—

ABB INDUSTRIAL DRIVES

ACS880-37 drives (160 to 3200 kW)

Hardware manual
ACS880-37 drives (160 to 3200 kW)
Hardware manual

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation

10. Start-up

3AXD50000020437 Rev F
EN
Original instructions
EFFECTIVE: 2025-01-10
 Table of contents 5

Table of contents

1 Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Safety in installation, start-up, maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2 Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Use of component designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Quick installation, commissioning and operation flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3 Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Licensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overview circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cabinet line-up and layout examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Frame 1×R8i+1×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Frame 2×R8i+2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Frame 3×R8i+3×R8i (with main breaker, option +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Auxiliary control cubicle (ACU) layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Door devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Main disconnecting device (Q1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Auxiliary voltage switch [Q21] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Grounding (earthing) switch [Q9], optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Other devices on the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control by PC tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6 Table of contents

Descriptions of options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
IP22 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
IP42 (UL Type 1 Filtered) (option +B054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
IP54 (UL Type 12) (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Marine construction (option +C121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cooling air inlet through bottom of cabinet (option +C128) . . . . . . . . . . . . . . . . . . . . . . . . 48
UL Listed (option +C129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Channeled air outlet (option +C130) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CSA Approved (option +C134) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Plinth height (options +C164 and +C179) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Seismic design (option +C180) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Empty cubicles on left (options +C199…C201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
EMC filter (option +E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
du/dt filter (option +E205) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Sine filter (option +E206) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cabinet heater with external supply (option +G300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cabinet lighting (option +G301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Terminals for external control voltage (option +G307) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Output for motor space heater (option +G313) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Supply connection by busbars (option +G317) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ready/Run/Fault lights (options +G327…G329) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Halogen-free wiring and materials (option +G330) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
V-meter with selector switch (option +G334) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wire markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Standard wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Additional wire markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Voltage measurement with BAMU auxiliary measurement unit (option +G442) . 51
Common mode filter temperature monitoring (option +G453) . . . . . . . . . . . . . . . . . . . . 52
Bottom cable entry/exit (options +H350 and +H352) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Top cable entry/exit (options +H351 and +H353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cable conduit entry (option +H358) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Common motor terminal cubicle (option +H359) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Common output terminals (option +H366) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connectivity for wired remote monitoring (option +K496) . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Connectivity for wireless remote monitoring (option +K497) . . . . . . . . . . . . . . . . . . . . . . 53
Additional terminal block X504 (option +L504) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513,
+L536, +L537) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
+L505, +2L505, +L513, +2L513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
+L536, +L537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Thermal protection with Pt100 relays (options +nL506, +nL514) . . . . . . . . . . . . . . . . . . 55
Starter for auxiliary motor fan (options +M600…M610) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
What the option contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4 Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
 Table of contents 7

Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Examining the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Moving and unpacking the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Moving the drive in its packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Lifting the crate with a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Lifting the crate with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Moving the crate with a forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Removing the transport package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Moving the unpacked drive cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Lifting the cabinet with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Moving the cabinet on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Moving the cabinet on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Moving the cabinet to its final position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Attaching the cabinet to the floor and wall or roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Attaching the cabinet (non-marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Alternative 1 – Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Alternative 2 – Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Alternative 3 – Cabinets with plinth options +C164 and +C179 . . . . . . . . . . . . . . . . . . 72
Attaching the cabinet (marine units, option +C121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Joining cabinet sections together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Air inlet through the bottom of the cabinet (option +C128) . . . . . . . . . . . . . . . . . . . . . . . . . 79
Air outlet duct on the cabinet roof (option +C130) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Calculating the required static pressure difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Installation of the cabinet on an elevated platform or a recess . . . . . . . . . . . . . . . . . . . . 81
Lifting lugs and bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Certificate of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Declarations of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5 Guidelines for planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Selecting the supply transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Basic guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Additional notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
A drive larger than 500 kVA with an IGBT supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Selecting the main contactor or breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Requirements tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Requirements for ABB motors, Pn < 100 kW (134 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Requirements for ABB motors, Pn > 100 kW (134 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Requirements for non-ABB motors, Pn < 100 kW (134 hp) . . . . . . . . . . . . . . . . . . . . . . . . 91
Requirements for non-ABB motors, Pn > 100 kW (134 hp) . . . . . . . . . . . . . . . . . . . . . . . . 92
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Availability of du/dt filter and common mode filter by drive type . . . . . . . . . . . . . . 93
8 Table of contents

Additional requirements for explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . . . . . . . 93

Additional requirements for ABB motors of types other than M2_, M3_, M4_,
HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Additional requirements for braking applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Additional requirements for the regenerative and low harmonics drives . . . . . 93
Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . . 93
Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . 93
Additional data for calculating the rise time and the peak line-to-line voltage . 94
Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Power cable selection procedure and applicability check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Preferred power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Alternate power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Power cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Grounding requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Additional grounding requirements – IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Additional grounding requirements – UL (NEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Signals that can be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Control panel to drive cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
General guidelines – IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Continuous motor cable shield/conduit and metal enclosure for equipment on
the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Protecting the drive, input power cable, motor and motor cable in short circuit
situations and against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Protecting the input cabling and the drive upon a short-circuit . . . . . . . . . . . . . . . . . . . . 102
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Protecting the drive and the power cables against thermal overload . . . . . . . . . . . . . 102
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Protecting the motor against overload without thermal model or temperature
sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Implementing the Prevention of unexpected start-up function . . . . . . . . . . . . . . . . . . . . . . . . 104
Implementing an ATEX-certified motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Implementing the functions provided by the FSO safety functions module . . . . . . . . 105
Implementing the functions provided by the FSPS-21 PROFIsafe safety functions
module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Implementing the functions provided by the FSCS-21 CIP Safety™ functions
module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
 Table of contents 9

Implementing the power loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Supplying power for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Implementing the control of a contactor between drive and motor . . . . . . . . . . . . . . . . . . 108
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Connecting a motor temperature sensor to the drive through an option mod-
ule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

6 Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Measuring the insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Measuring the insulation resistance of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Measuring the insulation resistance of the motor and motor cable . . . . . . . . . . . . . . . 113
Measuring the insulation resistance of the input power cable . . . . . . . . . . . . . . . . . . . . . . 114
Compatibility check - IT (ungrounded) earthing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Attaching the device stickers to the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Checking the settings of transformers T21, T101 and T111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
T21 and T101 tap settings (400…500 V units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
T21 and T101 tap settings (690 V units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
T111 tap settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Grounding the outer shields of the control cables 360° at the cabinet entry . 117
Routing the control cables inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Connecting control cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Connecting the motor cables (units without common motor terminal cubicle or
sine output filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Motor connection diagram (without option +H366) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Motor connection diagram (with option +H366) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Removing an inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Removing the fan carriage of an inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Connecting the motor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Installing the fan carriage of an inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Installing an inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Connecting the motor cables (units with common motor terminal cubicle or sine
output filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Output busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Connecting the input power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Layout of the input cable connection terminals and cable entries . . . . . . . . . . . . . . . . . 129
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Connecting an external brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Use of fasteners in cable lug connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Panel bus (control of several units from one control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
10 Table of contents

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Installing an I/O extension, fieldbus adapter or pulse encoder option module . . 136
Installing an FSO safety functions module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Installing the FSPS-21 PROFIsafe safety functions module . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Installing the FSCS-21 CIP Safety™ functions module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

7 Control unit (UCU)

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Default I/O diagram of the supply control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Default I/O diagram of the inverter control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Additional information on the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Connecting motor temperature sensors to the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Digital interlock (DIIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Control panel connection (XPAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
The XD2D connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Safe torque off (XSTO, XSTO OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Safety functions module connection (XFSO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
MicroSDHC memory card slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Ground isolation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

8 Control unit (BCU)

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Default I/O diagram of the supply control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Default I/O diagram of the inverter control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Additional information on the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Connecting motor temperature sensors to the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Digital interlock (DIIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
The XD2D connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Safe torque off (XSTO, XSTO OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
SDHC memory card slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
BCU ground isolation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

9 Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

10 Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Switching off the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
 Table of contents 11

11 Fault tracing
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Control unit LEDs (UCU-22…24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Control unit LEDs (BCU-x2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Control panel and panel platform/holder LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

12 Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Handling fiber optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Description of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Cleaning the exterior of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Cleaning the door air inlets (IP22 and IP42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Replacing the inlet door filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Cleaning the roof outlet filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Replacing the roof outlet filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Replacing R8i module cooling fan (speed-controlled version) . . . . . . . . . . . . . . . . . . . . . . 181
Replacing R8i module cooling fan (direct-on-line version) . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Replacing the fan of the LCL filter (BLCL-1x-x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Replacing the fan of the LCL filter (BLCL-2x-x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Replacing the circuit board compartment fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Replacing the cooling fan in the incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Replacing the roof fan (IP54/UL type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Replacing the common motor terminal cubicle fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Fan attached to the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Roof fan (with options +C128 and +H353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Floor fan (with options +C128 and +H353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Replacing the brake chopper and resistor cubicle fans (options +D150 and
+D151) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Supply and inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Replacing a supply or inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Removing a supply or inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Installing a supply or inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Cleaning the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Activating the reduced run function of the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Returning the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Activating the reduced run of the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Starting reduced run operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Resuming normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
LCL filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Replacing the LCL filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Replacing the AC and DC fuses in cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
12 Table of contents

UCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

UCU control unit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Replacing the memory unit (UCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Replacing the UCU control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Replacing the microSDHC memory card (UCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
BCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
BCU control unit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Replacing the memory unit (BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Replacing the BCU control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Functional safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

13 Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Output frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Derating for output voltage boosting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Frame sizes and power module types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Brake chopper DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Cooling data, noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Sine output filter data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Input cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Output cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Terminal and cable entry data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Connection capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Terminal data for the supply and inverter control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Terminal data for block X504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Energy efficiency data (ecodesign) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Packaging of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Packaging of options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
 Table of contents 13

Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
EMC compliance (IEC/EN 61800-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
UL and CSA checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Mechanical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Insulation supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Declarations of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

14 Dimensions
Cabinet line-up dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Dimension tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Dimension drawing examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Frame 1×R8i+1×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Frame 1×R8i+1×R8i, top cable entry/exit (+H351+H353) . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Frame 1×R8i+1×R8i with brake choppers and resistors (+D150+D151) . . . . . . . . 255
Frame 1×R8i+1×R8i with sine output filter (+E206) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Frame 2×R8i+2×R8i (eg. ACS880-37-1110A-3), IP22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Frame 2×R8i+2×R8i (eg. ACS880-37-1210A-3), IP54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Frame 2×R8i+2×R8i with main breaker (+F255) and common motor terminal
cubicle (+H359), 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Frame 2×R8i+2×R8i with main breaker (+F255) and common motor terminal
cubicle (+H359), 2/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Frame 2×R8i+2×R8i with main breaker (+F255) and top entry/top exit
(+H351+H353), 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Frame 2×R8i+2×R8i with main breaker (+F255) and top entry/top exit
(+H351+H353), 2/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Frame 3×R8i+3×R8i, 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Frame 3×R8i+3×R8i, 2/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Frame 3×R8i+3×R8i with common motor terminal cubicle (+H359), 1/2 . . . . . . 265
Frame 3×R8i+3×R8i with common motor terminal cubicle (+H359), 2/2 . . . . . . 266
Dimensions of empty cubicles (options +C199, +C200, +C201) . . . . . . . . . . . . . . . . . 267
Location and size of input terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Frame 1×R8i+1×R8i, bottom cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Frame 1×R8i+1×R8i, top cable entry (+H351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Frame 2×R8i+2×R8i with main switch/disconnector (400 mm), bottom cable
entry (+H353) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Frame 2×R8i+2×R8i with main switch/disconnector (600 mm), bottom cable
entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Units with main breaker (600 mm, +F255), bottom cable entry . . . . . . . . . . . . . . . . . . . . 271
Units with main breaker (600 mm, +F255), top cable entry (+H351) . . . . . . . . . . . . . . . 271
Units with main breaker (1000 mm), top cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Units with main breaker (1000 mm), bottom cable entry (+H350) . . . . . . . . . . . . . . . . . 273
14 Table of contents

Location and size of output terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Units without common motor terminal cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Frame 1×R8i+1×R8i (without sine output filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Inverter module cubicle with two R8i modules, bottom cable exit . . . . . . . . . . . . . 274
Inverter module cubicle with two R8i modules, top cable exit . . . . . . . . . . . . . . . . . . . 275
Inverter module cubicle with three R8i modules, bottom cable exit . . . . . . . . . . . 276
Inverter module cubicle with three R8i modules, top cable exit . . . . . . . . . . . . . . . . . 277
Brake chopper cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Sine filter cubicle, 1000 mm, bottom cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Sine filter cubicle, 1000 mm, top cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Units with common motor terminal cubicle (+H359) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Cubicle width 300 mm, bottom cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Cubicle width 300 mm, top cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Cubicle width 400 mm, bottom cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Cubicle width 400 mm, top cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Cubicle width 600 mm, bottom cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Cubicle width 600 mm, top cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

15 The Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Compliance with the European Machinery Directive and the UK Supply of Ma-
chinery (Safety) Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Dual-channel connection with internal power supply (UCU) . . . . . . . . . . . . . . . . . . . . . . . . . 290
Dual-channel connection with internal power supply (BCU) . . . . . . . . . . . . . . . . . . . . . . . . . 291
Single-channel connection of activation switch (UCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Single-channel connection of activation switch (BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Multiple drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Internal power supply (example, drives with UCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Internal power supply (example, drives with BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
External power supply (example, drives with UCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
External power supply (example, drives with BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Start-up including validation test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Validation test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Validation test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Perfect proof test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Simplified proof test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
TÜV certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
 Table of contents 15

16 Resistor braking
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Factory-installed brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Ratings of chopper/resistor combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
SAFUR resistor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Terminals and cable lead-through data of factory-installed chopper/resistor
cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Verifying the load capacity of the braking equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Custom resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Calculating the maximum braking power for a custom duty cycle . . . . . . . . . . . . . 313
Selecting and routing the cables of a custom resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Selecting the installation location for the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Protecting the brake system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Thermal protection of the resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Mechanical installation of custom brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Electrical installation of custom brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Brake system start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Replacing the brake resistor cabinet fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Further information
16
 Safety instructions 17

1
Safety instructions

Contents of this chapter

This chapter contains the safety instructions which you must obey when you install,
start-up, operate and do maintenance work on the drive. If you ignore the safety
instructions, injury, death or damage can occur.

Use of warnings and notes

Warnings tell you about conditions which can cause injury or death, or damage to the
equipment. They also tell you how to prevent the danger. Notes show a particular
condition or fact, or give information.
The manual uses these warning symbols:

WARNING!
Electricity warning tells about hazards from electricity which can cause injury
or death, or damage to the equipment.

WARNING!
General warning tells about conditions other than those caused by electricity,
which can cause injury or death, or damage to the equipment.

WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
18 Safety instructions

General safety in installation, start-up and maintenance

These instructions are for all persons who do work on the drive.

WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.

