

 Dimension drawings 361

OT400E22

a) The shaft must extend into the switch at least 20 mm (0.79”).

362 Dimension drawings

OT400U11

a) The shaft must extend into the switch at least 20 mm (0.8”).

 Dimension drawings 363

OT400U22

a) The shaft must extend into the switch at least 20 mm (0.8”).

364 Dimension drawings

OT600U11, OT630E11

a) The shaft must extend into the switch at least 20 mm (0.79”).

 Dimension drawings 365

OT1200U__, OT1600E__

mm
in 107 OT1000-1250E_ OT1600E_
122 82 4,21 OT1000-1250X_ OT1600X_
4,80 3,23 OT800U_
232 50 13,5
0,53
OT1200U_
M8 9,13 1,97
5/16 *) 83
3,27
116 A1
122
4,57 4,80

306 372
206 223,2 14,65
8,11 8,79 12,05

B1
135
*) 11
M00136/OT800U-1600E G

5,31
0,43 40 6
1,57 0,24
189 B 176 22,5
7,44
6,93 0,89
50 20
1,97 0,79
A C1
251...380 (OXP12x280)
*) N3 types 9,84...14,96
167
6,57
62,5 15
2,46 0,59
166,5 / 105
_11 _22
6,56 / 4,13 *) 6
0,24 12
mm (in) mm (in) 0,47
A 254.50 (10.02) 414.50 (16.32) 8 22
0,31 0,87
B - 80 (3.15)

A1 214 (8.43) 374 (14.72) 8

0,31
B1 244 (9.61) 404 (15.91)
14 274
C1 270 (10.63) 430 (16.93)
108 0,55
10,79
4,25
min 20
178 131,5 min 0,79
7,01 5,18 54
127 2,13
5
70
167 2,76
6,57 80
3,15
366 Dimension drawings

OT2500E22

mm 153
in 6,02

M8 85
3,35 13,5/0,53
5/16 *) 232
9,14

6
A1 0,24
M00138/ OT2000_2500E01-04 D

168
6,61

376,5
223
8,79
14,83

*) B1 20
210 A 181 0,79 40
8,27
7,13
1,57
B
176
25 25
*) N3 types
6,93
0,98 0,98

C1

251...380 (OXP12x280)
9,84...14,96
167
6,57
mm (in)
62,5 15
A 126 (4.96) 168/107,5 2,46 0,59
6,61/4,23
B 598.5 (23.56)
*) 6
A1 558 (21.97)
0,24 12
0,47
B1 588 (23.15)
22
C1 614 (24.17) 376 8 0,87
14,81 0,31
206
8,12 min 20
min 0,79

8 274
0,31 10,79
108
4,25 14
0,55
178 131,5
7,01 5,18 54
2,13
127 70
5 2,76
167 80
6,57 3,15
 Dimension drawings 367

 OHB_ switch handles

Note: The drawings are not to scale.

OHB65J6, OHB125J12, OHB145J12

Handle type L (mm) B (mm) Notes

OHB65J6 65 6×6 Used with OS_, OT200_

OHB125J12 125 12 × 12 Used with OT400_

OHB145J12 145 12 × 12 Used with OT600_ and OT630_

OHB150J12P

Ø31 Ø5
80 71
54

ø 69,4
L 45°
53
53

Handle type L (mm) Shaft (mm) Notes

OHB150J12P 300 12 × 12 Used with OT1200U11 and OT1600E11

368 Dimension drawings

OHB274J12

The drilling pattern is

the same as
OHB65/125/145.
S07015

Handle type L (mm) Shaft (mm) Notes

Used with OT1200U22, OT1600E22 and

OHB274J12 274 12 × 12
OT2500E22

 OA1G10/OA3G01 auxiliary contact blocks

2×0.75…2.5 mm2 (2×18…14 AWG)

0.8 N·m (7 lb.in)
Pozidriv M3.5 Form 2
 Dimension drawings 369

 AF190-30-22-13 contactor

Drilling pattern
370 Dimension drawings

 Charging controller

79 (3.11”)

66.5 (2.62”)
SWITCH FUSE
CONTROLLER

BSFC-02C

247 (9.72”)
 Dimension drawings 371

 CAV 120 C resistor

 ZRF 30/165 resistor

L 165 ±3

LB 183

fxi 5.5 × 8

D MAX 34

k 6 (minimum)

e 4.2
372 Dimension drawings

Miscellaneous components
 R3G225-RH17-23 / R2E225-RA92-17 cooling fan

 CRBB/4-400/188 cooling fan

218
 Dimension drawings 373

 Output (du/dt) filters for frames R1i…R5i

374 Dimension drawings

 Common mode filters

 Quick connector for frame R8i

Dimension drawings 375
376 Dimension drawings

 Insertion/extraction ramp for frame R8i modules

Dimension drawings 377
378 Dimension drawings
 Circuit diagrams 379

15
Circuit diagrams

Contents of this chapter

This chapter contains connection diagram examples for the whole inverter unit.
Note: By default, the Safe torque off (STO) function is not in use, and has been bridged at
the factory as shown in the diagrams. For information on implementing the function, see
chapter The Safe torque off function (page 309).
380 Circuit diagrams

Component designations used in the diagrams

 Frames R1i…R5i
• R1i…R4i: see page 383
• R5i: see page 386.
Designation Component
A41.x ZCU control unit
A47 FDPI diagnostics and control panel interface. For constructing a panel bus between
inverter modules without front cover (see page 167).
A48 DPMP-01 panel mounting platform kit (to be ordered separately)
A49 ACS-AP-x control panel
F10.x Main DC fuses
F11.x Module-specific DC fuses
G26.x Roof fan
K26 Roof fan control relay
Q11 Main DC switch/disconnector
R12 du/dt filter
T11 Inverter module
T22 24 V DC power supply

 Frame R6i
See page 389.
Designation Component
A41 ZCU control unit
A47 FDPI diagnostics and control panel interface. For constructing a panel bus between
inverter modules without front cover (see page 167).
A48 DPMP-01 panel mounting platform kit (to be ordered separately)
A49 ACS-AP-x control panel
F11.x DC fuses
Q11 Main DC switch/disconnector
R12 Output (du/dt) filter
T11 Inverter module
T22 24 V DC power supply
Z1.x Common mode filters
 Circuit diagrams 381

 Frame R7i
See page 391.
Designation Component
A47 FDPI diagnostics and control panel interface. For constructing a panel bus between
inverter modules without front cover (see page 167).
A48 DPMP-01 panel mounting platform kit (to be ordered separately)
A49 ACS-AP-x control panel
A51 ZCU control unit
F11.x DC fuses
Q11 Main DC switch/disconnector
Q14 Charging contactor
R14.x Charging resistors
T11 Inverter module
T22 24 V DC power supply
Z1.x Common mode filters

 Frame R8i and multiples

The following wiring diagram examples for frame R8i inverter modules are presented in
this chapter:
• R8i: see page 393
• 2×R8i: see page 398.
Designation Component
A11.x Charging controller
A41 BCU control unit
A47 FDPI diagnostics and control panel interface. For constructing a panel bus between
inverter modules without front cover (see page 167).
A48 DPMP-01 panel mounting platform kit (to be ordered separately)
A49 ACS-AP-x control panel
F11.xx DC fuses
Q10.x Charging switch
Q11.x Main DC switch/disconnector
R10.x Charging resistors
R11.xx Common mode filters
T11.x Inverter module
T22 External 24 V DC power supply
382 Circuit diagrams
 RD10277
=11