• Keep the drive in its package until you install it. After unpacking, protect the drive
from dust, debris and moisture.
• Use the required personal protective equipment: safety shoes with metal toe cap,
safety glasses, protective gloves and long sleeves, etc. Some parts have sharp
edges.
• Use a lifting device to lift a heavy drive. Use the designated lifting points. Refer
to the dimension drawings.
• Obey the local laws and regulations that apply to lifting, such as the requirements
for planning the lift, the capacity and condition of the lifting equipment, and
personnel training.
• The lifting bars attached to large drive cabinets are heavy. Be careful when
removing or reinstalling the bars. Whenever possible, use a lifting device attached
to the designated lifting points.
• Attach the drive cabinet to the floor to prevent it from falling over. The cabinet
has a high center of gravity. When you pull out heavy components or power
modules, there is a risk of overturning. Attach the cabinet also to the wall when
necessary.

• Do not stand or walk on the cabinet roof. Make sure that nothing presses against
the roof, side or back plates or door. Do not store anything on the roof while the
drive is in operation.
• Do not use the module extraction/installation ramp when the height of the drive
cabinet plinth is more than the maximum permitted height.
• Secure the module extraction/installation ramp carefully.
• Push the module into the cabinet and pull it from the cabinet carefully preferably
with help from another person. Keep a constant pressure with one foot on the
base of the module to prevent the module from falling on its back. Keep your
fingers away from the edges of the front flange of the module.
 Safety instructions 19

max.

•
WARNING!
Do not move the module on its wheels for long distances. It can cause
damage to the wheels. Also, there is a risk of the module falling over.

• Be careful when handling a tall module. The module overturns easily because it is
heavy and has a high center of gravity. Whenever possible, secure the module with
chains. Do not leave an unsupported module unattended especially on a sloping
floor.

• Wear protective gloves and long sleeves! Some parts have sharp edges.
• Do not use the module extraction/installation ramp with plinth heights that are
more than the ramp maximum allowed height.
• Attach the module extraction/installation ramp carefully.
• To prevent the drive module from falling over, attach its top lifting lugs with chains
to the cabinet (1) before you move the drive module into or out of the drive cabinet.
Use two persons to move the drive module. Be careful. Keep a constant pressure
with one foot on the base of the module (2) to prevent the module from falling
on its back.
20 Safety instructions

1 1

2
2

• Make sure that the module does not fall over when you move it on the floor.
• Use the support legs when applicable. To open the support legs, push each
leg down and turn it out (1, 2).
• Use chains to support the module whenever possible.
• Do not tilt the module. It is heavy and its center of gravity is high.
• Do not leave unattended on a sloping floor.
•
WARNING!
Do not move the module on its wheels for long distances. It can cause
damage to the wheels. Also, there is a risk of the module falling over.

• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors,

and brake resistors, can be hot for a period after operation.
• Before the start-up, vacuum clean the area around the drive to prevent the drive
cooling fan from drawing dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not go into the
drive during installation. Electrically conductive debris inside the drive can cause
damage or malfunction.
• Make sure that there is sufficient cooling. Refer to the technical data.
• Keep the drive cabinet doors closed when the drive has electrical power. If the
doors of the drive cabinet are open, there is a risk of a potentially fatal electric
shock, arc flash or high-energy arc blast exists.
• If you must do work on a drive that is connected to the power supply, obey the
local laws and regulations on live electrical work. This includes, but is not limited
to, electric shock and arc protection.
• Before you adjust the drive operation limits, make sure that the motor and all
driven equipment can operate throughout the set operation limits.
• Before you activate the automatic fault reset or automatic restart functions of
the drive control program, make sure that no dangerous situations can occur.
 Safety instructions 21

These functions reset the drive automatically and continue operation after a fault
or break in the power supply. If these functions are activated, the installation must
be clearly marked as defined in IEC/EN/UL 61800-5-1, subclause 6.5.3, for example,
"THIS MACHINE STARTS AUTOMATICALLY".
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors.
• If the drive has connected safety circuits (for example, Safe torque off or
emergency stop), validate them at start-up. Refer to separate instructions for the
safety circuits.
• Beware of hot air flow from the cooling outlets.
• Do not cover the air inlet or air outlet when the drive operates.
Note:
• If you select an external source for the start command and it is on, the drive starts
immediately after a fault reset unless you configure the drive for pulse start. Refer
to the firmware manual.
• If the drive is in remote control mode, you cannot stop or start the drive with the
control panel.
• Only authorized persons are permitted to repair a faulty drive.
22 Safety instructions

Electrical safety in installation, start-up and maintenance

￭ Electrical safety precautions
These electrical safety precautions are for all persons who do work on the drive, motor
cable or motor.

WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur. If you are not a qualified electrical professional, do not
do electrical installation or maintenance work. Do these steps before you do
installation or maintenance work.

1. Prepare for the work.

• Make sure that you have a work order.
• Do an on-site risk assessment or job hazard analysis.
• Make sure that you have the correct tools available.
• Make sure that the workers are qualified.
• Select the correct personal protective equipment (PPE).
• Stop the drive and motor(s).
2. Clearly identify the work location and equipment.
3. Disconnect all possible voltage sources. Make sure that connection is not possible.
Lock out and tag out.
• Open the main disconnecting device of the drive.
• Open the charging switch if it is present.
• Open the disconnector of the supply transformer. (The main disconnecting
device in the drive cabinet does not disconnect the voltage from the AC input
power busbars of the drive cabinet.)
• Close the grounding switch or switches ([Q9], option +F259) if present. Do
not use excessive force as the switch has electromagnetic interlocking.
• Open the auxiliary voltage switch-disconnector (if it is present), and all other
possible disconnecting devices that isolate the drive from dangerous voltage
sources.
• If there is a permanent magnet motor connected to the drive, disconnect the
motor from the drive with a safety switch or by other means.
• Open the main isolating device of the drive.
• Disconnect all dangerous external voltages from the control circuits.
• After you disconnect power from the drive, wait 5 minutes to let the
intermediate circuit capacitors discharge before you continue.
4. Protect other energized parts in the work location against contact and take special
precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a high-quality voltage tester. If
the measurement requires that you remove shrouding or other cabinet structures,
obey the local laws and regulations applicable to live electrical work. This includes,
but is not limited to, electric shock and arc protection.
• Before and after you measure the installation, verify the operation of the
voltage tester on a known voltage source.
• Make sure that the voltage between the input power terminals of the drive
(L1, L2, L3) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the output power terminals of the drive
(U, V, W) and the grounding (PE) busbar is zero.
 Safety instructions 23

Important! Repeat the measurement with the DC voltage setting of the voltage
tester. Measure between each phase and ground. There is a risk of dangerous
DC voltage charging due to leakage capacitances of the motor circuit. This
voltage can remain charged for a long time after the drive power-off. The
measurement discharges the voltage.
• Make sure that the voltage between the drive DC busbars and the grounding
(PE) busbar is zero.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person that is responsible for the electrical
installation work.

￭ Additional instructions and notes

WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.

• Keep the cabinet doors closed when the drive has electrical power. If the doors
the drive cabinet are open, there is a risk of a potentially fatal electric shock, arc
flash or high-energy arc blast exists.
• Make sure that the electrical power network, motor/generator, and environmental
conditions agree with the drive data.
• Do not do insulation or voltage withstand tests on the drive.
• If you have a cardiac pacemaker or other electronic medical device, do not go near
the motor, drive, and the drive power cabling when the drive is in operation. The
equipment produces electromagnetic fields that can cause interference in
electronic medical devices. This can cause a health hazard.
• ABB does not recommend attaching the cabinet by arc welding. If you have to,
obey the welding instructions in the drive manuals.
Note:
• When the drive is connected to the input power, the motor cable terminals and
the DC bus are at a dangerous voltage.
The brake circuit, including the brake chopper (option +D150) and brake resistor
(option +D151) are also at a dangerous voltage.
After you disconnect the drive from the input power, these remain at a dangerous
voltage until the intermediate circuit capacitors discharge.
• External wiring can supply dangerous voltages to the relay outputs of the control
units of the drive.
• The Safe torque off function does not remove the voltage from the main and
auxiliary circuits. The function is not effective against deliberate sabotage or
misuse.
24 Safety instructions

Printed circuit boards

WARNING!
Use ESD wristband when you handle printed circuit boards. Do not touch the
boards unnecessarily. The boards are sensitive to electrostatic discharge.

￭ Grounding
These instructions are for all persons who are responsible for the grounding of the
drive.

WARNING!
Obey these instructions. If you ignore them, injury or death, or equipment
malfunction can occur, and electromagnetic interference can increase.
If you are not a qualified electrical professional, do not do grounding work.

• Always ground the drive, the motor and adjoining equipment. This is necessary
for personnel safety.
• Make sure that the conductivity of the protective earth (PE) conductors is sufficient
and that other requirements are met. Refer to the electrical planning instructions
of the drive. Obey the applicable national and local regulations.
• When you use shielded cables, make a 360° grounding of the cable shields at the
cable entries to reduce electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) busbar of the power supply.
 Safety instructions 25

General safety in operation

These instructions are for all persons that operate the drive.

WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.

• Keep the cabinet doors closed when the drive has electrical power. If the doors
the drive cabinet are open, there is a risk of a potentially fatal electric shock, arc
flash or high-energy arc blast exists.
• If you have a cardiac pacemaker or other electronic medical device, do not go near
the motor, drive, and the drive power cabling when the drive is in operation. The
equipment produces electromagnetic fields that can cause interference in
electronic medical devices. This can cause a health hazard.
• Give a stop command to the drive before you reset a fault. If you have an external
source for the start command and the start is on, the drive starts immediately
after the fault reset, unless you configure the drive for pulse start. Refer to the
firmware manual.
• Before you activate the automatic fault reset or automatic restart functions of
the drive control program, make sure that no dangerous situations can occur.
These functions reset the drive automatically and continue operation after a fault
or break in the power supply. If these functions are activated, the installation must
be clearly marked as defined in IEC/EN/UL 61800-5-1, subclause 6.5.3, for example,
"THIS MACHINE STARTS AUTOMATICALLY".

Note:
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors. If you need to
start or stop the drive, use the control panel keys or commands through the I/O
terminals of the drive or the fieldbus interface.
• If the drive is in remote control mode, you cannot stop or start the drive with the
control panel.
26 Safety instructions

Additional instructions for permanent magnet motor

drives
￭ Safety in installation, start-up, maintenance
These are additional warnings for permanent magnet motor drives. The other safety
instructions in this chapter are also valid.

WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.

• Do not do work on the drive when a rotating permanent magnet motor is

connected to it. A rotating permanent magnet motor energizes the drive including
its input and output power terminals.
Before installation, start-up and maintenance work on the drive:
• Stop the drive.
• Disconnect the motor from the drive with a safety switch or by other means.
• If you cannot disconnect the motor, make sure that the motor cannot rotate during
work. Make sure that no other system, like hydraulic crawling drives, can rotate
the motor directly or through any mechanical connection such as belt, nip, rope,
etc.
• Do the steps in section Electrical safety precautions (page 22).
• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W).
Connect the output terminals together as well as to the PE.
During the start-up:
• Make sure that the motor cannot run at overspeed, for example, when it is driven
by the load. Motor overspeed causes an overvoltage that can cause damage to
the capacitors in the intermediate circuit of the drive.

￭ Safety in operation

WARNING!
Make sure that the motor cannot run at overspeed, for example, when it is
driven by the load. Motor overspeed causes an overvoltage that can cause
damage to the capacitors in the intermediate circuit of the drive.
 Introduction to the manual 27

2
Introduction to the manual

Contents of this chapter

This chapter describes the manual. It contains a flowchart of steps in checking the
delivery, installing and starting up the drive. The flowchart refers to chapters/sections
in this manual and to other manuals.

Target audience
This manual is intended for people who plan the installation, install, commission, and
do maintenance work on the drive, or create instructions for the end user of the drive
concerning the installation and maintenance of the drive.
Read the manual before you do work on the drive. You are expected to know the
fundamentals of electricity, wiring, electrical components, and electrical schematic
symbols.

Categorization by frame size and option code

Some instructions, technical data and dimension drawings which concern only certain
frame sizes are marked with the symbol of the frame size. The frame size indicates
the number of power modules that form the supply and inverter units respectively.
For example, the marking “2×R8i + 2×R8i” refers to a drive that has a supply unit
consisting of two frame R8i supply modules and an inverter unit consisting of two
frame R8i inverter modules. The frame size is marked on the type designation label,
and can also be determined from the type code.
The instructions, technical data and dimension drawings which only concern certain
optional selections are marked with option codes (such as "+E205"). The options
included in the drive can be identified from the option codes visible on the type
designation label. The option selections are listed in section Type designation
key (page 57).
28 Introduction to the manual

Use of component designations

Some device names in the manual include the component designation in brackets (for
example, [Q20]). This will help you to identify the components in the circuit diagrams
of the drive.

Quick installation, commissioning and operation flowchart

Task See

Plan the electrical installation and acquire the accessories Guidelines for planning the electrical in-
needed (cables, fuses, etc.). stallation (page 85)
Check the ratings, required cooling air flow, input power Technical data (page 215)
connection, compatibility of the motor, motor connection,
and other technical data.

Check the installation site. Ambient conditions (page 236)

Unpack and check the drive (only intact units may be started Mechanical installation (page 63)
up).
Make sure that all necessary optional modules and equipment
are present and correct.
Install the drive mechanically.

Route the cables. Routing the cables (page 101)

If the drive is about to be connected to an IT (ungrounded) Compatibility check - IT (ungrounded)

system, check that the drive is not equipped with EMC filter earthing system (page 114)
+E202.

Connect the power cables. Electrical installation (page 113)

Connect the control cables.

Check the installation. Installation checklist (page 167)

If the drive has been non-operational for
more than one year, reform the DC link
capacitors. See Converter module capa-
citor reforming instructions
(3BFE64059629 [English]).

Start the drive up. Start-up (page 169)

Operate the drive: start, stop, speed control etc. ACS880 quick start-up guide, firmware
manual
 Introduction to the manual 29

Terms and abbreviations

Term/ Description
Abbreviation
ACS-AP-I Industrial assistant non-Bluetooth control panel
ATEX Directives 2014/34/EU and 1999/92/EC are commonly referred to as the ATEX directives
(from "Atmosphères Explosibles")
BAMU Auxiliary measurement unit
BCU Type of control unit
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 a certain
maximum limit. The voltage rise is typically caused by deceleration (braking) of a high
inertia motor.
Brake resistor Dissipates the drive surplus braking energy conducted by the brake chopper to heat
Drive Frequency converter for controlling AC motors
EMC Electromagnetic compatibility
EMI Electromagnetic interference
EMT Electrical metallic tubing, type of cable conduit
FAIO-01 Analog I/O extension module
FCAN-01 Optional CANopen® adapter module
FCNA-01 Optional ControlNet™ adapter module
FDCO-01 DDCS communication module with two pairs of 10 Mbit/s DDCS channels
FDIO-01 Optional digital I/O extension module
FDNA-01 Optional DeviceNet™ adapter module
FEA-03 Optional I/O extension adapter
FECA-01 Optional EtherCAT® adapter module
FEIP-21 Optional Ethernet adapter module for EtherNet/IP™
FEN-01 Optional TTL incremental encoder interface module
FEN-11 Optional absolute encoder interface module
FEN-21 Optional resolver interface module
FEN-31 Optional HTL incremental encoder interface module
FENA-21 Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO
protocols, 2-port
FEPL-02 Optional Ethernet POWERLINK adapter module
FIO-01 Optional digital I/O extension module
FIO-11 Optional analog I/O extension module
FMBT-21 Optional Ethernet adapter module for Modbus TCP protocol
FPBA-01 Optional PROFIBUS DP® adapter module
FPNO-21 Optional PROFINET IO adapter module
FPTC-01 Optional thermistor protection module
FPTC-02 Optional ATEX-certified thermistor protection module for potentially explosive atmo-
spheres
Frame, frame Physical size of the drive or power module
size
FSCA-01 Optional RS-485 (Modbus/RTU) adapter
FSCS-21 CIP Safety™ functions module
FSE-31 Optional pulse encoder interface module for safety encoder
FSO-12, FSO-21 Optional functional safety modules
FSPS-21 PROFIsafe safety functions module
IGBT Insulated gate bipolar transistor
Inverter unit Inverter module(s) under control of one control unit, and related components. One in-
verter unit typically controls one motor.
Power module Common term for drive module, inverter module, supply module, brake chopper module
etc.
30 Introduction to the manual

Term/ Description
Abbreviation
RFI Radio-frequency interference
SAR Safe acceleration range
SBC Safe brake control
SLS Safely-limited speed
SS1 Safe stop 1 (IEC/EN 61800-5-2)
SSE Safe stop emergency
SSM Safe speed monitor
STO Safe torque off (IEC/EN 61800-5-2)
Supply unit Supply module(s) under control of one control unit, and related components.
UCU Type of control unit

Related manuals
You can find manuals on the Internet. See below for the relevant code/link. For more
documentation, go to www.abb.com/drives/documents.