1PE
+11.1

=-1PE
2PE
UNIT
FROM

1PE
SUPPLY

=-1PE
=-R12
NC

U2
U2 U1
C NO

=-T11

1PE
=-Q11
7K

V2
V2 V1

R1-R4
=-F11.1
>;DCP:1

>;DCM:1

Udc- 2 1 2 1

MODULE

W2
W2 W1

INVERTER
Udc+ 2 1 4 3

R-

PE
2PE NC

R+

=-1PE
14 13

MOTOR CONNECTION
C NO 020/7G
7K

PE
=-F11.2
ZCU-14

-A41
CONTROL UNIT

R4i
R3i
R2i
R1i
Optional dU/dt filter

4mm2

35mm2
16mm2
10mm2
>;DCM:2
>;DCP:2

-X13
RJ45 FOR PANEL ;A47X1:1
14K
=-A41_MEM

-X205
MEMORY MEMORY UNIT
UNIT

10
;12F11.1:1

BETATHERM
BETATHERM
BETATHERM
BETATHERM
TO NEXT

WIRES F11.1/F12.2-T11-R12
DRIVE UNIT

RELAY OUTPUT DESIGNATION ;12F11.2:1

RO1...RO3; 250VAC/30VDC, 6A -XRO1
-RO1

-XPOW
XPOW; 1-2

1
+24VDC 11_ESTOP FEEDBACK NO
To Inverter module 2

+24VDC SUPPLY

2
GND1 1=ESTOP ACTIVE NC
SEE PAGE 26
13 11 12

020/8G

020/5J
COM
+24V

;K11:A2
-X201

;F11.2:NC
MODULE
-XRO2

CONNECTION -RO2

37
11_RUNNING NO
1= RUNNING NC
23 21 22

COM
+24V ;13F11.1:1

INTERNAL FAN 1 ;13F11.2:1

-X208
1
X208; 1-2-3 INT_FAN

2
CABINET FAN CONTROL GND1

3
-XRO3

SEE PAGE 26 INT_FAN_FB

To Inverter module 3

-RO3
11_FAULT (-1) NO
1=NO FAULT NC
33 31 32

COM
+24V
INTERNAL FAN 2

-X210
1
INT_FAN

2
GND1

3
INT_FAN_FB2 DRIVE-TO-DRIVE LINK
TERMINATION JUMPER RS-485
-XD2D

FOR D2D LINK

1

J3
B ;14F11.1:1
2

TERMINATED
THERMISTOR FOR A

NC
NO
3

INCOMING AIR NOT TERMINATED BGND ;14F11.2:1

-X209
4

1
INAIR_TEMP (DEFAULT) SHIELD

C
2

=-F11.2

2D
GND1
To Inverter module N

-XAI
1

DEFAULT INPUT DESIGNATION +VREF

NC
NO
2

AI1; 0(2)...10V/-10V...+10V -VREF

3
Frames R1i…R4i – Sheet 001 (Main circuit, control unit)

DC FUSE SUPERVISION
AI2; 0(4)...20mA AGND

C
=-F11.1

1D
-AI1
4

AI1

11_SPEED REFERENCE +
5

0(2)...10V -
J1A
J1B

-AI2
6

14C
11_NOT SPECIFIED +
AI2

=-K11
7

By default not in use -

12
14
A2 A1 0(4)...20mA
J2A
J2B
SELECTOR JUMPER

11
DEFAULT OUTPUT DESIGNATION

FOR INVERTER 1
AO1, AO2; 0(4)...20mA
-XAO

DC SWITCH STATUS
-AO1
1

11_SPEED +
AI1, AI2 CURRENT/VOLTAGE

29.12.2016
29.12.2016
2

=-K12 0(4)...20mA <--> AGND

0(4)...Motor speed

12
14
A2 A1
-AO2
3

11_CURRENT +

11
4

0(4)...20mA <--> AGND

0(4)...Motor current

FOR INVERTER 2
DC SWITCH STATUS

Vanin Oleg
=-K13

Asikainen Mika
12
14

A2 A1
JUMPER IN J2B: VOLTAGE INPUT
JUMPER IN J1B: VOLTAGE INPUT
JUMPER IN J2A: CURRENT INPUT
JUMPER IN J1A: CURRENT INPUT

11

DEFAULT INPUT DESIGNATION

FOR INVERTER 3

DI1...DI6; NOMINAL VOLTAGE 24VDC

DC SWITCH STATUS
-XDI

-DI1
1

11_START/STOP
-SLOT1

=-K1N

12
14

A2 A1
-DI2
20
2

11_FORWARD/REVERSE
11

FOR INVERTER N

-DI3
3

DC SWITCH STATUS

11_RESET
OPTION SLOTS

-DI4
-SLOT2
4

11_EMERGENCY STOP
0=ACTIVE
20

ACS880-104

-DI5
5

11_RUN ENABLE
1=RUN ENABLED
ABB Drives
INU Frames R1i-R4i

-DI6
6

11_NOT IN USE
=-A47
FDPI-02
-SLOT3

OPEN
SWITCH S1
TERMINATION
20

DEFAULT INPUT/OUTPUT DESIGNATION

Main Circuit, ZCU-14 Control Unit 1/2
-XDIO

-DIO1
TERMINATED
1

11_OUTPUT:RELAY

-DIO2
2

11_OUTPUT:RUNNING
DIAGNOSTICS AND PANEL INTERFACE
J6A

-X100

-X3
-X2
-X1

1 2
-XSTO
1

OUT +24V
J6B

SGND 1 2
-XD24
1

IN1 24V DC IN1 =-K11

DIIL
2

IN2 24V DC IN2 14 11

+24VD
3

12
DICOM 8K
4

DI1...DI5
+24VD
5

FLOATING POSITION
Circuit Diagram

DIOGND
-X12

DICOM CONNECTED
;A47X1:1

=-A49
-DOOR

SAFETY J6B TO DIOGND (DEFAULT)

OPTION
ACS-AP-W
20

D3

J6A DICOM FLOATING

CONTROL PANEL

3AXD10000016758
X3

USB
6
-X100
=-A48
DPMP-01
PANEL KIT

-X103
-X102
-X101
=-XTE11

4
3
2
1

EN
020
001

001.DWG
383
384

Frames R1i…R4i – Sheet 020 (Auxiliary voltage distribution)

=11
+11.1

=-X25 CABINET ROOF FAN SUPPLY

>;F20L:1 214 >;F20L:2
NOTE: **) FAN UNIT G26.2 (IEC) and G26.4 (UL) are used only with 800mm CABINET

1
=-F21 =-F26

=-G26.1
I> I> =-X26.1 FAN UNIT =-X26.1
1 1

2
+10V RD

2 2

12
14
PWM YE =-G26.3
=-K26
=-X22 FAN UNIT
026/14B 3 3

11
11 TACHO WH
;X22:11.1 ;UL-FAN:L
1J 4 ;UL-FAN:L 4
GND BU BU
12 M
M BK 1
5 1
;UL-FAN:N 5
L BN BR
;UL-FAN:N
GNYE
6 6
13 N BU
=-X41.1 =-C3.1
7 ;UL-FAN:PE 7
PE GNYE 1
2
;UL-FAN:PE
=-X22
3

=-X22
PE1 =-G26.2
2 =-X26.2 FAN UNIT =-X26.2
**)
1 1
+10V RD
;X22:1.1
1J

1PE
1 2 2
PWM YE =-G26.4

=-20PE **) FAN UNIT

3 3
TACHO WH

4 4
GND BU BU
M
M BK 1
=-X25 5 1 5
L BN BR
>;F20N:1 204 >;F20N:2
GNYE
6 6
N BU
=-X43.1 =-C4.1
7 7 1
PE GNYE
2

=-F112
=-X21 =-X21 =-Q11
4 5 1 2 13 14 >;11F11.2:NC
I>

001/4K
001/2B
1

=-F110 =-F111

I> I>
2

=-X21
6 ;X51_24VP:1
026/12K

=-X21
7 ;X51_24VP:2
026/12K

=-T22
;X22:11.1 L 230VAC
5C + =-X21
5E
;X22:1.1 N ~ - 1 >;11K11:A2
PE 001/4K
24VDC

2 ;X51_24VN:1
026/12K
=-X22
PE2
3 ;X51_24VN:2
026/12K
2PE

=-20PE

020.DWG
29.12.2016 Vanin Oleg ACS880-104 Circuit Diagram
29.12.2016 Asikainen Mika INU Frame R1i-R4i
RD10277

Aux.Voltage Supply, Roof fans 3AXD10000016758 020

026
ABB Drives EN
 385

Frames R1i…R4i – Sheet 026 (Cabinet cooling fan control)

=11
+11.1

CABINET ROOF FAN CONTROL

=-X26.4
1

A1
2
=-K26

A2
14 11
12
020/9C
24 21
1A 2A 1A 2A 1A 2A 1A 2A
22
=-X26.3B =-X26.3B =-X26.3B =-X26.3B
1B 2B 1B 2B 1B 2B 1B 2B

2
=-R26 =-R26 =-R26 =-R26
1

1
=-A51 =-A51.2 =-A51.3 =-A51.N
1 2 3 1 2 3 1 2 3 1 2 3
-X208 -X208 -X208 -X208
GND1

GND1

GND1

GND1
INT_FAN

INT_FAN

INT_FAN

INT_FAN
INT_FAN_FB

INT_FAN_FB

INT_FAN_FB

INT_FAN_FB
CONTROL UNIT

CONTROL UNIT

CONTROL UNIT

CONTROL UNIT
ZCU-14

ZCU-14

ZCU-14

ZCU-14
+24VDC

+24VDC

+24VDC

+24VDC
GND1

GND1

GND1

GND1
-XPOW -XPOW -XPOW -XPOW
1 2 1 2 1 2 1 2

INVERTER MODULE N
24V SUPPLY FOR ZCU

24V SUPPLY FOR ZCU

24V SUPPLY FOR ZCU

24V SUPPLY FOR ZCU

INVERTER MODULE 2

INVERTER MODULE 3

=-X51B 1B 2B =-X51B 1B 2B =-X51B 1B 2B =-X51B 1B 2B

1A 2A 1A 2A 1A 2A 1A 2A

;X51_24VP:1
020/5H
;X51_24VN:1
020/5J
;X51_24VP:2
020/5J
;X51_24VN:2
020/5K

026.DWG
29.12.2016 Vanin Oleg ACS880-104 Circuit Diagram
29.12.2016 Asikainen Mika INU Frames R1i-R4i
RD10277

ZCU-14 Control unit 2/2, Roof fan control 3AXD10000016758 026

-
ABB Drives EN
 386

RD10277

1PE
=11
+11.1

=-1PE
UNIT
FROM
2PE

SUPPLY

1PE

=-1PE
NC

=-R12
U2
U2 U1 C NO

=-Q11
7K

=-T11

1PE
R5i
=-F10.1

V2
=-F11.1
V2 V1 >;DCP:1

>;DCM:1
Udc- 2 1 2 1 2 1

MODULE

W2
W2 W1

INVERTER
Udc+ 2 1 2 1 4 3

PE
NC

PE
2PE 14 13

=-1PE
C NO

MOTOR CONNECTION
7K

=-F11.2
020/7G

=-F10.2
ZCU-12

Optional dU/dt filter

CONTROL UNIT

=-A41
XPOW; 1-2
+24VDC SUPPLY +24VDC
SEE PAGE 26 GND1
>;DCM:2
>;DCP:2

=-A41_MEM

-X205
MEMORY MEMORY UNIT
UNIT

10
;12F11.1:1

-X201
TO NEXT
DRIVE UNIT

MODULE
CONNECTION RELAY OUTPUT DESIGNATION ;12F11.2:1

37
RO1...RO3; 250VAC/30VDC, 6A

-XRO1
-RO1
To Inverter module 2
READY_11 NO
1 --> READY NC

13 11 12

020/8G

020/5J
COM
+24V

;K11:A2
;F11.2:NC
-XRO2
-RO2
RUNNING_11 NO
1 --> RUNNING NC
23 21 22

COM ;13F11.1:1
+24V

;13F11.2:1
To Inverter module 3

-XRO3

-RO3
FAULT (-1)_11 NO
1 --> NO FAULT NC
33 31 32

COM
+24V

DRIVE-TO-DRIVE LINK
TERMINATION JUMPER RS-485
-XD2D

J3 FOR D2D LINK

1

;14F11.1:1
B
2

TERMINATED
A

NC
NO
3

NOT TERMINATED ;14F11.2:1

BGND
Frame R5i – Sheet 001 (Main circuit, control unit)

(DEFAULT)

C
=-F11.2

2D
To Inverter module N

-XAI
1

DEFAULT INPUT DESIGNATION +VREF

NC
NO
2

AI1; 0(2)...10V/-10V...+10V -VREF

3

AI2; 0(4)...20mA

DC FUSE SUPERVISION
AGND

C
=-F11.1

1D
-AI1
4

AI1
MOTOR TEMP MONIT_11 +
5

0(2)…10V -

J1A
J1B

-AI2
6

14C
AI2 NOT SPECIFIED_11 +
AI2

=-K11
7

BY DEFAULT NOT IN USE -

12
14
A2 A1 0 (4)…20mA
J2A
J2B
SELECTOR JUMPER

11
DEFAULT OUTPUT DESIGNATION

FOR INVERTER 1
AO1, AO2; 0(4)...20mA
-XAO

DC SWITCH STATUS
-AO1
1

CURR SOU MOT TEMP MONIT_11 +

AI1, AI2 CURRENT/VOLTAGE

29.12.2016
29.12.2016
2

0(4)…20mA

14C
AGND

=-K12

12
14
A2 A1
-AO2
3

CURRENT_11 +

11
4

0(4)…20mA <--> AGND

0(4)… MOTOR CURRENT

FOR INVERTER 2
DC SWITCH STATUS

Vanin Oleg
14C
=-K13

Asikainen Mika
12
14
A2 A1
JUMPER IN J2B: VOLTAGE INPUT
JUMPER IN J1B: VOLTAGE INPUT
JUMPER IN J2A: CURRENT INPUT
JUMPER IN J1A: CURRENT INPUT

11
DEFAULT INPUT DESIGNATION

FOR INVERTER 3
DI1...DI6; NOMINAL VOLTAGE 24VDC

DC SWITCH STATUS
-XDI

-DI1
1

START/STOP_11
1 --> START

14C
=-K1N

12
14
A2 A1
-DI2
2

FORWARD/REVERSE_11
11

1 --> REVERSE

FOR INVERTER N
-DI3
3

DC SWITCH STATUS
RESET_11

-DI4

INU R5i
-XSTO
4

OUT +24V ACC/DEC TIME_11

2

SGND SET 1 (0) / SET 2 (1)