ACS880-37 (160 to 3200 kW) manuals

 Operation principle and hardware description 31

3
Operation principle and hardware
description

Contents of this chapter

This chapter briefly describes the operation principle and construction of the drive.

Operation principle
The ACS880-37 is a low-harmonic, air-cooled, cabinet-installed drive for controlling
asynchronous AC induction motors, permanent magnet synchronous motors, AC
induction servomotors and ABB synchronous reluctance (SynRM) motors.
The drive consists of several cubicles that contain
• the supply and motor terminals
• 1 to 6 IGBT supply module(s) forming the supply unit (line-side converter)
• 1 to 6 inverter modules forming the inverter unit (motor-side converter)
• optional equipment.
The actual arrangement of the cubicles varies from type to type and the selected
options. Some optional equipment require additional cubicles. See chapter Dimensions
for examples of cabinet line-ups.

￭ Supply unit
The supply unit rectifies three-phase AC current to direct current for the intermediate
DC link of the drive.
The following figure shows the simplified main circuit diagram of the supply unit.
Larger drives have supply units that consist of multiple supply modules connected in
parallel.
32 Operation principle and hardware description

2 3

1 5

3~ 4 DC

1 AC fuses

2 LCL filter

3 Supply module (with IGBTs)

4 DC capacitors with discharge resistors

5 DC fuses

AC voltage and current waveforms

The AC current is sinusoidal at a unity power factor. The LCL filter suppresses the AC
voltage distortion and current harmonics. The high AC inductance smooths the line
voltage waveform distorted by the high-frequency switching of the converter. The
capacitive component of the filter effectively filters the high-frequency (over 1 kHz)
harmonics.

Charging
Charging is needed to power up the DC link capacitors smoothly. Discharged capacitors
cannot be connected to the full supply voltage. The voltage must be increased gradually
until the capacitors are charged and ready for normal use. The drive contains a resistive
charging circuit consisting of fuses, contactor and charging resistors. The charging
circuit is in use after start-up until the DC voltage has risen to a predefined level.

Licensing
Each supply module has a hardware license (+N8201) which allows the module to be
used as an ACS880-37 supply module only. For example, a module with +N8201 cannot
be used as an inverter module. On the other hand, it is possible to use a module without
+N8201 as a spare part for an ACS880-37 supply module as long as the types of the
modules are otherwise the same.

￭ Inverter unit
The inverter unit converts the DC back to AC that rotates the motor. It is also able to
feed the braking energy from a rotating motor back into the DC link.
 Operation principle and hardware description 33

￭ Overview circuit diagram of the drive

„
~3

12 12

3 11 13
2 4
10 14

5
1

6 9

M
15
3~

1 Auxiliary voltage transformer(s)

Auxiliary voltage switch [Q21]. Frame 1×R8i+1×R8i has fuse disconnectors [F20.x] in place of
2
an auxiliary voltage switch. The auxiliary voltage is switched by the main switch/disconnector.
3 *Main switch/disconnector [Q1.1]
*AC fuses [F1.x]. If the drive has multiple LCL filters, there are additional AC fuses at the input
4
of each filter.
5 *Main contactor [Q2]
*Some drive types can be ordered with a main circuit breaker (or are equipped with a main circuit
breaker as standard) [Q1]. In that case, the AC fuses are located at the input of each LCL filter.
6 Charging switch [Q3] and fuses
7 Charging contactor [Q4]
8 Charging resistors [R4.x]
9 LCL filter [R3.x]
10 Supply module(s) [T1.x]. The diagram shows two modules connected in parallel.
11 Common mode filters [R1.x] at the output of each supply module
DC fuses at the output of each supply module [F2.x], and at the input of each inverter module
12
[F11.x]. Frame 1×R8i+1×R8i drives do not have DC fuses.
13 Common mode filters [R11.x] at the input of each inverter module (except frame 1×R8i+1×R8i)
14 Inverter unit consisting of one or several inverter modules [T11.x]
15 Motor
34 Operation principle and hardware description

Cabinet line-up and layout examples

￭ Frame 1×R8i+1×R8i „

A B

3 4 2

Cabinet line-up example

A Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections.
See section Auxiliary control cubicle (ACU) layout (page 40).
B Supply and inverter module cubicle. Contains the supply module, LCL filter, inverter module
and switchgear, as well as the power cable terminals.
1 Main switch-disconnector (Q1.1)
2 Charging switch [Q3]
3 Drive control panel. See section Control panel (page 45).
4 Door switches and lights. See section Door devices (page 43).
 Operation principle and hardware description 35

6 8 10
7
9 5
4

2 11 12

13

Cabinet layout example

A Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 40).
1 Input cable lead-throughs, PE busbar
2 LCL filter module
3 Input terminals (behind LCL filter module)
4 Main switch/disconnector [Q1.1] (behind mounting plate)
5 AC fuses (behind mounting plate)
6 Fuse disconnectors for auxiliary voltage [F20.x]
7 Main contactor [Q2.1]
8 Charging fuse switch [Q3]
9 Charging contactor
10 Charging resistors
11 Supply module
12 Inverter module
13 Output terminals (behind inverter module)
36 Operation principle and hardware description

￭ Frame 2×R8i+2×R8i
„

A B C D

3 4
5 6

Cabinet line-up example

A Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections.
See section Auxiliary control cubicle (ACU) layout (page 40).
B Incoming cubicle. Contains the input terminals, switchgear and charging equipment.
C Supply module cubicle. Contains two R8i supply modules together with an LCL filter module.
D Inverter module cubicle. Contains two R8i inverter modules. As standard, the motor cables are
run from each inverter module to the motor unless the drive is equipped with option +H359
(common motor terminal cubicle), +H366 (common output terminals) or +E206 (sine filters).
1 Main switch-disconnector (Q1.1)
2 Grounding/earthing switch [Q9.1] (option +F259)
3 Drive control panel. See section Control panel (page 45).
4 Door switches and lights. See section Door devices (page 43).
5 Auxiliary voltage switch [Q21]
6 Charging switch [Q3]
 Operation principle and hardware description 37

11 11 11 11
10

8 9
7
6

5
13 13 14 14

4
12

Cabinet layout example

A Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 40).
1 Input cable lead-throughs, PE busbar
2 Input terminals
3 Main switch-disconnector (Q1.1)
4 Grounding/earthing switch [Q9.1] (option +F259)
5 AC fuses
6 Charging resistors and contactor
7 Main contactor (behind charging equipment)
8 Auxiliary voltage switch [Q21]
9 Charging switch [Q3]
10 Incoming cubicle cooling fan
11 DC fuses (at the output of each supply module and at the input of each inverter module)
12 LCL filter module
13 Supply modules
14 Inverter modules. The output terminals are located behind each module. Each module must
be individually connected to the motor using separate cables unless the drive is equipped with
option +H359 (common motor terminal cubicle), +H366 (common output terminals) or +E206
(sine filters).
38 Operation principle and hardware description

￭ Frame
„ 3×R8i+3×R8i (with main breaker, option +F255)

A B C D E

6
3 4
2

Cabinet line-up example

A Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections.
See section Auxiliary control cubicle (ACU) layout (page 40).
B Incoming cubicle. Contains the input terminals, switchgear and charging equipment.
C Supply module cubicle (1). Contains two LCL filter modules.
D Supply module cubicle (2). Contains three R8i supply modules.
E Inverter module cubicle. Contains three R8i inverter modules. As standard, the motor cables
are run from each inverter module to the motor unless the drive is equipped with option +H359
(common motor terminal cubicle), +H366 (common output terminals) or +E206 (sine filters).
1 Main switch-disconnector (Q1.1)
2 Grounding/earthing switch [Q9.1] (option +F259)
3 Drive control panel. See section Control panel (page 45).
4 Door switches and lights. See section Door devices (page 43).
5 Auxiliary voltage switch [Q21]
6 Charging switch [Q3]
 Operation principle and hardware description 39

6 10 13 13
8 9
7

4
11 12 14
3

Cabinet layout example

A Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 40).
1 Input cable lead-throughs, PE busbar
2 Input terminals
3 Charging resistors
4 Incoming cubicle cooling fans (behind the charging resistor mounting plate)
5 Main breaker [Q1]
6 Charging switch [Q3]
7 Auxiliary voltage switch [Q21]
8 Grounding/earthing switch [Q9.1] (option +F259)
9 Charging contactor (behind auxiliary equipment)
10 AC fuses
11 LCL filter modules
12 Supply modules
13 DC fuses (at the output of each supply module and at the input of each inverter module)
14 Inverter modules. The output terminals are located behind each module. Each module must
be individually connected to the motor using separate cables unless the drive is equipped with
option +H359 (common motor terminal cubicle), +H366 (common output terminals) or +E206
(sine filters).
40 Operation principle and hardware description
40 Operation principle and hardware description

￭ Auxiliary control cubicle (ACU) layout

„ Auxiliary control cubicle (ACU) layout
A layout example of the auxiliary control cubicle (ACU) is shown below. On the left:
A layout example
Swing-out of the auxiliary
frame closed, control
detachable cubicle (ACU)
mounting platesisinshown
place. below.
On the right: Swing-out
frame open, without detachable mounting plates.
Swing-out frame closed, Swing-out frame open,
detachable mounting plates in place without detachable mounting plates

1 2

4 5 6
7

20 21
8
22

23
10 24

11 27
25
9 9 26
12
25 30

13 28
34 32 31

33
14 15 16

29 35
17 18

19

1 Fuse-disconnectors F101. On the primary of 19 Lead-through for control cables

transformer T101 (item 27).
1 Fuse-disconnectors F101. On the primary of 19 Lead-through for control cables
transformer T101 (item
2 Fuse-disconnectors 27).for motor cooling
(F27) 20 Terminal block (X68) for FSO-xx safety func-
fan outputs (options +M602…610)
2 Fuse-disconnectors F27 for motor cooling fan tions module
20 Terminal block (option +Q972 or
X68 for FSO-xx +Q973)
safety functions
outputscontrol
3 Supply (optionsunit
+M602…610)
(A51). See chapters Con- 21 module (optionblock
I/O terminal +Q973)
(option +L504). The I/O
3 trol unitcontrol
Supply (UCU)unit
and[A51].
Control
See unit (BCU).
chapter Control of the
21 I/O inverter
terminal blockcontrol
(optionunit is wired
+L504). to this
The I/O of the
units of the drive (page 123) block. control unit is wired to this block.
inverter
44 Inverter
Inverter control
control unit
unit[A41].
(A41).Three
Three optional
optionalI/O
I/O 22
22 Grounding/clamping
Grounding/clamping point forfor
point control cables
control cables
extension, encoder
extension, encoder interface,
interface,ororfieldbus
fieldbus ad-
adapter
apter modules
modules can
can bebe installedon
installed onthetheunit.
unit.
Additional modules
Additional modulesare areinstalled
installedononitem 13.13.
item
See
Seechapters Controlunits
chapter Control unitof
(UCU) and (page
the drive Control
unit
123)(BCU).
55 Auxiliary
Auxiliary voltage
voltage circuit
circuitbreaker
breakerF112.
F112.OnOnthe
the 23
23 24
24 V
V DC power
power supply
supplyand
andbuffer
buffermodule
module
secondary of
secondary of transformer
transformerT111
T111(item
(item29).
29).
Mounted on
Mounted on the
theright-hand
right-handinside
insidewall.
wall.
 Operation principle and hardware description 41

6 Switch (F90) for ground fault monitoring 24 Motor fan starters and contactors (options
(item 12) +M602…610)
7 FSO-xx safety functions module (option 25 Terminal blocks (X601) for motor fan connec-
+Q972 or +Q973 and other options requiring tions (options +M602…610)
FSO-xx)
8 Temperature monitoring relays (options 26 24 V DC power supply for cabinet lighting
+L505 and +L506). The terminals (X506) are (option +G301)
located on the back of the detachable
mounting plate.
9 Swing-out frame 27 Auxiliary voltage transformer T101 (at the
back of the cubicle, not visible). Supplies
IP54, brake chopper and brake resistor cab-
inet cooling fans (options +B055, +D150 and
+D151).
10 Mounting rail for additional equipment 28 Auxiliary voltage transformer T21 (at the back
of the cubicle, not visible). Supplies the con-
trol circuitry and the cooling fans in both the
incoming unit (ICU) and the auxiliary control
unit (ACU).
11 Safety relays for safety options (emergency 29 Auxiliary voltage transformer T111. (Custom-
stop, safe torque off) ized equipment only.)
12 Ground fault monitoring equipment for un- 30 Auxiliary voltage circuit breakers F22 and
grounded systems (option +Q954) F102. On the secondary of transformers T21
(item 28) and T101 (item 27) respectively.
13 FEA-03 extension adapter (option +L515). 31 Input voltage setting for auxiliary voltage
transformer T101 (item 27)
14 Switch and circuit breaker for externally- 32 Input voltage setting for auxiliary voltage
supplied motor space heater (option +G313). transformer T21 (item 28)
The terminals (X313) are located on the back
of the detachable mounting plate.
15 Switch and circuit breaker for externally- 33 Input voltage setting for auxiliary voltage
supplied control voltage (option +G307), eg. transformer T111 (item 29)
UPS. The terminals (X307) are located on the
back of the detachable mounting plate.
16 Switch and circuit breaker for externally- 34 Terminal blocks
supplied cabinet lighting and heating (op- X250: indication of main switch-disconnector
tions +G300 and +G301). The terminals and contactor status
(X300) are located on the back of the detach- X951: connection of external emergency stop
able mounting plate. button
X954: ground fault alarm indication
X957: for connection of Prevention of unex-
pected start-up switch.
Mounted on the left-hand side wall.
17 Fuse-disconnectors F21. On the primary of 35 Cubicle heater element (option +G300).
transformer T21 (item 28). Mounted on a de- Mounted on the right-hand side wall.
tachable plate.
18 Fuse-disconnectors F111. On the primary of
transformer T111 (item 29). Mounted on a
detachable plate.
42 Operation principle and hardware description

Overview of power and control connections

The diagram shows the power connections of the drive and the control interfaces of
the inverter control unit (type UCU and BCU, wiring diagram designation A41).