ACS880-104
3

IN1 24V DC IN1 -DI5

5

IN2 24V DC IN2 CONSTANT SPEED 1_11

1 --> On
-X12

=-A47

SAFETY
FDPI-02

-DI6
OPTION
6

DI6 NOT IN USE_11

20

OPEN
SWITCH S1
TERMINATION

TERMINATED

DEFAULT INPUT/OUTPUT DESIGNATION

Main Circuit, ZCU-12 Control Unit 1/2
-XDIO

-DIO1
1

OUTPUT: READY_11
DIAGNOSTICS AND PANEL INTERFACE

-DIO2
-X3
-X2
-X1
-X100
2

OUTPUT: RUNNING_11

J6
-XD24
1

DIIL =-K11
2

14 11
+24VD
3

12 8K
DICOM
4

DI1...DI5 +24VD
=-A49
-DOOR

Circuit Diagram

FLOATING POSITION
5

ACS-AP-W

J6 DIOGND
DICOM CONNECTED
CONTROL PANEL

TO DIOGND (DEFAULT)
DICOM FLOATING
X3

USB
6
-SLOT3

3AXD10000332272

INTERNAL FAN 1
-X208

20
1

INT_FAN
2

-X100
=-A48

GND1
3

DPMP-01
PANEL KIT

INT_FAN_FB

INTERNAL FAN 2
-X210

-X103
-X102
-X101
1

INT_FAN X210; 1-2-3

2

GND1 CABINET FAN CONTROL

3

INT_FAN_FB2 SEE PAGE 26 (27)

-X13

THERMISTOR FOR
-X209

INCOMING AIR
1

INAIR_TEMP
=-XTE11

4
3
2
1
2

RJ45 FOR PANEL

GND1
EN
020
001

001.DWG
 387

Frame R5i – Sheet 020 (Auxiliary voltage distribution)

=11
+11.1

=-X25 CABINET ROOF FAN SUPPLY

>;F20L:1 214 >;F20L:2
NOTE: *) 400/600 mm IP20 IP42 CABINET FAN UNIT example.

1
=-F21 =-F26
*) *)
=-G26.1
I> I> =-X26.1 FAN UNIT =-X26.1
1 1

2
+10V RD

2 2

12
14
PWM YE =-G26.1
=-K26
=-X22 FAN UNIT
026/14B 3 3

11
11 TACHO WH
;X22:11.1 ;UL-FAN:L
1J 4 ;UL-FAN:L 4
GND BU BU
M
12 M BK 1
5 1
;UL-FAN:N 5
L BN BR
;UL-FAN:N
GNYE
6 6
13 N BU
-X41.1 =-C3.1
7 ;UL-FAN:PE 7
1
PE GNYE
2
;UL-FAN:PE
=-X22
3
=-X22
PE1
2

;X22:1.1
1J

1PE
1

=-20PE

=-X25
>;F20N:1 204 >;F20N:2

=-F112
=-X21 =-X21 =-Q11
4 5 1 2 13 14 ;F11.2:NC

I>
001/4K
001/2B
1

=-F110 =-F111

I> I>
2

=-X21
6 ;X51_24VP:1
026/12K

=-X21
7 ;X51_24VP:2
026/12K

=-T22
;X22:11.1 L 230VAC
5C + =-X21
5E
;X22:1.1 N ~ - 1 ;K11:A2 001/4K
PE
24VDC

2 ;X51_24VN:1
026/12K
=-X22
PE2
3 ;X51_24VN:2
026/12K
2PE

=-20PE

020.DWG
29.12.2016 Vanin Oleg ACS880-104 Circuit Diagram
29.12.2016 Asikainen Mika INU R5i
RD10277

Aux. Voltage Supply, Roof fans 3AXD10000332272 020

026
EN
388

Frame R5i – Sheet 026 (Cabinet cooling fan control)

=11
+11.1

CABINET ROOF FAN CONTROL

=-X26.4
1

A1
2
=-K26

A2
14 11
12
020/9C
24 21
1A 2A 1A 2A 1A 2A 1A 2A
22
=-X26.1B =-X26.2B =-X26.3B =-X26.4B
2 1B 2B 1B 2B 1B 2B 1B 2B

2
=-R26.1 =-R26.2 =-R26.3 =-R26.4
1

1
=-A41.1 =-A41.2 =-A41.3 =-A41.N
1 2 3 1 2 3 1 2 3 1 2 3
-X210 -X210 -X210 -X210
INT_FAN_FB 2

INT_FAN_FB 2

INT_FAN_FB 2

INT_FAN_FB 2
GND1

GND1

GND1

GND1
INT_FAN

INT_FAN

INT_FAN

INT_FAN
CONTROL UNIT

CONTROL UNIT

CONTROL UNIT

CONTROL UNIT
ZCU-12

ZCU-12

ZCU-12

ZCU-12
+24VDC

+24VDC

+24VDC

+24VDC
GND1

GND1

GND1

GND1
-XPOW -XPOW -XPOW -XPOW
1 2 1 2 1 2 1 2
INVERTER MODULE N
24V SUPPLY FOR ZCU

24V SUPPLY FOR ZCU

24V SUPPLY FOR ZCU

24V SUPPLY FOR ZCU

INVERTER MODULE 2

INVERTER MODULE 3

=-X51B 1B 2B =-X51B 1B 2B =-X51B 1B 2B =-X51B 1B 2B

4J, 5J, 6J

4J, 5J, 6J

2J, 5J, 6J

3J, 5J, 6J

2J, 4J, 6J

3J, 4J, 6J

2J, 4J, 5J

3J, 4J, 5J

1A 2A 1A 2A 1A 2A 1A 2A

;X51_24VP:1
020/5H
;X51_24VN:1
020/5J
;X51_24VP:2
020/5J
;X51_24VN:2
020/5K

026.DWG
29.12.2016 Vanin Oleg ACS880-104 Circuit Diagram
29.12.2016 Asikainen Mika INU R5i
RD10277

ZCU-12 Control unit 2/2, Roof fan control 3AXD10000332272 026

-
EN
 =11

1PE
+11.1

=-1PE
FROM
SUPPLY

1PE

U2
U2 U1

=-Q11

Z1.1-3

=-T11
=-R12.1
;DCP:2

;DCM:2

=-F11.1

V2
V2 V1
Udc- 2 1 2 1
=-R12.2

W2
R6i
W2 W1
Udc+ 2 1 4 3

MODULE
INVERTER
=-R12.3

PE

3PE
14 13

MOTOR CONNECTION
=-1PE
=-F11.2
ZCU-14

-A41
CONTROL UNIT
;DCM:3
;DCP:3

OPTIONAL dU/dt filter

-X13
RJ45 FOR PANEL ;A47X1:1
;24VM:8
;24VP:7

K13
=-A41_MEM

-X205
TO NEXT DRIVE

MEMORY MEMORY UNIT

020/K8

UNIT
020/G8

10
RELAY OUTPUT DESIGNATION
RO1...RO3; 250VAC/30VDC, 6A

-XRO1
-RO1

-XPOW
1
;24VP:1 +24VDC 11_ESTOP FEEDBACK NO

2
020/K4 ;24VM:1 GND1 1=ESTOP ACTIVE NC
COM 13 11 12
+24V

-X201
MODULE
-XRO2

CONNECTION -RO2

37
11_RUNNING NO
1= RUNNING NC
23 21 22

COM
+24V

INTERNAL FAN 1

-X208
1
INT_FAN

2
GND1

3
-XRO3

INT_FAN_FB -RO3
11_FAULT (-1) NO
1=NO FAULT NC
33 31 32

COM
+24V
INTERNAL FAN 2

-X210
1
INT_FAN

2
GND1

3
INT_FAN_FB2 DRIVE-TO-DRIVE LINK
TERMINATION JUMPER RS-485
-XD2D

FOR D2D LINK

1

J3
B
2

TERMINATED
THERMISTOR FOR A
3

INCOMING AIR NOT TERMINATED

Frame R6i – Sheet 001 (Main circuit, control unit)

BGND

-X209
4

1
INAIR_TEMP (DEFAULT) SHIELD

2
GND1
-XAI
1

DEFAULT INPUT DESIGNATION +VREF

2

AI1; 0(2)...10V/-10V...+10V -VREF

3

AI2; 0(4)...20mA AGND

-AI1
4

AI1

11_SPEED REFERENCE +
5

0(2)...10V -
J1A
J1B

-AI2
6

11_NOT SPECIFIED +
AI2
7

By default not in use -

0(4)...20mA
J2A
J2B
SELECTOR JUMPER

DEFAULT OUTPUT DESIGNATION

AO1, AO2; 0(4)...20mA
-XAO

-AO1
1

11_SPEED +
AI1, AI2 CURRENT/VOLTAGE

29.12.2016
29.12.2016
2

0(4)...20mA <--> AGND

0(4)...Motor speed

-AO2
3

11_CURRENT +
4

0(4)...20mA <--> AGND

0(4)...Motor current

Oleg Vanin
Asikainen Mika
JUMPER IN J2B: VOLTAGE INPUT
JUMPER IN J1B: VOLTAGE INPUT
JUMPER IN J2A: CURRENT INPUT
JUMPER IN J1A: CURRENT INPUT

DEFAULT INPUT DESIGNATION

DI1...DI6; NOMINAL VOLTAGE 24VDC
-XDI

-DI1
1

11_START/STOP
-SLOT1

-DI2
20
2

11_FORWARD/REVERSE

-DI3
3

11_RESET
OPTION SLOTS

-DI4
-SLOT2
4

11_EMERGENCY STOP
Frame R6i

0=ACTIVE
20

ACS880-104

-DI5
5

11_RUN ENABLE
1=RUN ENABLED
ABB Drives

-DI6
020/G6
=-K112

11_NOT IN USE 12
=-A47

11 14
FDPI-02
-SLOT3

OPEN
SWITCH S1
TERMINATION
20

DEFAULT INPUT/OUTPUT DESIGNATION

Drive Module & ZCU-14 Control Unit
-XDIO

-DIO1
TERMINATED
1

11_OUTPUT:RELAY

-DIO2
2

11_OUTPUT:RUNNING
DIAGNOSTICS AND PANEL INTERFACE
J6A

-X100

-X3
-X2
-X1

1 2
-XSTO
1

OUT +24V
J6B

SGND 1 2
-XD24
1

IN1 24V DC IN1 DIIL

2

IN2 24V DC IN2 +24VD

3

DICOM
4

DI1...DI5
+24VD
5

FLOATING POSITION
Circuit diagram

DIOGND
-X12

DICOM CONNECTED
;A47X1:1

=-A49
-DOOR

SAFETY J6B TO DIOGND (DEFAULT)

OPTION
ACS-AP-W
20

E3

J6A DICOM FLOATING

CONTROL PANEL

3AXD10000027152
X3

USB
6
-X100
=-A48
DPMP-01
PANEL KIT

-X103
-X102
-X101

EN
020
001

001.DWG
389
390

Frame R6i – Sheet 020 (Auxiliary voltage distribution)

=11 AUXILIARY VOLTAGE DISTRIBUTION

+11.1

=-X25
FROM SUPPLY UNIT ;F22L:1 211 ;F22L:2 TO NEXT DRIVE UNIT

1
=-F22

I>

2
=-X22
11
;X22:11
J1

12

=-X22
PE1

=-X22

1PE
3

=-20PE

;X22:1
J1
1

=-X25 =-X25
204 FROM SUPPLY UNIT ;F22N:1 201 ;F22N:2 TO NEXT DRIVE UNIT

24V CONTROL VOLTAGE DISTRIBUTION

=-F112
=-X21 =-K112
3 1 2 A1 A2 ;24VP:7
I>

001/D3

12
=-F110
1

11 14
001/C12

I>
2

5 ;24VP:1

=-T22 001/K4
;X22:11 L 230VAC
C4 + =-X21
D4
;X22:1 N ~ - 1 ;24VM:1
PE
24VDC

=-X22 2
PE2
2PE

;24VM:8
001/D3
=-20PE

020.DWG
29.12.2016 Oleg Vanin ACS880-104 Circuit diagram
29.12.2016 Asikainen Mika Auxiliary Voltage Supply
Frame R6i 3AXD10000027152 020
-
ABB Drives EN
 =12

1PE
+12.1

=-1PE
FROM
SUPPLY

1PE

U2
U2 U1

=-Q11

Z1.1-3

=-T11
=-R12.1
;DCP:2

;DCM:2

=-F11.1

V2
V2 V1
Udc- 2 1 2 1
=-R12.2

W2
R7i
W2 W1
Udc+ 2 1 2 1 4 3

MODULE
INVERTER
=-R12.3

PE

3PE
K6
14 13

MOTOR CONNECTION
=-1PE
=-Q14
4 3

=-F11.2
6 5

ZCU-14

-A41
CONTROL UNIT
;DCM:3
;DCP:3

=-R14.1

OPTIONAL dU/dt filter

2 1

-X13
RJ45 FOR PANEL
;24VM:8
;24VP:7

=-R14.2
=-A41_MEM 2 1

-X205
TO NEXT DRIVE

MEMORY MEMORY UNIT

020/K8

UNIT
020/G8

10
RELAY OUTPUT DESIGNATION
RO1...RO3; 250VAC/30VDC, 6A

-XRO1
-RO1

-XPOW
1
;24VP:1 +24VDC 12_ESTOP FEEDBACK NO

2
020/J4 ;24VM:1 GND1 1=ESTOP ACTIVE NC
COM 13 11 12
+24V

;A47X1:1
K14

-X201
MODULE
-XRO2

CONNECTION -RO2

37
12_RUNNING NO
1= RUNNING NC
23 21 22

COM
+24V

=-T11
INTERNAL FAN 1

-X208

-X7
1
INT_FAN

2
1
GND1

3
-XRO3

CONT+
INT_FAN_FB -RO3
12_FAULT (-1) NO
1=NO FAULT

K6
E2
E2
E2
NC

=-Q14
33 31 32

COM

5
3
1
+24V

13
2 A2 A1 INTERNAL FAN 2

-X210
1

CONT-
INT_FAN

6
4
2

14
2
GND1

3
INT_FAN_FB2 DRIVE-TO-DRIVE LINK
TERMINATION JUMPER RS-485

=-Q14
K6
-XD2D

FOR D2D LINK

1

3 13 14 J3

FB OUT
B
2

TERMINATED
THERMISTOR FOR A
3

4 INCOMING AIR NOT TERMINATED BGND

Frame R7i – Sheet 001 (Main circuit, control unit)

-X209

IN
4

1
INAIR_TEMP (DEFAULT) SHIELD

2
GND1
-XAI
1

DEFAULT INPUT DESIGNATION +VREF

2

AI1; 0(2)...10V/-10V...+10V -VREF

3

AI2; 0(4)...20mA AGND

-AI1
4

AI1

12_SPEED REFERENCE +
5

0(2)...10V -
J1A
J1B

-AI2
6

12_NOT SPECIFIED +
AI2
7

By default not in use -

0(4)...20mA
J2A
J2B
SELECTOR JUMPER

DEFAULT OUTPUT DESIGNATION

AO1, AO2; 0(4)...20mA
-XAO

-AO1
1

12_SPEED +
AI1, AI2 CURRENT/VOLTAGE

29.12.2016
29.12.2016
2

0(4)...20mA <--> AGND

0(4)...Motor speed

-AO2
3

12_CURRENT +
4

0(4)...20mA <--> AGND

0(4)...Motor current

Vanin Oleg
Asikainen Mika
JUMPER IN J2B: VOLTAGE INPUT
JUMPER IN J1B: VOLTAGE INPUT
JUMPER IN J2A: CURRENT INPUT
JUMPER IN J1A: CURRENT INPUT