A
B
C
5 XPAN/X13
..........
..........

1
6 XETH1...4

2 ..........
..........

3
. . .
7
.....
.....

MEM/X205

4
..........
..........

XFSO/X12 V1T/R...
8

L1 L1 U2
10
L2 L2 V2 M3~

L3 L3 9 11 W2

PE PE

12

A Drive
B Supply control unit
C Inverter control unit
1 Option modules can be inserted into slots 1, 2, 3 and 4 as follows:
2 Module type Slots

Analog and digital I/O extension modules 1, 2, 3

Feedback interface modules 1, 2, 3

Fieldbus communication modules 1, 2, 3

RDCO-04 DDCS communication option module (standard equipment). As 4

standard, a fiber optic link connects the supply and inverter control units.

Additional modules can be installed on an optional FEA-03 extension adapter connected to

an RDCO module on slot 4.
3 Memory unit connection
 Operation principle and hardware description 43

4 Connection for FSO safety functions module

5 Control panel and PC connection
6 Ethernet connectors (not in BCU)
7 I/O terminal blocks on the inverter control unit
8 Fiber optic connectors to each inverter module
9 Supply unit (consists of one or more supply modules)
10 DC intermediate link
11 Inverter unit (consists of one or more inverter modules)
12 Optional brake chopper (+D150) and resistors (+D151)

Door devices

Label in Eng- Label in local Description

lish language
1 READY - Ready light (option +G327)
2 RUN - Run light (option +G328)
3 FAULT - Fault light (option +G329)
4 ENABLE / RUN - Run enable signal switch for the supply unit
0-1
0 No Run enable or Start signal

1 Run enable and Start signal on

5 E-STOP RESET - Emergency stop reset push button (with emergency stop options
only)
44 Operation principle and hardware description

6 EARTH FAULT - Ground (earth) fault light and reset push button (option +Q954)
7 - - Reserved for order-based engineered equipment
8 EMERGENCY - Emergency stop push button (with emergency stop options only)
STOP
The layout depends on the options selected.
 Operation principle and hardware description 45

￭ Main disconnecting device (Q1.1)

Depending on the configuration of the drive, the main disconnecting device of the
drive is either a switch-disconnector or a main circuit breaker. Units with a
switch-disconnector also have a main contactor.
The main disconnecting device switches the main supply to the drive on and off. To
disconnect the main supply, turn the switch-disconnector to the 0 (OFF) position, or
rack out the main breaker (whichever device is installed).

WARNING!
The main disconnecting device does not isolate the input power terminals, AC
voltage meters, or the auxiliary voltage circuit from the power line. To isolate
the auxiliary voltage circuit, open the auxiliary voltage switch (Q21). To isolate
the input power terminals and AC voltage meters, open the main breaker of
the supply transformer.

To close the main disconnecting device, auxiliary voltage must be switched on, and
the grounding switch (if present) must be open.

￭ Auxiliary voltage switch [Q21]

The auxiliary voltage switch controls the supply to the internal auxiliary voltage
transformers. The transformer feeds the control circuits inside the drive such as
cooling fans, relays and measuring equipment.

Note: Frame 1×R8i+1×R8i units are not fitted with an auxiliary voltage switch. The
auxiliary voltage is switched on and off by the main disconnecting device [Q1], and
protected by fuse disconnectors F20.1…F20.3.

￭ Grounding (earthing) switch [Q9], optional

The grounding switch [Q9] (option +F259) connects the main AC power bus to the PE
busbar.
To close the grounding switch, auxiliary voltage must be switched on, and the main
disconnecting device must be open.

WARNING!
The grounding switch does not ground the input power terminals of the drive
or the auxiliary (control) voltage circuits.

￭ Other devices on the door

• Voltmeter (option +G334); comes with a phase selector switch.

Note: The voltage is measured on the supply side of the main switch or breaker.
• AC current meter (option +G335) on one phase.

￭ Control panel
The ACS-AP-W is the user interface of the drive. It provides the essential controls such
as Start/Stop/Direction/Reset/Reference, and the parameter settings for the inverter
control program.
The control panel can be removed by pulling it forward by the top edge and reinstalled
in reverse order. For the use of the control panel, see ACS-AP-I, -S, -W and ACH-AP-H,
46 Operation principle and hardware description

-W Assistant control panels user’s manual (3AUA0000085685 [English]) and the

firmware manual.

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.
 Operation principle and hardware description 47

Descriptions of options
Note: All options are not available for all drive types, are not compatible with some
other options, or require additional engineering.

￭ Degree of protection
Definitions
According to IEC/EN 60529, the degree of protection is indicated by an IP code where
the first numeral means protection against ingress of solid foreign objects, and the
second numeral protection against ingress of water. The IP codes of the standard
cabinet and options covered in this manual are defined below.

The equipment is protected …

IP code
First numeral Second numeral
IP22 against ingress of solid foreign objects > against dripping (15° tilting) water
12.5 mm diameter *
IP42 against ingress of solid foreign objects > 1 mm against dripping (15° tilting) water
IP54 dust-protected against splashing water

* meaning for protection of persons: against access to hazardous parts with finger

IP22 (UL Type 1)

The degree of protection of the standard drive cabinet is IP22 (UL type 1). The air
outlets at the top of the cabinet and the air inlet gratings are covered with metallic
gratings. With doors open, the degree of protection of the standard cabinet and all
cabinet options is IP20. The live parts inside the cabinet are protected against contact
with clear plastic shrouds or metallic gratings.

IP42 (UL Type 1 Filtered) (option +B054)

This option provides the degree of protection of IP42 (UL type 1). The air inlet gratings
are covered with a metallic mesh between the inner and outer metallic gratings.

IP54 (UL Type 12) (Standard)

This option provides the degree of protection of IP54 (UL type 12). It provides the
cabinet air inlets with filter housings containing folded board air filter mats between
the inner and outer metallic gratings. An additional fan and filtered outlets on the
cabinet roof are also included.

￭ Marine construction (option +C121)

The option includes the following accessories and features by default:
• reinforced mechanics
• grab railings
• door flush bolt which allows the door to open 90 degrees and prevents it from
slamming close
• self-extinctive materials
• flat bars at base of the cabinet for fastening
• fastening brackets at the top of the cabinet.
48 Operation principle and hardware description

Marine product certifications may require additional wire markings. Refer to section
Wire markings (page 50).

￭ Cooling air inlet through bottom of cabinet (option +C128)

See section Air inlet through the bottom of the cabinet (option +C128) (page 79).

￭ UL Listed (option +C129)

The cabinet contains the following accessories and features:
• top entry and exit with US cable conduit entries (plain plate without ready-made
holes)
• all components UL/CSA Listed/Recognized
• maximum supply voltage 600 V
• US-type main switch and fuses.

￭ Channeled air outlet (option +C130)

This option provides a collar for connection to an air outlet duct. The collar is located
on the cabinet roof. Depending on the equipment installed in each cubicle, the
channeled air outlet either replaces, or adds to, the standard roof arrangement.
With option +B055, this option also provides the cabinet air inlets with filter housings
containing folded board air filter mats between the inner and outer metallic gratings.
See also section Air outlet duct on the cabinet roof (option +C130) (page 80).

￭ CSA Approved (option +C134)

The option includes the following accessories and features:
• bottom entry and exit of cables with US cable conduit entry (plain plate without
ready-made holes)
• all components UL/CSA listed/recognized
• maximum supply voltage 600 V
• main (air circuit) breaker when available for the particular drive type.

￭ Plinth height (options +C164 and +C179)

The standard height of the cabinet plinth is 50 mm. These options specify a plinth
height of 100 mm (+C164) or 200 mm (+C179).

￭ Seismic design (option +C180)

The option involves seismic capability according to International building code 2012,
test procedure ICC-ES AC-156. The installation level must not exceed 25% of the height
of the building, and SDS (installation site specific spectral acceleration response) must
not exceed 2.0 g.
The option adds the following accessories and features:
• reinforced mechanics
• flat bars at base of the cabinet for fastening.
 Operation principle and hardware description 49

￭ Empty cubicles on left (options +C199…C201)

The option adds an empty 400, 600 or 800 mm wide cubicle to the left end of the
line-up. The cubicle is equipped with blank power cable entries both at the top and
the bottom.
The cubicle is equipped with blank panel entries (full panel or two-half panels) on the
back.

￭ EMC filter (option +E202)

EMC filter for 1st Environment (category C2) for TN (grounded) system.

￭ du/dt filter (option +E205)

The du/dt filter protects the motor insulating system by reducing the voltage rise
speed at the motor terminals. The filter also protects the motor bearings by reducing
the bearing currents.
More information on when the option is required: See section Examining the
compatibility of the motor and drive (page 88).

￭ Sine filter (option +E206)

A sine filter provides true sinusoidal voltage waveform at the drive output by
suppressing the high-frequency voltage components of the output. These
high-frequency components cause stress to motor insulation as well as output
transformer saturation (if present).
The sine filter option consists of three single-phase reactors and delta-connected
capacitors at the output of the drive. The sine filter is fitted in a separate cubicle and
has a dedicated cooling fan.

￭ Cabinet heater with external supply (option +G300)

The option contains:
• heating elements in the cubicles or supply/inverter modules
• load switch for providing electrical isolation during service
• miniature circuit breaker for overcurrent protection
• terminal block for external power supply.
The heater prevents condensation inside the cabinet when the drive is not in operation.
The power output of the heating elements increases when the surrounding air
temperature is low and decreases when the surrounding air temperature is high. The
customer must stop the heating when it is not needed by disconnecting the heater
supply voltage.
The customer must supply the heater from an external 110…240 V AC power source.
For the actual wiring, see the circuit diagrams delivered with drive.

￭ Cabinet lighting (option +G301)

This option contains LED lighting fixtures in each cubicle (except joining and brake
resistor cubicles) and a 24 V DC power supply. The lighting is powered from the same
external 110…240 V AC power source as the cabinet heater (option +G300).
50 Operation principle and hardware description

￭ Terminals for external control voltage (option +G307)

The option provides terminals for connecting an external uninterruptible control
voltage to the control unit and control devices when the drive is not powered.
See also:
• Supplying power for the auxiliary circuits (page 107)
• circuit diagrams delivered with drive for the actual wiring.

￭ Output for motor space heater (option +G313)

The option contains:
• load switch for providing electrical isolation during service
• miniature circuit breaker for overcurrent protection
• terminal block for heater and external heater supply connection.
When the drive is powered (and not faulted), the heater is switched off. Otherwise,
the heater is controlled by the external supply voltage.
The power and voltage of the heater depend on the motor.
See also:
• Supplying power for the auxiliary circuits (page 107)
• circuit diagrams delivered with drive for the actual wiring.

￭ Supply connection by busbars (option +G317)

This option provides input (supply) terminals and a busbar entry that enable direct
connection to busbar trunking systems.

￭ Ready/Run/Fault lights (options +G327…G329)

These options provide "ready" (+G327, white), "run" (+G328, green) and "fault" (+G329,
yellow) lights installed on the cabinet door.

￭ Halogen-free wiring and materials (option +G330)

The option provides halogen-free cable ducts, control wires and wire sleeves, thus
reducing toxic fire gases.

￭ V-meter with selector switch (option +G334)

The option contains a voltmeter and a selector switch on the cabinet door. The switch
selects the two input phases across which the voltage is measured.

￭ Wire markings
Standard wiring

Color
The standard color of the wiring is black, with the following exceptions:
• PE wiring: Yellow/Green, or yellow/green sleeving
• UPS input wiring (option +G307): Orange
• Pt100 sensor wiring with ATEX-certified thermal protection (option +nL514): Light
blue.
 Operation principle and hardware description 51

Markings
As standard, wires and terminals are marked as follows:
• Main circuit terminals: Connector identifier (eg. "U1") marked on terminal, or on
insulating material close to the terminal. Input and output main circuit cables are
not marked.
„
• Plug-in connectors of wire sets (except those that require special tools to
disconnect) are labeled with connector designation (eg. "X1"). The marking is
either directly on the connector, or near the connector on printed sleeving or tape.
• Grounding busbars are marked with stickers.
• Fiber optic cable pairs and data cables have component designation and connector
designations (eg. "A1:V1", "A1:X1") marked with rings or tape.
• Data cables are marked with tape.
• Ribbon cables are marked with either labels or tape.
• Customer-specific (engineered) wiring (option +P902) is not marked.

Additional wire markings

The following additional wire markings are available.

Option Additional markings

+G340 Single wires not attached to plug-in connectors are marked with component pin numbers
(class A3) on snap-on or ring markers. Plug-in connectors are marked with an identification label
placed on the wires near the connector (individual wires are not marked). Short, obvious
connections are not marked. PE wires are not marked unless connected directly to
components.

7
9. 7

+G342 Single wires connected to components, between modules, or to terminal blocks are
(class C1) marked with component identification and pin numbers for both ends. The marking is
printed on sleeving or, if necessary, snap-on markers. Plug-in connectors are marked
with an identification label (or snap-on markers) placed on the wires near the connector
(individual wires are not marked). Short, obvious connections are not marked. PE wires
are not marked unless connected directly to components.

K1 24 K 1 2 4 T 2 3 T2 3

K1 24 K1 24 T2 3 T2 3

￭ Voltage measurement with BAMU auxiliary measurement unit (option

+G442)
In weaker supply networks with a short-circuit ratio less than 8, it is highly
recommended to install a BAMU auxiliary measurement unit to the drive. In such
networks, there is a risk of nuisance DC overvoltage tripping due to disturbances
caused by probable high-voltage THD in the supply voltage.
Short-circuit ratio is defined as the supply network's apparent short-circuit power
Sk,net V divided by the drive's nominal apparent power Sn.
52 Operation principle and hardware description

￭ Common mode filter temperature monitoring (option +G453)

This option contains thermal switches installed within the common mode filter
assemblies of the drive. An overtemperature warning is generated when overheating
is detected.
This is primarily intended for drive systems prone to high common mode currents,
such as drive systems with long motor cabling connected to an ungrounded supply
network.

￭ Bottom cable entry/exit (options +H350 and +H352)

For UL Listed (+C129) units, the default input and output cabling direction is through
the roof of the cabinet. The bottom entry (+H350) and bottom exit (+H352) options
provide power and control cable entries at the floor of the cabinet. The entries are
equipped with grommets and 360° grounding hardware.
For non-UL Listed units, bottom entry/exit is the default cabling arrangement.

￭ Top cable entry/exit (options +H351 and +H353)

The top entry (+H351) and top exit (+H353) options provide power and control cable
entries at the roof of the cabinet. The entries are equipped with grommets and 360°
grounding hardware.

￭ Cable conduit entry (option +H358)

The option provides US/UK conduit plates (plain 3 mm thick steel plates without any
ready-made holes).

￭ Common motor terminal cubicle (option +H359)

As standard, each inverter module must be individually cabled to the motor. This
option provides an additional cubicle containing a single set of terminals for the motor
cables.
The width of the cubicle and the size of the terminals within depend on the power
rating of the drive.
Note that this option is not available with option +E206 (sine filters), In this case, the
motor cables are connected to the sine filter cubicle.