DEFAULT INPUT DESIGNATION

DI1...DI6; NOMINAL VOLTAGE 24VDC
-XDI

-DI1
1

12_START/STOP
-SLOT1

-DI2
20
2

12_FORWARD/REVERSE

-DI3
3

12_RESET
OPTION SLOTS

-DI4
-SLOT2
4

12_EMERGENCY STOP
Frame R7i

0=ACTIVE
20

ACS880-104

-DI5
5

12_RUN ENABLE
1=RUN ENABLED
ABB Drives

-DI6
020/G6
=-K112

12_NOT IN USE 12
=-A47

11 14
FDPI-02
-SLOT3

OPEN
SWITCH S1
TERMINATION
20

DEFAULT INPUT/OUTPUT DESIGNATION

-XDIO

-DIO1
TERMINATED

Drive Module & ZCU-14 Control Board

1

12_OUTPUT:RELAY

-DIO2
2

12_OUTPUT:RUNNING
DIAGNOSTICS AND PANEL INTERFACE
J6A

-X100

-X3
-X2
-X1

1 2
-XSTO
1

OUT +24V
J6B

SGND 1 2
-XD24
1

IN1 24V DC IN1 DIIL

2

IN2 24V DC IN2 +24VD

3

DICOM
4

DI1...DI5
+24VD
5

FLOATING POSITION
Circuit diagram

DIOGND
-X12

DICOM CONNECTED
;A47X1:1

=-A49
-DOOR

SAFETY J6B TO DIOGND (DEFAULT)

OPTION
ACS-AP-W
20

C4

J6A DICOM FLOATING

CONTROL PANEL

3AXD10000029831
X3

USB
6
-X100
=-A48
DPMP-01
PANEL KIT

-X103
-X102
-X101

EN
020
001

001.DWG
391
392

Frame R7i – Sheet 020 (Auxiliary voltage distribution)

=12 AUXILIARY VOLTAGE DISTRIBUTION

+12.1

=-X25
FROM SUPPLY UNIT ;F22L:1 211 ;F22L:2 TO NEXT DRIVE UNIT

1
=-F22

I>

2
=-X22
11
;X22:11
J1

12

=-X22
PE1

=-X22

1PE
2

=-20PE

;X22:1
J1
1

=-X25 =-X25
204 FROM SUPPLY UNIT ;F22N:1 201 ;F22N:2 TO NEXT DRIVE UNIT

24V CONTROL VOLTAGE DISTRIBUTION

=-F112 =-K112
=-X21
1 1 2 A1 A2 ;24VP:7
I>

001/D3

12
=-F110 11 14
1

001/C12

I>
2

2 ;24VP:1

=-T22 001/J4
;X22:11 L 230VAC
C4 + =-X21
D4
;X22:1 N ~ - 3 ;24VM:1
PE
24VDC

=-X22
PE2
2PE

;24VM:8
001/D3
=-20PE

020.DWG
29.12.2016 Vanin Oleg ACS880-104 Circuit diagram
29.12.2016 Asikainen Mika Auxiliary Voltage Distribution
Frame R7i 3AXD10000029831 020
-
ABB Drives EN
 393

Frame R8i (with DC switch) – Sheet 001 (DC circuit)

=11
+11.1
CHARGING CIRCUIT MAIN CIRCUIT
DC BUS
+ +
- -

-A11.1
BSFC-02

1
SWITCH FUSE CONTROLLER

=-UDC+
X1:1

1
IR+
X1:2

=-UDC-
X1:3
IR-
DIS
X2:1 S1
IR2+ EN
X2:2
X2:3 IR2- DIS
S2
EN
X3:1 -R10.1
IR3+
X3:2 DIS
X3:3 S3
IR3- EN
X4:1

1
15V -Q10.1
;Q10.1:2 X4:2

-R2.1

-R1.1
-R4.1

-R3.1
2

2
7D AUX2

2
X4:3
GND
GND1 X4:4

3
-GND GND

1
;Q10.1:2

;Q10.1:1
X5:1
L

8
X5:2 N
X5:3
PE

4D

2H
X5:4
-Q11.1

13

33
21

41
2

4
X5:5 LSOL
X5:6 NSOL

14

22

34
42
;I1V60 V1
STAT
005/5H ;I1V50 V2 INV 1
UDC

;X13:3
;X13:4
;X13:5
;X13:6
V3
STAT
V4 INV 2
UDC
V5

2K

2K
STAT
V6 INV 3
UDC

-K11.1
A2 A1

2
=-UDC+
2
=-UDC-
1

1
-F11.11 -F11.12
8D

2
;Q10.1:1

=-R11.1

-T11.1

-X13 -X13 -X13 - +

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1PE
-1.1PE
;X22:13.2

;X22:3.2

;X13:3

;X13:4

;X13:5

;X13:6

inverter
=-DOOR
module R8i
X1
020/4C

020/4D

-P11.1
14E

15E

GREEN
X2

Load OK
U2 V2 W2

-X11.1

U2 V2 W2 1.1PE

001.DWG
MOTOR CONNECTION

05.01.2017 Vanin Oleg ACS880-104-0760A-3+C183 Circuit Diagram

05.01.2017 Asikainen Mika 1xR8i INU
DC Main circuit, Charging circuit 3AXD10000077658 001
005
ABB Drives EN
394

Frame R8i (with DC switch) – Sheet 005 (Inverter module)

=11
+11.1 INVERTER MODULE 1xR8i

=-T11.1

=-X50.1
1 FAN U

2 FAN V

3 FAN W

;X22:13.1 4 BDPS L
020/4C
;X22:3.1 5 BDPS N
020/4D
6
;HEAT.1:L 7 HEAT L

020/14G ;HEAT.1:N 8 HEAT N

=-X53.1
1 GND BCON

2 24VDC BCON

3 GND

4 24 VDC

5 FE

;A41:V1R V10
040/4K
;A41:V1T V20

V30
V40
V60 ;I1V60
V50 ;I1V50 001/4E

DC FAN AC FAN
X54 X55

FAN BOX

DC FAN HEATER

V1
V2

005.DWG
05.01.2017 Vanin Oleg ACS880-104-0760A-3+C183 Circuit Diagram
05.01.2017 Asikainen Mika 1xR8i INU
Module connections 3AXD10000077658 005
020
ABB Drives EN
 395

Frame R8i (with DC switch) – Sheet 020 (Auxiliary voltage distribution)

=11 AUXILIARY VOLTAGE DISTRIBUTION

+11.2

=-X25
211 >;F22L:1
From Main Supply
(or Previous Drive Unit)

1
=-F21 =-F26

I> I>

2
=-X22
11 =-X22
15
;HEAT.CTRL:L
11J
12
;X22:11
1J
13
;X22:13.1
005/1C
;X22:13.2
001/2K

;X22:3.1 FAN UNIT

005/1C
=-X22 ;X22:3.2
3 001/2K =-G26 L
L
M N
1
N
PE PE
2
;X22:1
1J =-X22
PE2
1

2PE
;HEAT.CTRL:N
11K
=-20PE

=-X22 =-X25
PE1 201 >;F22N:1
From Main Supply
(or Previous Drive Unit)
1PE

=-20PE

=-F95 =-K95
21 24
;HL 2 1 13J 22 ;HEAT.1:L

I>
24V CONTROL VOLTAGE DISTRIBUTION EXTERNAL SUPPLY FOR
MODULES HEATERS 005/1C
;HN 4 3 ;HEAT.1:N

I>
for option C183
=-X21 14 11
4 12

5 ;X21:5.1
040/3K
MODULES
HEATERS
CONTROL
6

=-T22 ;HEAT.CTRL:L
4C
4C
;X22:11 L 230VAC
+ =-X21
4D
;X22:1 N ~ - 1

A1
PE
24VDC =-K95

A2
=-X22 2 ;X21:2.1
040/3K ;HEAT.CTRL:N
PE2 4E
2PE

24 21
3
22
=-20PE 13G

020.DWG
05.01.2017 Vanin Oleg ACS880-104-0760A-3+C183 Circuit Diagram
05.01.2017 Asikainen Mika 1xR8i INU
Aux. voltage distribution 3AXD10000077658 020
040
ABB Drives EN
 396