￭ Common output terminals (option +H366)

As standard, each inverter module must be individually cabled to the motor. This
option adds bridging that connects the outputs of multiple (in practice, two or three)
inverter modules mounted in the same cubicle. The bridging balances the motor
current between the modules, which allows more cabling options. For example, it is
possible to use a number of cables that could not otherwise be evenly distributed
between the inverter modules.

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.
 Operation principle and hardware description 53

Note: The +H366 option only interconnects the outputs of inverter modules within
the same cubicle, not modules installed in different cubicles. Therefore, when the drive
has more than three inverter modules, 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.

￭ Connectivity for wired remote monitoring (option +K496)

This option provides a gateway to connect the drive to ABB Ability™ via a local Ethernet
network. Includes NETA-21 remote monitoring tool and FMBT-21 Modbus/TCP adapter
module.
See the appropriate manual for more information.

Code
Manual
(English)
NETA-21 remote monitoring tool user’s manual 3AUA0000096939
NETA-21 remote monitoring tool installation and start-up guide 3AUA0000096881
FMBT-21 Modbus/TCP adapter module user’s manual 3AXD50000158607
FMBT-21 Modbus/TCP adapter module quick installation and start-up guide 3AXD50000158560

￭ Connectivity for wireless remote monitoring (option +K497)

This option provides a gateway to connect the drive to ABB Ability™ via a wireless 4G
network. Includes NETA-21 remote monitoring tool, FMBT-21 Modbus/TCP adapter
module and modem.
See the appropriate manual for more information.

Code
Manual
(English)
NETA-21 remote monitoring tool user’s manual 3AUA0000096939
NETA-21 remote monitoring tool installation and start-up guide 3AUA0000096881
FMBT-21 Modbus/TCP adapter module user’s manual 3AXD50000158607
FMBT-21 Modbus/TCP adapter module quick installation and start-up guide 3AXD50000158560
InRouter 615-S commissioning guide 3AXD50000837939

￭ Additional terminal block X504 (option +L504)

The standard terminal blocks of the drive control unit are wired to the additional
terminal block at the factory for customer control wiring. The terminals are spring
loaded.

Note: The optional modules inserted in the slots of the control unit are not wired to
the additional terminal block. The customer must connect the optional module control
wires directly to the modules.
54 Operation principle and hardware description

Cables accepted by the terminals of the additional I/O terminal block:

• solid wire 0.2 … 2.5 mm2 (24…12 AWG)
• stranded wire with ferrule 0.25 … 2.5 mm2 (24…12 AWG)
• stranded wire without ferrule 0.2 … 2.5 mm2 (24…12 AWG).

￭ Thermal protection with PTC relays (options +L505, +2L505, +L513,

+2L513, +L536, +L537)
PTC thermistor relay options are used for overtemperature supervision of motors
equipped with PTC sensors. When the motor temperature rises to the thermistor
wake-up level, the resistance of the sensor increases sharply. The relay detects the
change and indicates motor overtemperature through its contacts.

+L505, +2L505, +L513, +2L513

Option +L505 provides a thermistor relay and a terminal block. The terminal block has
connections for the measuring circuit (one to three PTC sensors in series), an output
indication of the relay, and an optional external reset button. The relay can be reset
either locally or externally, or the reset circuit can be jumpered for automatic reset.
By default, the thermistor relay is wired internally to digital input DI6 of the drive
control unit. The loss of the input is set to trigger an external fault.
The output indication on the terminal block can be wired by the customer, for example,
to an external monitoring circuit. See the circuit diagrams delivered with the drive.
Option +L513 is an ATEX-certified thermal protection function that has the same
external connectivity as +L505. In addition, +L513 comes with +Q971 (ATEX-certified
safe disconnection function) as standard and is wired at the factory to activate the
Safe torque off function of the drive in an overtemperature situation. A manual reset
for the protection function is required by Ex/ATEX regulations. For more information,
see ATEX-certified motor thermal protection functions for cabinet-built ACS880 drives
(options +L513+Q971 and +L514+Q971) user's manual (3AXD50000014979 [English]).
Options +2L505 and +2L513 duplicate options +L505 and +L513 respectively, containing
the relays and connections for two separate measurement circuits.

+L536, +L537
An alternative to a thermistor relay option is the FPTC-01 (option +L536) or FPTC-02
(option +L537, also requires option +Q971) thermistor protection module. The module
mounts onto the inverter control unit, and has reinforced insulation to keep the control
unit PELV-compatible. The connectivity of the FPTC-01 and the FPTC-02 is the same,
but the FPTC-02 is Type Examined as a protective device within the scope of the
European ATEX (and UKEX) Product Directive.
For protection purposes, the FPTC has a "fault" input for the PTC sensor. An
overtemperature situation executes the SIL/PL-capable SMT (Safe motor temperature)
safety function by activating the Safe torque off function of the drive.
The FPTC also has a "warning" input for the sensor. When the module detects
overtemperature through this input, it sends a warning indication to the drive.
For more information and wiring examples, see the module manuals and the circuit
diagrams delivered with the drive.
 Operation principle and hardware description 55

See also
• firmware manual for parameter settings
• FPTC-01 thermistor protection module (option +L536) for ACS880 drives user's
manual (3AXD50000027750 [English])
• FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option
+L537+Q971) for ACS880 drives user's manual (3AXD50000027782 [English])
• circuit diagrams delivered with the drive for the actual wiring.

￭ Thermal protection with Pt100 relays (options +nL506, +nL514)

Pt100 temperature monitoring relays are used for overtemperature supervision of
motors equipped with Pt100 sensors. For example, there can be three sensors to
measure the temperature of the motor windings and two sensors for the bearings.
As the temperature rises, the sensor resistance increases linearly. At an adjustable
wake-up level, the monitoring relay de-energizes its output.
The standard Pt100 relay options include two (+2L506), three (+3L506), five (+5L506)
or eight (+8L506) relays.
By default, the relays are wired internally to digital input DI6 of the drive control unit.
The loss of the input is set to trigger an external fault. The options include a terminal
block for sensor connection. The output indication on the terminal block can be wired
by the customer, for example, to an external monitoring circuit. See the circuit diagrams
delivered with the drive.
Options +3L514 (3 relays), +5L514 (5 relays) and +8L514 (8 relays) are ATEX-certified
thermal protection functions that have the same external connectivity as +nL506. In
addition, each monitoring relay has a 0/4…20 mA output that is available on the
terminal block. Option +nL514 comes with +Q971 (ATEX-certified safe disconnection
function) as standard and is wired at the factory to activate the Safe torque off function
of the drive in an overtemperature situation. As the monitoring relay does not have a
reset functionality, the manual reset required by Ex/ATEX regulations must be
implemented using drive parameters. For more information, see ATEX-certified motor
thermal protection functions for cabinet-built ACS880 drives (options +L513+Q971
and +L514+Q971) user's manual (3AXD50000014979 [English]).
See also
• firmware manual for parameter settings
• ATEX-certified motor thermal protection functions for cabinet-built ACS880 drives
(options +L513+Q971 and +L514+Q971) user's manual (3AXD50000014979 [English])
• Pt100 relay alarm and trip limit setting instructions in the start-up instructions
• circuit diagrams delivered with the drive for the actual wiring.

￭ Starter for auxiliary motor fan (options +M600…M610)

What the option contains
The option provides switched and protected connections for 3-phase auxiliary motor
fans. Each fan connection is equipped with:
• fuses
• a manual motor starter switch with an adjustable current limit
56 Operation principle and hardware description

• a contactor controlled by the drive, and

• terminal block X601 for customer connections.

Description
The output for the auxiliary fan is wired from the 3-phase supply voltage to terminal
block X601 through a motor starter switch and a contactor. The contactor is operated
by the drive. The 230 V AC control circuit is wired through a jumper on the terminal
block; the jumper can be replaced by an external control circuit.
The starter switch has an adjustable trip current limit, and can be opened to
permanently switch the fan off.
The statuses of both the starter switch and the fan contactor are wired to the terminal
block.
See the circuit diagrams delivered with the drive for the actual wiring.
 Operation principle and hardware description 57

Type designation label

The type designation label includes ratings, appropriate markings, a type designation
and a serial number, which allow the identification of each unit. A sample label is shown
below.
Quote the complete type designation and serial number when contacting technical
support.

,..,
jl 1111
.•.•
Origin Finland
Made in Finland
ABB Oy
Hiomofie 13
Input U1
11
3N 400 VAC
1123 A
1
ACS880•37•1210A·3+B055+G340+H366+K475+L504+Q951
5

00380 Helsinki f1 50/60 Hz

Finland Output u2 aN o...u1 4
12 1210 A
FRAME 12 o...soo Hz
2 Sn 838 kVA
2xR8i
+2xR8i

Air COOiing MSI P·REl·Abb·ACS880-17

lcw 50 kA
IP54
3 7
6
11S/N:
111111 111200904514
1111 I Ill 11111
1 Type designation (see section Type designation key)
2 Frame size
Short-time withstand current rating (see chapter Technical data (page 215)); degree of protection;
3
UL/CSA specifications
4 Ratings. See also chapter Technical data (page 215).
5 Valid markings
Serial number. The first digit of the serial number refers to the manufacturing plant. The next
6 four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits
complete the serial number so that there are no two units with the same number.
7 Link to product information

Type designation key

The type designation contains information on the specifications and configuration
of the drive. The first digits from left express the basic drive type. The optional
selections are given thereafter, separated by plus signs, eg, +E202. Codes preceded
by a zero (eg. +0J400) indicate the absence of the specified feature. The main selections
are described below. Not all selections are available for all types. For more information,
refer to the ordering instructions available separately on request.

Code Description
Basic code
ACS880 Product series
Default configuration: air-cooled cabinet-installed drive, low harmonic, IP22 (UL type 1), main
switch-disconnector (and contactor) or breaker, aR fuses, ACS-AP-W assistant control panel
(with Bluetooth), EMC filter (category 3, 2nd Environment), du/dt filters, common mode fil-
ACS880-
tering, standard wire markings, ACS880 primary control program, Safe torque off function,
37
coated circuit boards, bottom entry and exit of cables with lead-through-type entries, multi-
lingual door device label sticker, USB memory stick containing circuit diagrams, dimension
drawings and manuals.
Size
58 Operation principle and hardware description

Code Description
xxxxx Refer to the rating tables
Voltage range
380…415 V AC. This is indicated in the type designation label as typical input voltage level
3
(3~ 400 V AC)
380…500 V AC. This is indicated in the type designation label as typical input voltage levels
5
(3~ 400/480/500 V AC)
525…690 V AC. This is indicated in the type designation label as typical input voltage levels
7
(3~ 525/600/690 V AC)

￭ Option codes

Code Description
B054 IP42 (UL Type 1 Filtered)
B055 IP54 (UL Type 12)
C121 Marine construction. See section Marine construction (option +C121) (page 47).
Air inlet through bottom of cabinet. See section Air inlet through the bottom of the cabinet
C128
(option +C128) (page 79).
UL Listed (evaluated to both U.S. and Canadian safety requirements). See section UL Listed
C129
(option +C129) (page 48).
C130 Channeled air outlet. See section Channeled air outlet (option +C130) (page 48).
Marine type approval. Refer to ACS880…+C132 marine type-approved cabinet-built drives
C132
supplement (3AXD50000039629 [English]).
C134 CSA approved. See section CSA Approved (option +C134) (page 48).
C164 Plinth height 100 mm. See section Plinth height (options +C164 and +C179) (page 48).
C179 Plinth height 200 mm. See section Plinth height (options +C164 and +C179) (page 48).
C180 Seismic design. See section Seismic design (option +C180) (page 48).
Empty 400 mm wide cubicle on left. See section Empty cubicles on left (options
C199
+C199…C201) (page 49).
Empty 600 mm wide cubicle on left. See section Empty cubicles on left (options
C200
+C199…C201) (page 49).
Empty 800 mm wide cubicle on left. See section Empty cubicles on left (options
C201
+C199…C201) (page 49).
C205 Marine product certification issued by DNV GL
C206 Marine product certification issued by the American Bureau of Shipping (ABS)
C207 Marine product certification issued by Lloyd's Register (LR)
C209 Marine product certification issued by Bureau Veritas
C228 Marine product certification issued by China Classification Society (CCS)
C229 Marine product certification issued by Russian Maritime Register of Shipping (RS)
D150 Brake choppers
D151 Brake resistors
E202 EMC/RFI filter for 1st environment TN (grounded) system, category C2
E205 du/dt filtering
E206 Sine output filter
F255 Main circuit breaker
F259 Grounding (earthing) switch
 Operation principle and hardware description 59

Code Description
Cabinet and module heating elements (external supply). See section Cabinet heater with ex-
G300
ternal supply (option +G300) (page 49).
G301 Cabinet lighting. See section Cabinet lighting (option +G301) (page 49).
Terminals for connecting external control voltage (230 V AC or 115 V AC, eg. UPS). See section
G307
Terminals for external control voltage (option +G307) (page 50).
G313 Output for motor space heater (external supply)
G317 Supply connection by busbars
G327 Ready light on door
G328 Run light on door
G329 Fault light on door
G330 Halogen-free wiring and materials
G334 V-meter with selector switch
G335 A-meter in one phase
G340 Wire marking class A3. See section Wire markings (page 50).
G342 Wire marking class C1. See section Wire markings (page 50).
BAMU auxiliary measurement unit. See section Voltage measurement with BAMU auxiliary
G442
measurement unit (option +G442) (page 51).
Common mode filter temperature monitoring. See section Common mode filter temperature
G453
monitoring (option +G453) (page 52).
Power cabling entry from bottom. See section Bottom cable entry/exit (options +H350 and
H350
+H352) (page 52).
Power cabling entry from top. See section Top cable entry/exit (options +H351 and
H351
+H353) (page 52).
Power cabling exit from bottom. See section Bottom cable entry/exit (options +H350 and
H352
+H352) (page 52).
Power cabling exit from top. See section Top cable entry/exit (options +H351 and
H353
+H353) (page 52).
H358 Cable gland plates (3 mm steel, undrilled)
Common motor terminal cubicle. See section Common motor terminal cubicle (option
H359
+H359) (page 52).
Common output terminals (for inverter modules mounted in the same cubicle). See section
H366
Descriptions of options (page 47).
J425 ACS-AP-I control panel (without Bluetooth)
K451 FDNA-01 DeviceNet™ adapter module
K454 FPBA-01 PROFIBUS DP® adapter module
K457 FCAN-01 CANopen® adapter module
K458 FSCA-01 RS-485 (Modbus/RTU) adapter module
K462 FCNA-01 ControlNet™ adapter module
K469 FECA-01 EtherCAT® adapter module
K470 FEPL-02 Ethernet POWERLINK adapter module
FENA-21 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols,
K475
2-port
K490 FEIP-21 Ethernet adapter module for EtherNet/IP™
K491 FMBT-21 Ethernet adapter module for Modbus TCP
K492 FPNO-21 Ethernet adapter module for PROFINET IO
60 Operation principle and hardware description