=11
+11.2

BCU-02
DRIVE CONTROL UNIT

=-A41

V24
V23
V22
V21
=-A41_MEM

-X205
MEMORY MEMORY UNIT
UNIT

10
RED
-XETH

FAULT
WRITE
GREEN
GREEN
RJ45 FOR PC

-X9
YELLOW
SD CARD SD CARD

POWER OK

9
BATTERY OK

-XPOW
1
;X21:5.1 +24VIN1 RELAY OUTPUT DESIGNATION
020/4H

2
;X21:2.1 0VIN1 RO1...RO3; 250VAC, 6A/24VDC, 6A
020/4K

3
-XRO1
+24VIN2 -RO1

4
0VIN2 -A41 READY NO
1 = READY NC
0(4)...20mA

13 11 12
COM
+24V

POWER STAGE LINKS

;A41:V1T -V1T

-XRO2
CH1 -RO2
005/1D ;A41:V1R -V1R -A41 RUNNING NO
1 = RUNNING NC
0(4)...20mA

23 21 22
COM
+24V

-V2T
-V2R
CH2

-XRO3
-RO3
-A41 FAULTED (-1) NO
NC
COM 33 31 32
+24V -X485
5

D2D LINK
B
6

AI1 I/U SELECTION TERMINATION

A
7

S4 I S6 ON BGND
8

U OFF SHIELD

RS-485
-XD2D

FOR D2D LINK

1

AI2 I/U SELECTION GROUND SELECTION

B
2

S5 I S7 ON A
3

U OFF BGND
4

DICOM = DIOGND SHIELD

-XAI

DEFAULT INPUT DESIGNATION

1

+10VREF
AI1; 0(2)...10V/-10V...+10V
2

AGND
3

AI2; 0(4)...20mA
-10VREF
-AI1
Frame R8i (with DC switch) – Sheet 040 (Control unit)

-A41 SPEED REFERENCE +

5

0(2)...10V -

-AI2
6

-A41 NOT SPECIFIED +

7

By default not in use -

0(4)...20mA

DEFAULT OUTPUT DESIGNATION

AO1, AO2; 0(4)...20mA
-AO1
-XAO
1

-A41 SPEED +
2

0(4)...20mA <--> AGND

0(4)...Motor speed

-AO2
3

-A41 CURRENT +

05.01.2017
05.01.2017
4

0(4)...20mA <--> AGND

0(4)...Motor current

DEFAULT INPUT DESIGNATION

DI1...DI6+DIIL; NOMINAL VOLTAGE 24VDC
S7
DCCOM

Vanin Oleg
-XDI

-DI1
1

-A41 START/STOP

Asikainen Mika
-DI2
2

-A41 FORWARD/REVERSE

-DI3
3

-A41 RESET
1 = Reset
0(4)...20mA

-DI4
4

-A41 ACC/DEC SELECT_11

-DI5
5

-A41 CONSTANT SPEED1

1xR8i INU
-XSTO
1

OUT1 +24V -DI6

6

SGND -A41 NOT SPECIFIED

3

By default not in use

XSTO

IN1 24V DC IN1 0(4)...20mA

4

IN2 24V DC IN2 -DIIL

=-A47

ABB Drives
7

FDPI-02

-A41 START INTERLOCK

see page 061

SINE FILTER OVERTEMP

0 = START INTERLOCK
OPEN
SWITCH S1

Drive control unit BCU-02

TERMINATION

ACS880-104-0760A-3+C183
TERMINATED

DEFAULT INPUT/OUTPUT DESIGNATION

-XSTO.OUT
5

IN1
-XDIO

-DIO1
6

SGND
1

-A41 NOT SPECIFIED +

7

IN2
3

By default not in use 0VD

8

SGND 0(4)...20mA
DIAGNOSTICS AND PANEL INTERFACE
XSTO.OUT
see page 061

-DIO2
-X3
-X2
-X1
-X100
2

-A41 NOT SPECIFIED +

4

SAFETY OPTION By default not in use 0VD

0(4)...20mA
-X12
20

0VD
-SLOT1
-XD24

OPTION SLOTS
5

20

+24DI
=-A49
-DOOR
6

DCOM
7

ACS-AP-W

Circuit Diagram

+24DI
8

0VD
-SLOT2

CONTROL PANEL
20

X3

USB
6
-SLOT3

3AXD10000077658
20

-X100
=-A48
DPMP-01
PANEL KIT

COMMUNICATION OPTION
-SLOT4

RDCO-04
20

-X103
-X102
-X101
-X13

=-XTE11

4
3
2
1

EN
061
040

040.DWG
 397

Frame R8i (with DC switch) – Sheet 061 (STO)

=11
+11.2

=-A41
BCU-02 =11
CONTROL UNIT
+11.1

=-T11.1

STO
-XSTO.OUT =-X52.1 =-X51.1
IN1 5 1 1

-XSTO SGND 6 2 2
1 OUT +24V IN2 7 3 3
2 SGND SGND 8 4 4
5 5

3 IN1 24V DC IN1

4 IN2 24V DC IN2

-X12
1
/
20 SAFETY OPTION

061.DWG
05.01.2017 Vanin Oleg ACS880-104-0760A-3+C183 Circuit Diagram
05.01.2017 Asikainen Mika 1xR8i INU
BCU-02 & R8i module STO default connection 3AXD10000077658 061
-
ABB Drives EN
398

Frame 2×R8i – Sheet 001 (DC circuit)

=11
+11.1

DC MAIN CIRCUIT
DC BUS
+ +
- -

1
-F11.11 -F11.12 -F11.21 -F11.22

2
=-R11.11-12 =-R11.21-22

=-T11.1 =-T11.2
- + - +

inverter inverter
module R8i module R8i

U2 V2 W2 U2 V2 W2

-X11.1 -X11.2

U2 V2 W2 1.1PE U2 V2 W2 1.2PE

MOTOR CONNECTION MOTOR CONNECTION

001.DWG
29.12.2016 Vanin Oleg ACS880-104-1150A-5+C183+C188 Circuit Diagram
29.12.2016 Asikainen Mika 2xR8i INU
DC Main circuit 3AXD10000407765 001
005
ABB Drives EN
 399

Frame 2×R8i – Sheet 003 (Inverter modules)

=11
+11.1 INVERTER MODULE S 2xR8i

DOL fan supply

;F112L:1

;F112L:2

;F112L:3
1

5
=-F115.1

I> I> I>

2

6
=-T11.1 =-T11.2

=-X50.1 =-X50.2
1 FAN U 1 FAN U

2 FAN V 2 FAN V

3 FAN W 3 FAN W

;X22:13.1 4 BDPS L 4 BDPS L

020/4C
;X22:3.1 5 BDPS N 5 BDPS N
020/4D
6 6
;HEAT.1:L 7 HEAT L 7 HEAT L

020/14G ;HEAT.1:N 8 HEAT N 8 HEAT N

9 9

=-X53.1 =-X53.2
1 GND BCON 1 GND BCON

2 24VDC BCON 2 24VDC BCON

3 GND 3 GND

4 24 VDC 4 24 VDC

5 FE 5 FE

;A41:V1R V10 ;A41:V2R V10

040/4K 040/5K
;A41:V1T V20 ;A41:V2T V20

V30 V30
V40 V40
V60 V60
V50 V50

DC FAN AC FAN DC FAN AC FAN

X54 X55 X54 X55

FAN BOX FAN BOX

HEATER HEATER
DOL FAN DOL FAN
V1 V1
V2 V2

005.DWG
29.12.2016 Vanin Oleg ACS880-104-1150A-5+C183+C188 Circuit Diagram
29.12.2016 Asikainen Mika 2xR8i INU
Modules connections 3AXD10000407765 005
020
ABB Drives EN
400