Code Description
Connectivity for wired remote monitoring. Includes NETA-21 remote monitoring tool with
K496 Ethernet connection, FMBT-21 Modbus/TCP adapter module (+K491). See section Connectivity
for wired remote monitoring (option +K496) (page 53).
Connectivity for wireless remote monitoring. Includes NETA-21 remote monitoring tool, FMBT-
K497 21 Modbus/TCP adapter module (+K491) and 4G modem. See section Connectivity for wireless
remote monitoring (option +K497) (page 53).
L500 FIO-11 analog I/O extension module
L501 FIO-01 digital I/O extension module
L502 FEN-31 HTL incremental encoder interface module
L503 FDCO-01 optical DDCS communication adapter module
Additional I/O terminal block. See section Additional terminal block X504 (option
L504
+L504) (page 53).
Thermal protection with PTC relays (1 or 2 pcs). See section Thermal protection with PTC relays
L505
(options +L505, +2L505, +L513, +2L513, +L536, +L537) (page 54).
Thermal protection with Pt100 relays (2, 3, 5 or 8 pcs). See section Thermal protection with
L506
Pt100 relays (options +nL506, +nL514) (page 55).
L508 FDCO-02 optical DDCS communication adapter module
L513 ATEX-certified thermal protection with PTC relays (1 or 2 pcs)
L514 ATEX-certified thermal protection with Pt100 relays (3, 5 or 8 pcs)
L515 FEA-03 I/O extension adapter
L516 FEN-21 resolver interface module
L517 FEN-01 TTL incremental encoder interface module
L518 FEN-11 TTL absolute encoder interface module
L521 FSE-31 pulse encoder interface module
L525 FAIO-01 analog I/O extension module
L526 FDIO-01 digital I/O extension module
L536 FPTC-01 thermistor protection module
L537 FPTC-02 ATEX-certified thermistor protection module
M602 Starter for auxiliary motor fan, trip limit 2.5 … 4 A
M603 Starter for auxiliary motor fan, trip limit 4 … 6.3 A
M604 Starter for auxiliary motor fan, trip limit 6.3 … 10 A
M605 Starter for auxiliary motor fan, trip limit 10…16 A
M606 Starter for auxiliary motor fan, trip limit 16…20 A
M610 Starter for auxiliary motor fan, trip limit 20…25 A
N5000 Winder control program
N5050 Crane control program
N5100 Winch control program
N5200 PCP (Progressive Cavity Pump) control program
N5300 Test bench control program
N5350 Cooling tower control program
N5450 Override control program
N5600 ESP (Electrical Submersible Pump) control program
N5700 Position control program
N5800 Offshore winch control program
 Operation principle and hardware description 61

Code Description
N8010 IEC 61131-3 application programmability
N8200 High speed (> 598 Hz) license
P902 Customized
P904 Extended warranty (30 months from delivery or 24 months from commissioning)
P909 Extended warranty (42 months from delivery or 36 months from commissioning)
P911 Extended warranty (66 months from delivery or 60 months from commissioning)
P912 Seaworthy packaging
P913 Special color (RAL Classic)
P947 Safety data calculation and validation for tailored safety functions
P948 Customized extended warranty
P966 Special color (other than RAL Classic)
Prevention of unexpected start-up with FSO safety functions module, by activating the Safe
Q950
torque off function
Q951 Emergency stop (category 0) with safety relays, by opening the main breaker/contactor
Q952 Emergency stop (category 1) with safety relays, by opening the main breaker/contactor
Q954 Earth fault monitoring for IT (ungrounded) systems
Q957 Prevention of unexpected start-up with safety relays, by activating the Safe torque off function
Q963 Emergency stop (category 0) with safety relays, by activating the Safe torque off function
Q964 Emergency stop (category 1) with safety relays, by activating the Safe torque off function
Q965 Safely-limited speed with FSO-21 and encoder
Q971 ATEX-certified safe disconnection function
Q972 FSO-21 safety functions module
Q973 FSO-12 safety functions module
Emergency stop (configurable for category 0 or 1) with FSO safety functions module, by
Q978
opening the main breaker/contactor
Emergency stop (configurable for category 0 or 1) with FSO safety functions module, by ac-
Q979
tivating the Safe torque off function
Q982 PROFIsafe with FSO safety functions module and FPNO-21 Ethernet adapter module
Q986 FSPS-21 PROFIsafe safety functions module
Q989 FSCS-21 CIP Safety™ functions module
R700 Printed documents in English
R701 Printed documents in German 1)
R702 Printed documents in Italian1)
R703 Printed documents in Dutch1)
R704 Printed documents in Danish1)
R705 Printed documents in Swedish1)
R706 Printed documents in Finnish1)
R707 Printed documents in French1)
R708 Printed documents in Spanish1)
R709 Printed documents in Portuguese1)
R711 Printed documents in Russian1)
R712 Printed documents in Chinese1)
R713 Printed documents in Polish1)
62 Operation principle and hardware description

Code Description
R714 Printed documents in Turkish1)
V112 Module auxiliary and fan power supply connector change
V998 UCU-22…24 control unit

1) The delivery can include documents in English if the requested language is not available.
 Mechanical installation 63

4
Mechanical installation

Contents of this chapter

This chapter tells you how to examine the installation site, examine the delivery, and
10
mechanically install the drive.

Examining the installation site

Examine the installation site. Make sure that:
• The installation site is sufficiently ventilated or cooled to remove heat from the
drive. Refer to the technical data.
• The ambient conditions of the drive meet the specifications. Refer to the technical
data.
• The material behind, above, and below the drive is non-flammable.
• There is sufficient free space above the drive for cooling, maintenance work, and
operation of the pressure relief (if present).
• The floor that the drive cabinet is installed on is of non-flammable material, as
smooth as possible, and strong enough to hold the weight of the unit. Examine
the flatness of the floor with a spirit level. The maximum permitted deviation from
a level surface is 5 mm (0.2 in) for every 3 meters (10 ft). If it is necessary, level the
installation site, as the cabinet does not have adjustable feet.

Necessary tools
The tools required for moving the unit to its final position, fastening it to the floor
and wall and tightening the connections are listed below:
• crane, fork-lift or pallet truck (check load capacity!), slate/spud bar, jack and rollers
• Pozidriv and Torx screwdrivers
64 Mechanical installation

• torque wrench
• set of wrenches or sockets.

Examining the delivery

The drive delivery contains:
• drive cabinet line-up
• optional modules (if ordered) installed onto the control unit(s) at the factory
• appropriate drive and optional module manuals
• delivery documents.
Make sure that there are no signs of damage. Before attempting installation and
operation, see the information on the type designation labels of the drive to verify
that the delivery is of the correct type.

Moving and unpacking the drive

Move the drive in its original packaging to the installation site as shown below to avoid
damaging the cabinet surfaces and door devices. When you are using a pallet truck,
check its load capacity before you move the drive.
The drive cabinet is to be moved in the upright position.
The center of gravity of the cabinet is high. Be therefore careful when moving the unit.
Avoid tilting.
 Mechanical installation 65

￭ Moving the drive in its packaging

Lifting the crate with a forklift

WARNING!
Obey the local laws and regulations that apply to lifting, such as the
requirements for planning the lift, the capacity and condition of the lifting
„ equipment, and personnel training.

10
66 Mechanical installation

Lifting the crate with a crane

WARNING!
Obey the local laws and regulations that apply to lifting, such as the
requirements for planning the lift, the capacity and condition of the lifting
equipment, and personnel training.

max 20

a Lifting point
b Optimal position for the lifting sling: as close to the traverse board as possible
 Mechanical installation 67
Mechanical installation 61

Moving the crate with a forklift

Moving the crate with a forklift

10

750 mm (29.5'')

￭ Removing the transport package

Remove the transport package as follows:
1. Undo the screws that attach the wooden parts of the transport crate to each
other.
2. Remove the wooden parts.
3. Remove the clamps with which the drive cabinet is mounted onto the transport
pallet by undoing the fastening screws.
4. Remove the plastic wrapping.
62 Mechanical installation

 Removing the transport package

68 Mechanical installation
Remove the transport package as follows:
1. Undo the screws that attach the wooden parts of the transport crate together.
￭ Moving the unpacked drive cabinet
2. Remove the wooden parts.
Lifting the cabinet with a crane
3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet
by undoing the fastening screws.
WARNING!
4. Remove
Obey the
theplastic wrapping.
local laws and regulations that apply to lifting, such as the
requirements for planning the lift, the capacity and condition of the lifting
 Moving the unpacked
equipment, drive
and personnel cabinet
training.
Lifting the cabinet with a crane
Lift the drive cabinet by its designated lifting points. Depending on the size of the
Lift the drive cabinet using its lifting eyes. The lifting eyes can be removed after the cabinet
cabinet, it has either bolt-on lifting lugs, or lifting bars with lifting holes.
is in its final position, but their mounting holes must be blocked to retain the degree of
protection.
Note: The minimum allowed height of the lifting slings with IP54 units is 2 meters
(6’7”).
Note: The minimum allowed height of the lifting slings with IP54 units is 2 meters (6’7”).

IP54

Moving the cabinet on rollers

WARNING!
Do not move marine versions (option +C121) on rollers.
 Mechanical installation 69

Lay the cabinet on the rollers and move it carefully

until close to its final location.
Remove the rollers by lifting the unit with a crane,
forklift, pallet truck or jack.

Moving the cabinet on its back

WARNING!
Do not transport a drive with an LCL or L filter on its back. It will damage the
filter.
Do not transport a drive with a sine filter (option +E206) on its back. It will
damage the filter.

Support the cabinet from below alongside the cubicle seams.

1 2

10
1 Cabinet back panel

2 Support

Moving the cabinet to its final position

Move the cabinet into its final position with a slate

bar (spud bar). Put a piece of wood between the
edge of the cabinet and the bar to protect the
cabinet frame.
 70 Mechanical installation

Attaching the cabinet to the floor and wall or roof

￭ General rules
• Install the drive in an upright vertical position.
• Leave 400 mm (15.75”) of free space above the basic roof level of the cabinet for
cooling.
• You can install the cabinet with its back against a wall (a), or back-to-back with
another unit (b).
• Leave some space (w) at the side where the cabinet outmost hinges are to allow
„ the doors to open sufficiently. The doors must open 120° to allow module
„
replacement.

> 400 mm (15.75”) w

120°

Note 1: Adjust the cabinet height before you attach the cabinet sections to the floor
or to each other. To adjust the height, use metal shims between the cabinet bottom
and floor.
Note 2: Depending on the size of the cabinet, it has either bolt-on lifting eyes, or lifting
bars with lifting holes. Remove the bolt-on lifting eyes if you need to use the holes to
attach the cabinet. If the cabinet is delivered with lifting bars, remove them and store
them for decommissioning. Plug any unused holes using the existing bolts and sealing
rings included. Tighten to 70 N·m (52 lbf·ft).
 Mechanical installation 71

WARNING!
Do not stand or walk on the cabinet roof. Make sure that nothing presses
„ against the roof, side or back plates or door. Do not store anything on the roof
while the drive is in operation.

￭ Attaching the cabinet (non-marine units)

„
Alternative 1 – Clamping
1. Insert the clamps (included) into the twin slots along the front and rear edges of
the cabinet frame body and fasten them to the floor with a bolt. The recommended
„ maximum distance between the clamps in the front edge is 800 mm (31.5”).
2. If floor mounting at the back is not possible, attach the top of the cabinet to the
wall with L-brackets (not included in the delivery) bolted to the lifting eye/bar
holes, and suitable hardware.
„
Clamping bottom to floor Attaching top to wall

M16

10
„

„
„

72 Mechanical installation

„
Alternative 2 – Using the holes inside the cabinet
1. Attach the cabinet to the floor through the bottom fastening holes with size
M10…M12 (3/8”…1/2”) bolts. The recommended maximum distance between the
front edge fastening points is 800 mm (31.5”).
2. If the back fastening holes are not accessible, attach the top of the cabinet to the
wall with L-brackets (not included in the delivery) bolted to the lifting eye/bar
holes.
„
Attaching bottom to floor Attaching cabinet top to wall

M16

Alternative 3 – Cabinets with plinth options +C164 and +C179

Attach the plinth to the floor with the L-brackets with which the cabinet is attached
to the transportation pallet.

„
 Mechanical installation 73

￭ Attaching the cabinet (marine units, option +C121)

See the dimension drawing delivered with the drive for details of the fastening points.
Fasten the cabinet to the floor and roof (wall) as follows:
1. Fasten the cabinet to the floor through the flat bars at the base of the back and
the front of the cabinet. Use M10 or M12 screws.

2. If there is not enough room behind the cabinet for installation, fasten the rear
edges of the flat bars (c) to the floor with clamps (a). Refer to the figure below.
3. Attach corner brackets (d) to the roof of the cabinet. Use M16 screws and the
lifting lug or lifting bar holes. Attach support brackets (e) between two cabinets.
Fasten the brackets on the rear, front and corners of the cabinet to the wall and/or10
roof with suitable hardware such as L- and U-brackets (f). Refer to the figure below.

2 3
e

a b
d

c f

a Clamp2). Refer to dimension drawing below d Corner bracket 1)

b Back panel of cabinet e Support bracket between two cabinets1)

c Flat bars at base of cabinet f L- and U-bracket 2)

1) In the delivery.
2) Not in the delivery, must be acquired by the installer.
74 Mechanical installation

Dimension drawing for clamp (a), example.

13 [0.51’’]
45 [1.77’’]

13.5 [0.53’’] 45
°

23.5 [0.93’’]

12 [0.47’’]
50 [1.97’’]

5 [0.20’’]
Ø13 [0.51’’]

100 [3.94’’]
50 [1.97’’]

Ø13 [0.51’’]
30 [1.18’’]

95 [3.74’’]
 Mechanical installation 75

Joining cabinet sections together

Wide cabinet line-ups are delivered in multiple sections. The sections must be joined
together at the installation site. There is a joining cubicle at the end of a section for
this purpose. The screws for joining the sections are in a plastic bag inside the cabinet.
1. Attach the first section to the floor.
2. Remove any plates covering the rear post of the joining cubicle.
3. Align the two sections. The illustration below shows the placement of the sections.

a b c

a First section
b Joining cubicle
c Second section

4. Attach the front and rear posts of the joining cubicle to the posts of the other
section with 16 screws (8 per post). Tighten the screws to 5 N·m (3.7 lbf·ft).

10

5. Attach the second section to the floor.

76 Mechanical installation

6. Connect the PE (ground) busbars using the M10 bolts included. Tighten to
35…40 N·m (25…30 lbf·ft). If necessary, adjust the connection between two PE
busbars with the spacer plates (included in the delivery).

b d e
c

a Bolt
b Spring washer
c Plain washer
d Self-clinching nut
e Spacer plate

7. Remove the shroud covering the DC busbars in the joining cubicle.

 Mechanical installation 77

8. Connect the DC and AC busbars. Tighten the bolts to 55…70 N·m (40…50 lbf·ft).

aa

a
a
aa a
Units with single DC busbars

aa
ad

ac ad
ab

ac
ab
Units with double DC busbars

Accessories kit identification:

Single DC busbars: 3AXD50000125876 10
Double DC busbars: 3AXD50000126361
Triple DC busbars (not shown): 3AXD50000126378
a Joint piece
b Plain washer with electroplated zinc coating and blue chromate passivation
c Spring washer with mechanically sprayed zinc coating
d Nut (M12)
78 Mechanical installation

Units with single AC busbars

c d
e b
a f
Units with double AC busbars

Accessories kit identification:

Single AC busbars: 3AXD50000126392
Double AC busbars: 3AXD50000126408
Triple AC busbars (not shown): 3AXD50000126514
a Bolt (M12)
b Bolt (M12)
c Joint piece
d Plain washer with electroplated zinc coating and blue chromate passivation
e Spring washer with mechanically sprayed zinc coating
f Nut (M12)

WARNING!
Make sure that you install the washers in the correct order, as shown in
the illustration. For example, placing an unpassivated zinc-coated spring
washer directly against the joint piece will cause corrosion.

WARNING!
Do not use any joining parts other than those delivered with the unit. The
parts are carefully selected to match the material of the busbars. Other
parts or materials can form a galvanic couple and cause corrosion.

9. Reinstall any shrouding removed earlier.

10. Repeat procedure for any further sections.
 Mechanical installation 79

Miscellaneous
￭ Cable duct in the floor below the cabinet
„A cable duct can be constructed below the 500 mm wide middle part of the cabinet.
The cabinet weight lies on the two 50 mm wide transverse sections which the floor
must carry.
Prevent the cooling air flow from the cable duct to the cabinet by bottom plates. To
ensure the degree of protection for the cabinet, use the original bottom plates delivered
with the unit. With user-defined cable entries, take care of the degree of protection,
fire protection and EMC compliance.
500 (19.68”)

50 (1.97”) 500 (19.68”) 50 (1.97”)

„￭ Arc welding 10
ABB does not recommend attaching the cabinet by arc welding. However, if arc welding
is the only option, connect the return conductor of the welding equipment to the
cabinet frame at the bottom within 0.5 meters (1’6”) of the welding point.

Note: The cabinet frame is zinc-plated.

WARNING!
Make sure that the return wire is connected correctly. Welding current must
not return via any component or cabling of the drive. If the welding return wire
is connected incorrectly, the welding circuit can damage electronic circuits in
the cabinet.

WARNING!
Do not inhale the welding fumes.

￭ Air inlet through the bottom of the cabinet (option +C128)

Drives with air inlet through the bottom of the cabinet (option +C128) are intended
for installation on an air duct in the floor. Each cubicle (except top entry adapter and
joining cubicles) have an inlet through the bottom plate. The option also adds a 130 mm
deep inlet area at the back of the cubicle.
An example of the air inlets in the cabinet bottom plate is shown below. Refer also to
the dimension drawings delivered with the drive.
 „

80 Mechanical installation

1 1 1 1

1 1 1 1

1 Air inlet area

Support the plinth of the cabinet all round.

The air duct must be able to supply a sufficient volume of cooling air. See technical
data for the minimum air flow values.
Top cable entry adapter and joining cubicles have no air inlet.

WARNING!
Make sure that the incoming air is sufficiently clean. If not, dust goes into the
cabinet. The outlet filter on the cabinet roof prevents dust from going out. The
collected dust can cause drive malfunction and danger of fire.

￭ Air outlet duct on the cabinet roof (option +C130)

The option adds air outlet ducts to each cubicle of the cabinet line-up. The outlet
diameter (and quantity) of the ducts depend on the cubicle width. The ducts used are
from the Veloduct series by FläktGroup.

Outlet duct Channel

Cubicle width
Recommended
(mm) Outer diameter Inner diameter Cross-sectional
Veloduct type 2 inner diameter
(mm) (mm) area (m )
(mm)

300 BDEA-6-020 200 194 0.030 200.0 … 200.7

BDEA-6-020 200 194 0.030 200.0 … 200.7

400 1)
BDEA-6-031 310 304 0.073 315.0 … 315.9

500 BDEA-6-031 310 304 0.073 315.0 … 315.9

600 BDEA-6-040 400 394 0.122 400.0 … 401.0

700 BDEA-6-040 400 394 0.122 400.0 … 401.0

800 2 × BDEA-6-031 310 304 0.145 315.0 … 315.9

1000 2 × BDEA-6-031 310 304 0.145 315.0 … 315.9

1) Both 200 mm and 300 mm ducts are in use. Refer to the delivery-specific dimension drawings for the actual measure.
 Mechanical installation 81

The ventilation system must keep the static pressure in the air outlet duct sufficiently
below the pressure of the room where the drive is located in order that the cabinet
fans can produce the required air flow through the cabinet. Make sure that no dirty
or moist air is able to flow backward to the drive in any case, even during off-time or
while servicing the drive or the ventilation system.

Calculating the required static pressure difference

The required static pressure difference between the exit air duct and the drive
installation room can be calculated as follows:
Δps = (1.5…2) · pd
where
pd = 0.5 · ρ · vm2
vm = q / Ac

pd Dynamic pressure
ρ Air density (kg/m3)
vm Average air velocity in the exit duct(s) (m/s)
q Rated air flow of the drive (m3/s)
Ac Cross-sectional area of the exit duct(s) (m2)

Example
The cabinet has 3 exit openings of 315 mm diameter. The rated air flow of the cabinet
is 4650 m3/h =1.3 m3/s.
10
Ac = 3 · 0.3152 · π / 4 = 0.234 m2
vm = 1.3 / 0.234 = 5.5 m/s
pd = 0.5 · ρ · vm2 = 0.5 · 1.1 · 5.52 = 17 Pa
The required pressure in the exit air duct is then 1.5…2 · 17 Pa = 26…34 Pa below the
pressure in the room.

￭ Installation of the cabinet on an elevated platform or a recess

Do not install the drive cabinet on an elevated platform if you only have the default
power module extraction/installation ramp. It is applicable only for the height of the
cabinet plinth. This applies to both the deliveries with the standard cabinet plinth and
the deliveries with optional cabinet plinths (options +C164, +C179).
If you must install the cabinet on an elevated platform, make sure that you obey these
guidelines:
• The power module extraction/installation ramp meets these requirements:
• The ramp is applicable for the total height of the plinth and the platform.
• The slope of the ramp does not exceed 15 degrees.
• The ramp can carry the weight of a heavy power module.
• You can attach the ramp securely to the cabinet.
• There is enough space in front of the cabinet for the ramp. The higher the total
height of the plinth and the platform is, the longer the ramp must be.
82 Mechanical installation

• The elevated platform complies with the installation floor specification for the
drive cabinet.
• The drive cabinet is attached to the elevated platform as specified in the floor
mounting instructions.
 Mechanical installation 83

Lifting lugs and bars

￭ Certificate of conformity
The certificate is available in ABB Library at www.abb.com/drives/documents
(document number 3AXD10001061361).

￭ Declarations of conformity

Link to Declaration of conformity according to EU Machinery Directive

2006/42/EU (3AXD10000686042)

Link to Declaration of conformity according to UK Supply of Machinery (Safety)

Regulations 2008 (3AXD10001329600)

10
84
 Guidelines for planning the electrical installation 85

5
Guidelines for planning the electrical
installation

Contents of this chapter

This chapter contains instructions for planning the electrical installation of the drive.
Some instructions are mandatory to follow in every installation, others provide useful
information that only concerns certain applications.

Limitation of 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. Furthermore, if the
recommendations given by ABB are not followed, the drive may experience problems
that the warranty does not cover.

￭ North America
Installations must be compliant with NFPA 70 (NEC)1) and/or Canadian Electrical Code
(CE) along with state and local codes for your location and application.
1) National Fire Protection Association 70 (National Electric Code).
86 Guidelines for planning the electrical installation

Selecting the supply transformer

￭ Basic guidelines
1. Define the apparent power of the transformer. You can use this rule of thumb:
SN (kVA) = 1.16 × sum of the motor shaft power (kW)
2. Define the nominal voltage for the transformer secondary winding according to
the nominal input voltage of the drive. See the supply unit hardware manual.
3. Make sure that the transformer complies with the electrical power network
specification of the drive. See the appropriate drive or supply unit hardware manual
for:
• nominal input voltage, allowed voltage variation and imbalance
• nominal frequency and allowed variation
• short-circuit withstand strength and short-circuit current protection
requirements
• etc.
4. Consider the additional notes below.
5. Contact the transformer manufacturer for more information on the transformer
selection.

￭ Additional notes
A drive larger than 500 kVA with an IGBT supply unit
Use a two-winding transformer dedicated to drives. Alternatively, use a three-winding
transformer, and connect only drives to the same secondary winding. If it is necessary
to connect other equipment to the same transformer winding, obey these instructions
to prevent damage:
• Do not connect a direct online motor to the same transformer winding as the
drive unless the motor is designed for use with variable frequency drives.
• Do not connect capacitive loads (for example, lighting, PCs, PLCs, power factor
compensation capacitors) to the same transformer winding as the drive.
 Guidelines for planning the electrical installation 87

1
2 2

3 3

6 5 4

1
2

6 4
5

1 Medium voltage network

2 Transformer
3 Low voltage network
4 Drive
5 Other drives
6 Other load (not drives)

Selecting the supply disconnecting device

The drive is equipped with a main disconnecting device as standard. Depending on
the size of the drive, and the selected options, the type of disconnecting device may
vary. Examples: switch-disconnector, withdrawable air circuit breaker, etc.

Selecting the main contactor or breaker

Depending on the drive type and size, it is fitted with a main contactor or a main
breaker by default. With certain drive types, you can select either of the two.
88 Guidelines for planning the electrical installation

Examining the compatibility of the motor and drive

Use asynchronous AC induction motors, permanent magnet synchronous motors, AC
induction servomotors or ABB synchronous reluctance motors (SynRM motors) with
the drive.
Select the motor size and drive type from the rating table on basis of the AC line
voltage and motor load. You can find the rating table in the appropriate hardware
manual. You can also use the DriveSize PC tool.
Make sure that the motor can be used with an AC drive. See Requirements
tables (page 88). For basics of protecting the motor insulation and bearings in drive
systems, see Protecting the motor insulation and bearings (page 88).
Note:
• Consult the motor manufacturer before using a motor with nominal voltage that
differs from the AC line voltage connected to the drive input.
• The voltage peaks at the motor terminals are relative to the supply voltage of the
drive, not to the drive output voltage.

￭ Protecting the motor insulation and bearings

The drive employs modern IGBT inverter technology. Regardless of frequency, the
drive output comprises pulses of approximately the drive DC bus voltage with a very
short rise time. The pulse voltage can almost double at the motor terminals, depending
on the attenuation and reflection properties of the motor cable and the terminals.
This can cause additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can generate current pulses that flow through the motor bearings. This
can gradually erode the bearing races and rolling elements.
du/dt filters protect motor insulation system and reduce bearing currents. Common
mode filters mainly reduce bearing currents. Insulated N-end (non-drive end) bearings
protect the motor bearings.

￭ Requirements tables
These tables show how to select the motor insulation system and when a drive du/dt
and common mode filters and insulated N-end (non-drive end) motor bearings are
required. Ignoring the requirements or improper installation may shorten motor life
or damage the motor bearings and voids the warranty.
 Guidelines for planning the electrical installation 89

Requirements for ABB motors, Pn < 100 kW (134 hp)

See also Abbreviations (page 92).

Motor type Nominal AC line Requirement for

voltage
Motor insula- ABB du/dt and common mode filters, insulated
tion system N-end motor bearings
Pn < 100 kW and frame size < IEC 315
Pn < 134 hp and frame size < NEMA 500
Random-wound Un ≤ 500 V Standard -
M2_, M3_ and M4_
500 V < Un ≤ 600 V Standard + du/dt
Reinforced -
600 V < Un ≤ 690 V Reinforced + du/dt
(cable length ≤
150 m)
600 V < Un ≤ 690 V Reinforced -
(cable length >
150 m)
Form-wound HX_ 380 V < Un ≤ 690 V Standard N/A
and AM_

Old 1) form-wound 380 V < Un ≤ 690 V Check with + N + du/dt with voltages over 500 V + CMF
HX_ and modular the motor
manufac-
turer.

Random-wound HX_ 0 V < Un ≤ 500 V Enamelled + N + CMF

and AM_ 2) 500 V < Un ≤ 690 V
wire with
+ N + du/dt + CMF
fiber glass
taping
HDP Consult the motor manufacturer.

1) manufactured before 1.1.1998

2) For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
90 Guidelines for planning the electrical installation

Requirements for ABB motors, Pn > 100 kW (134 hp)

See also Abbreviations (page 92).

Motor type Nominal AC line Requirement for

voltage
Motor insula- ABB du/dt and common mode filters, insulated
tion system N-end motor bearings
100 kW ≤ Pn < 350 kW Pn ≥ 350 kW
or or
IEC 315 ≤ frame size < frame size ≥ IEC 400
IEC 400
134 hp ≤ Pn < 469 hp Pn ≥ 469 hp
or or
NEMA 500 ≤ frame size frame size > NEMA 580
≤ NEMA 580
Random-wound Un ≤ 500 V Standard +N + N + CMF
M2_, M3_ and M4_
500 V < Un ≤ 600 V Standard + N + du/dt + N + du/dt + CMF
Reinforced +N + N + CMF
600 V < Un ≤ 690 V Reinforced + N + du/dt + N + du/dt + CMF
(cable length ≤
150 m)
600 V < Un ≤ 690 V Reinforced +N + N + CMF
(cable length >
150 m)
Form-wound HX_ 380 V < Un ≤ 690 V Standard + N + CMF Pn < 500 kW: +N + CMF
and AM_
Pn ≥ 500 kW: +N +
du/dt + CMF

Old 1) form-wound 380 V < Un ≤ 690 V Check with + N + du/dt with voltages over 500 V + CMF
HX_ and modular the motor
manufac-
turer.

Random-wound HX_ 0 V < Un ≤ 500 V Enamelled + N + CMF

and AM_ 2) 500 V < Un ≤ 690 V
wire with
+ N + du/dt + CMF
fiber glass
taping
HDP Consult the motor manufacturer.

1) manufactured before 1.1.1998

2) For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
 Guidelines for planning the electrical installation 91

Requirements for non-ABB motors, Pn < 100 kW (134 hp)

See also Abbreviations (page 92).

Motor type Nominal AC line Requirement for

voltage
Motor insula- ABB du/dt and common mode filters, insulated
tion system N-end motor bearings
Pn < 100 kW and frame size < IEC 315
Pn < 134 hp and frame size < NEMA 500
Random-wound and Un ≤ 420 V Standard: -
form-wound ÛLL = 1300 V
420 V < Un ≤ 500 V Standard: + du/dt
ÛLL = 1300 V
Reinforced: -
ÛLL = 1600 V,
0.2 µs rise
time
500 V < Un ≤ 600 V Reinforced: + du/dt
ÛLL = 1600 V
Reinforced: -
ÛLL = 1800 V
600 V < Un ≤ 690 V Reinforced: + du/dt
ÛLL = 1800 V
Reinforced: -
ÛLL = 2000 V,
0.3 µs rise
time 1)

1) If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor
braking cycles, check with the motor manufacturer if additional output filters are needed.
92 Guidelines for planning the electrical installation

Requirements for non-ABB motors, Pn > 100 kW (134 hp)

See also Abbreviations (page 92).

Motor type Nominal AC line Requirement for

voltage
Motor insula- ABB du/dt and common mode filters, insulated
tion system N-end motor bearings
100 kW ≤ Pn < 350 kW Pn ≥ 350 kW
or or
IEC 315 ≤ frame size < frame size ≥ IEC 400
IEC 400
134 hp ≤ Pn < 469 hp Pn ≥ 469 hp
or or
NEMA 500 ≤ frame size frame size > NEMA 580
≤ NEMA 580
Random-wound and Un ≤ 420 V Standard: + N or CMF + N + CMF
form-wound ÛLL = 1300 V
420 V < Un ≤ 500 V Standard: + du/dt + (N or CMF) + N + du/dt + CMF
ÛLL = 1300 V
Reinforced: + N or CMF + N + CMF
ÛLL = 1600 V,
0.2 µs rise
time
500 V < Un ≤ 600 V Reinforced: + du/dt + (N or CMF) + N + du/dt + CMF
ÛLL = 1600 V
Reinforced: + N or CMF + N + CMF
ÛLL = 1800 V
600 V < Un ≤ 690 V Reinforced: + du/dt + N + N + du/dt + CMF
ÛLL = 1800 V
Reinforced: + N + CMF + N + CMF
ÛLL = 2000 V,
0.3 µs rise
time 1)

1) If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor
braking cycles, check with the motor manufacturer if additional output filters are needed.