Frame 2×R8i – Sheet 020 (Auxiliary voltage distribution)

=11 AUXILIARY VOLTAGE DISTRIBUTION

+11.2

=-X25
211 >;F22L:1
From Main Supply
(or Previous Drive Unit)

1
=-F21 =-F26

I> I>

2
=-X22
11 =-X22
15
;HEAT.CTRL:L
11J
12
;X22:11
1J
13
;X22:13.1
005/1C

;X22:3.1 FAN UNIT

005/1C
=-X22
3 =-G26 L
L
M N
1
N
PE PE
2
;X22:1
1J =-X22
PE2
1

2PE
;HEAT.CTRL:N
11K
=-20PE

=-X22 =-X25
PE1 201 >;F22N:1
From Main Supply
(or Previous Drive Unit)
1PE

=-20PE

=-F95 =-K95
21 24
;HL 2 1 13J 22 ;HEAT.1:L

I>
24V CONTROL VOLTAGE DISTRIBUTION EXTERNAL SUPPLY FOR
MODULES HEATERS 005/1C
;HN 4 3 ;HEAT.1:N

I>
for option C183
=-X21 14 11
4 12

5 ;X21:5.1
040/3K
MODULES
HEATERS
CONTROL
6

=-T22 ;HEAT.CTRL:L
4C
4C
;X22:11 L 230VAC
+ =-X21
4D
;X22:1 N ~ - 1

A1
PE
24VDC =-K95

A2
=-X22 2 ;X21:2.1
040/3K ;HEAT.CTRL:N
PE2 4E
2PE

24 21
3
22
=-20PE 13G

020.DWG
29.12.2016 Vanin Oleg ACS880-104-1150A-5+C183+C188 Circuit Diagram
29.12.2016 Asikainen Mika 2xR8i INU
Aux.voltage distribution 3AXD10000407765 020
040
ABB Drives EN
 =11
+11.2

BCU-02
DRIVE CONTROL UNIT

=-A41

V24
V23
V22
V21
=-A41_MEM

-X205
MEMORY MEMORY UNIT
UNIT

10
RED
-XETH

FAULT
WRITE
GREEN
GREEN
RJ45 FOR PC

-X9
YELLOW
SD CARD SD CARD

POWER OK

9
BATTERY OK

-XPOW
1
;X21:5.1 +24VIN1 RELAY OUTPUT DESIGNATION
020/4H

2
;X21:2.1 0VIN1 RO1...RO3; 250VAC, 6A/24VDC, 6A
020/4K

3
-XRO1
+24VIN2 -RO1

4
0VIN2 -A41 READY NO
1 = READY NC
0(4)...20mA

13 11 12
COM
+24V

POWER STAGE LINKS

;A41:V1T -V1T
-XRO2
CH1 -RO2
005/1D ;A41:V1R -V1R -A41 RUNNING NO
1 = RUNNING NC
0(4)...20mA
23 21 22

COM
+24V

;A41:V2T -V2T
005/3D ;A41:V2R -V2R
CH2
-XRO3

-RO3
-A41 FAULTED (-1) NO
NC
33 31 32

COM
+24V
Frame 2×R8i – Sheet 040 (Control unit)

-X485
5

D2D LINK
B
6

AI1 I/U SELECTION TERMINATION

A
7

S4 I S6 ON BGND
8

U OFF SHIELD

RS-485
-XD2D

FOR D2D LINK

1

AI2 I/U SELECTION GROUND SELECTION

B
2

S5 I S7 ON A
3

U OFF BGND
4

DICOM = DIOGND SHIELD

-XAI

DEFAULT INPUT DESIGNATION

1

+10VREF
AI1; 0(2)...10V/-10V...+10V
2

AGND
3

AI2; 0(4)...20mA
-10VREF
-AI1
4

-A41 SPEED REFERENCE +

5

0(2)...10V -

-AI2
6

-A41 NOT SPECIFIED +

7

By default not in use -

0(4)...20mA

DEFAULT OUTPUT DESIGNATION

AO1, AO2; 0(4)...20mA
-AO1
-XAO
1

-A41 SPEED +
2

0(4)...20mA <--> AGND

0(4)...Motor speed

-AO2
3

-A41 CURRENT +

29.12.2016
29.12.2016
4

0(4)...20mA <--> AGND

0(4)...Motor current

DEFAULT INPUT DESIGNATION

DI1...DI6+DIIL; NOMINAL VOLTAGE 24VDC
S7
DCCOM

Vanin Oleg
-XDI

-DI1
1

-A41 START/STOP

Asikainen Mika
-DI2
2

-A41 FORWARD/REVERSE

-DI3
3

-A41 RESET
1 = Reset
0(4)...20mA

-DI4
4

-A41 ACC/DEC SELECT_11

-DI5
5

-A41 CONSTANT SPEED1

2xR8i INU
-XSTO
1

OUT1 +24V -DI6

6

SGND -A41 NOT SPECIFIED

3

By default not in use

XSTO

IN1 24V DC IN1 0(4)...20mA

4

IN2 24V DC IN2 -DIIL

=-A47

ABB Drives
7

FDPI-02

-A41 START INTERLOCK

see page 061

SINE FILTER OVERTEMP

0 = START INTERLOCK
OPEN
SWITCH S1

Drive control unit BCU-02

TERMINATION

TERMINATED

DEFAULT INPUT/OUTPUT DESIGNATION

-XSTO.OUT
5

IN1
-XDIO

ACS880-104-1150A-5+C183+C188

-DIO1
6

SGND
1

-A41 NOT SPECIFIED +

7

IN2
3

By default not in use 0VD

8

SGND 0(4)...20mA
DIAGNOSTICS AND PANEL INTERFACE
XSTO.OUT
see page 061

-DIO2
-X3
-X2
-X1
-X100
2

-A41 NOT SPECIFIED +

4

SAFETY OPTION By default not in use 0VD

0(4)...20mA
-X12
20

0VD
-SLOT1
-XD24

OPTION SLOTS
5

20

+24DI
=-A49
-DOOR
6

DCOM
7

ACS-AP-W

Circuit Diagram

+24DI
8

0VD
-SLOT2

CONTROL PANEL
20

X3

USB
6
-SLOT3

3AXD10000407765
20

-X100
=-A48
DPMP-01
PANEL KIT

COMMUNICATION OPTION
-SLOT4

RDCO-04
20

-X103
-X102
-X101
-X13

=-XTE11

4
3
2
1

EN
061
040

040.DWG
401
402

Frame 2×R8i – Sheet 061 (STO)

=11
+11.2

=-A41
BCU-02 =11
CONTROL UNIT
+11.1

=-T11.1 =-T11.2
STO STO
-XSTO.OUT =-X52.1 =-X51.1 =-X52.2 =-X51.2
IN1 5 1 1 1 1

-XSTO SGND 6 2 2 2 2
1 OUT +24V IN2 7 3 3 3 3
2 SGND SGND 8 4 4 4 4
5 5 5 5

3 IN1 24V DC IN1

4 IN2 24V DC IN2

-X12
1
/
20 SAFETY OPTION

061.DWG
29.12.2016 Vanin Oleg ACS880-104-1150A-5+C183+C188 Circuit Diagram
29.12.2016 Asikainen Mika 2xR8i INU
BCU-02 & R8i modules STO default connection 3AXD10000407765 061
-
ABB Drives EN
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and
service contacts can be found by navigating to www.abb.com/searchchannels.

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Contact us

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3AUA0000104271 Rev G (EN) 2017-01-16