Abbreviations

Abbr. Definition
Un Nominal AC line voltage
ÛLL Peak line-to-line voltage at motor terminals which the motor insulation must
withstand
Pn Motor nominal power
du/dt du/dt filter at the output of the drive
CMF Common mode filter of the drive
N N-end bearing: insulated motor non-drive end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor
manufacturer.
 Guidelines for planning the electrical installation 93

Availability of du/dt filter and common mode filter by drive type

Availability of common mode fil-

Product type Availability of du/dt filter
ter (CMF)
ACS880-37 Standard Standard

Additional requirements for explosion-safe (EX) motors

If you use an explosion-safe (EX) motor, obey the rules in the requirements table above.
In addition, consult the motor manufacturer for any further requirements.

Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and
AM_
Use the selection criteria given for non-ABB motors.

Additional requirements for braking applications

When the motor brakes the machinery, the intermediate circuit DC voltage of the drive
increases, the effect being similar to the motor supply voltage increasing by up to
20 percent. Consider this voltage increase when specifying the motor insulation
requirements if the motor will be braking a large part of its operation time.
Example: Motor insulation requirement for a 400 V AC line voltage application must
be selected as if the drive were supplied with 480 V.

Additional requirements for the regenerative and low harmonics drives

It is possible to increase the intermediate circuit DC voltage from the nominal
(standard) level with a parameter in the control program. If you choose to do this,
select the motor insulation system which withstands the increased DC voltage level.

Additional requirements for ABB high-output and IP23 motors

The rated output power of high output motors is higher than what is stated for the
particular frame size in EN 50347 (2001).
This table shows the requirements for protecting the motor insulation and bearings
in drive systems for ABB random-wound motor series (for example, M3AA, M3AP and
M3BP).

Nominal AC supply Requirement for

voltage
Motor insulation ABB du/dt and common mode filters, insulated N-end motor
system bearings
Pn < 100 kW 100 kW ≤ Pn < Pn ≥ 200 kW
200 kW
Pn < 140 hp 140 hp ≤ Pn < Pn ≥ 268 hp
268 hp
Un ≤ 500 V Standard - +N + N + CMF
500 V < Un ≤ 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
Reinforced - +N + N + CMF
600 V < Un ≤ 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF

Additional requirements for non-ABB high-output and IP23 motors

The rated output power of high-output motors is higher than what is stated for the
particular frame size in EN 50347 (2001).
94 Guidelines for planning the electrical installation

If you plan to use a non-ABB high-output motor or an IP23 motor, consider these
additional requirements for protecting the motor insulation and bearings in drive
systems:
• If motor power is below 350 kW: Equip the drive and/or motor with the filters
and/or bearings according to the table below.
• If motor power is above 350 kW: Consult the motor manufacturer.

Nominal AC supply Requirement for

voltage
Motor insulation system ABB du/dt and common mode filters, insulated N-
end motor bearings
Pn < 100 kW or frame size 100 kW < Pn < 350 kW or
< IEC 315 IEC 315 < frame size < IEC
400
Pn < 134 hp or frame size 134 hp < Pn < 469 hp or
< NEMA 500 NEMA 500 < frame size <
NEMA 580
Un ≤ 420 V Standard: ÛLL = 1300 V + N or CMF + N or CMF
420 V < Un < 500 V Standard: ÛLL = 1300 V + du/dt + (N or CMF) + N + du/dt + CMF
Reinforced: ÛLL = 1600 V, + N or CMF + N or CMF
0.2 microsecond rise time
500 V < Un ≤ 600 V Reinforced: ÛLL = 1600 V + du/dt + (N or CMF) + N + du/dt + CMF
Reinforced: ÛLL = 1800 V + N or CMF + N + CMF
600 V < Un ≤ 690 V Reinforced: ÛLL = 1800 V + N + du/dt + N + du/dt + CMF

Reinforced: ÛLL = 2000 V, + N + CMF + N + CMF

0.3 microsecond rise
time 1)

1) If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor
braking cycles, check with the motor manufacturer if additional output filters are needed.

Additional data for calculating the rise time and the peak line-to-line voltage
The diagrams below show the relative peak line-to-line voltage and rate of change of
voltage as a function of the motor cable length. If you need to calculate the actual
peak voltage and voltage rise time considering the actual cable length, proceed as
follows:
• Peak line-to line voltage: Read the relative ÛLL/Un value from the diagram below
and multiply it by the nominal supply voltage (Un).
• Voltage rise time: Read the relative values ÛLL/Un and (du/dt)/Un from the diagram
below. Multiply the values by the nominal supply voltage (Un) and substitute into
equation t = 0.8 · ÛLL/(du/dt).
 Guidelines for planning the electrical installation 95

3.0
ÛLL/UN
2.5

2.0

1.5
du/dt
------------- (1/Ps)
UN
1.0

0.5

0.0
100 200 300 l (m)

I Motor cable length

ÛLL/UN Relative peak line-to-line voltage
(du/dt)/UN Relative du/dt value

Note: ÛLL and du/dt values are approximately 20% higher during resistor braking.
Note: Due to installation, cable types and motor inductance, the worst case may be higher than the
existing values in the curve. Note that actual value depends on the converter type.

„ sine filters
Additional note for
A sine filter also protects the motor insulation system. The peak phase-to-phase
voltage with a sine filter is approximately 1.5 · Un.

Selecting the power cables

￭ Power cable selection procedure and applicability check
Select each power cable as follows. Obey the local regulations.
1. Select the cable type. Obey the general guidelines and recommendations for the
drive power cabling. Refer to General guidelines (page 96) and Power cable
types (page 96) .
2. Select the cable size. Refer to the listing of typical power cable sizes given in the
technical data.
3. Make sure that the short-circuit rating of the cable is sufficient. Take into account
the disconnection time of the protective device. If the rating is not sufficient,
select a larger cable, increase the number of parallel cables or change the cable
to a type with higher conductor temperature rating.
4. Select the cable lugs.
5. Make sure that the cable can enter the cabinet through the cable entry plate. Refer
to the dimension drawings of the drive delivery or technical data in the drive
hardware manual. For special cable entry solutions, consult ABB.
6. Make sure that there is sufficient space to install the cable(s) and cable lugs to
the terminals. Refer to the terminal and cable entry data given in the technical
data.
96 Guidelines for planning the electrical installation

￭ General guidelines
Select the input power and motor cables according to local regulations.
• Current: Select a cable capable of carrying the maximum load current and suitable
for the prospective short-circuit current provided by the supply network. The
method of installation and ambient temperature affect the cable current carrying
capacity. Obey local regulations and laws.
• Temperature: For an IEC installation, select a cable rated for at least 70 °C (158 °F)
maximum permissible temperature of conductor in continuous use.
For North America, select a cable rated for at least 75 °C (167 °F).
Important: For certain product types or option configurations higher temperature
rating may be required. See the technical data for details.
• Voltage: 600 V AC cable is accepted for up to 500 V AC. 750 V AC cable is accepted
for up to 600 V AC. 1000 V AC cable is accepted for up to 690 V AC.
To comply with the EMC requirements of the CE mark, use one of the preferred cable
types. See Preferred power cable types (page 96).
Symmetrical shielded cable reduces electromagnetic emission of the whole drive
system as well as the stress on motor insulation, bearing currents and wear.
Metal conduit reduces electromagnetic emission of the whole drive system.

￭ Typical power cable sizes

See the technical data in the appropriate hardware manual.

￭ Power
„ cable types
Preferred power cable types
„
This section shows the preferred cable types. Make sure that the selected cable type
also complies with local/state/country electrical codes.

Cable type Use as input power cabling Use as motor cabling and as
brake resistor cabling

PE Yes Yes

Symmetrical shielded (or ar-

mored) cable with three phase
conductors and concentric PE
conductor as shield (or armor)

PE Yes Yes

Symmetrical shielded (or ar-

mored) cable with three phase
conductors and symmetrically
constructed PE conductor and a
shield (or armor)
 Guidelines for planning the electrical installation 97

Cable type Use as input power cabling Use as motor cabling and as
brake resistor cabling

Yes Yes

PE

„
Symmetrical shielded (or ar-
mored) cable with three phase
conductors and a shield (or ar-
mor), and separate PE conduct-
or/cable 1)

1) A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the PE use.

Alternate power cable types

Cable type Use as input power cabling Use as motor cabling and as
brake resistor cabling
Yes Yes with phase conductor smaller
than 10 mm2 (8 AWG) Cu, or mo-
tors up to 30 kW (40 hp)

Four-conductor armored cable

(three phase conductors and PE)
Yes Yes with motors up to 100 kW
(135 hp). A potential equalization
between the frames of motor and
driven equipment is required.
„
Shielded (Al/Cu shield or armor) 1)
four-conductor cable (three phase
conductors and a PE)
PE Yes No
WARNING!
A single-core cable system: three If you use unshielded single-
phase conductors and PE conduct- core cables in an IT network,
or on cable tray make sure that the non-
conductive outer sheath
L1 L2 L3
L2 L3 L3 L1 L1 L2
(jacket) of the cables have
good contact with a prop-
Preferable cable arrangement to erly grounded conductive
avoid voltage or current unbal- surface. For example, install
ance between the phases the cables on a properly
grounded cable tray. Other-
wise voltage may become
present on the non-conduct-
„ ive outer sheath of the
cables, and there is even a
risk of an electric shock.

1) Armor may act as an EMC shield, as long as it provides the same performance as a concentric EMC shield of a
shielded cable. To be effective at high frequencies, the shield conductivity must be at least 1/10 of the phase
conductor conductivity. The effectiveness of the shield can be evaluated based on the shield inductance, which
must be low and only slightly dependent on frequency. The requirements are easily met with a copper or aluminum
shield/armor. The cross-section of a steel shield must be ample and the shield helix must have a low gradient. A
galvanized steel shield has a better high-frequency conductivity than a non-galvanized steel shield.
98 Guidelines for planning the electrical installation

Not allowed power cable types

Cable type Use as input power cabling Use as motor cabling and as
brake resistor cabling
No No
PE

Symmetrical shielded cable with

„
individual shields for each phase
conductor

￭ Power cable shield

If the cable shield is used as the sole protective earth (PE) conductor, make sure that
its conductivity agrees with the PE conductor requirements.
„
To effectively suppress radiated and conducted radio-frequency emissions, the cable
shield conductivity must be at least 1/10 of the phase conductor conductivity. The
requirements are easily met with a copper or aluminum shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of a
concentric layer of copper wires with an open helix of copper tape or copper wire. The
better and tighter the shield, the lower the emission level and bearing currents.

1 2 3 4 5

1 Insulation jacket
2 Helix of copper tape or copper wire
3 Copper wire shield
4 Inner insulation
5 Cable core

Grounding requirements
This section gives general requirements for grounding the drive. When you plan the
grounding of the drive, obey all the applicable national and local regulations.
The conductivity of the protective earth conductor(s) must be sufficient.
Unless local wiring regulations state otherwise, the cross-sectional area of the
protective earth conductor must agree with the conditions that require automatic
disconnection of the supply required in 411.3.2 of IEC 60364-4-41:2005 and be capable
of withstanding the prospective fault current during the disconnection time of the
protective device. The cross-sectional area of the protective earth conductor must be
selected from the table below or calculated according to 543.1 of IEC 60364-5-54.
The table shows the minimum cross-sectional area of the protective earth conductor
related to the phase conductor size according to IEC/UL 61800-5-1 when the phase
 Guidelines for planning the electrical installation 99

conductor(s) and the protective earth conductor are made of the same metal. If they
are different metals, the cross-sectional area of the protective earth conductor must
be determined in a manner which produces a conductance equivalent to that which
results from the application of this table.

Cross-sectional area of the phase conductors Minimum cross-sectional area of the corresponding
S (mm2) protective earth conductor
Sp (mm2)
S ≤ 16 S 1)
16 < S ≤ 35 16
35 < S S/2

1) For the minimum conductor size in IEC installations, refer to Additional grounding requirements – IEC (page 99).

If the protective earth conductor is not part of the input power cable or input power
cable enclosure, the minimum permitted cross-sectional area is:
• 2.5 mm2 if the conductor is mechanically protected,
or
• 4 mm2 if the conductor is not mechanically protected. If the equipment is
cord-connected, the protective earth conductor must be the last conductor to be
interrupted if there is a failure in the strain relief mechanism.

￭ Additional grounding requirements – IEC

This section gives grounding requirements according to standard IEC/EN 61800-5-1.
Because the normal touch current of the drive is more than 3.5 mA AC or 10 mA DC:
• the minimum size of the protective earth conductor must comply with the local
safety regulations for high protective earth conductor current equipment, and
• you must use one of these connection methods:
1. a fixed connection and:
• a protective earth conductor with a minimum cross-sectional area of
10 mm2 Cu or 16 mm2 Al (as an alternative when aluminum cables are
permitted),
or
• a second protective earth conductor of the same cross-sectional area as
the original protective earth conductor,
or
• a device that automatically disconnects the supply if the protective earth
conductor is damaged.
2. a connection with an industrial connector according to IEC 60309 and a
minimum protective earth conductor cross-section of 2.5 mm2 as part of a
multi-conductor power cable. Sufficient strain relief must be provided.

If the protective earth conductor is routed through a plug and socket, or similar means
of disconnection, it must not be possible to disconnect it unless power is
simultaneously removed.

Note: You can use power cable shields as protective earth conductors only when their
conductivity is sufficient.
 100 Guidelines for planning the electrical installation

￭ Additional grounding requirements – UL (NEC)

This section gives grounding requirements according to standard UL 61800-5-1.
The protective earth conductor must be sized as specified in Article 250.122 and table
250.122 of the National Electric Code, ANSI/NFPA 70.
For cord-connected equipment, it must not be possible to disconnect the protective
earth conductor before power is removed.

Selecting the control cables

￭ Shielding
Only use shielded control cables.
Use a double-shielded twisted pair cable for analog signals. ABB recommends this
type of cable also for the pulse encoder signals. Use one individually shielded pair for
each signal. Do not use common return for different analog signals.
A double-shielded cable (a) is the best alternative for low-voltage digital signals, but
single-shielded (b) twisted pair cable is also acceptable.

a b

￭ Signals in separate cables

„ Run analog and digital signals in separate, shielded cables. Do not mix 24 V DC and
115/230 V AC signals in the same cable.

￭ Signals that can be run in the same cable

If their voltage does not exceed 48 V, relay-controlled signals can be run in the same
„ cables as digital input signals. The relay-controlled signals should be run as twisted
pairs.

￭ Relay cable
The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL,
Germany) has been tested and approved by ABB.

„￭ Control panel to drive cable

Use EIA-485, Cat 5e (or better) cable with male RJ45 connectors. The maximum length
of the cable is 100 m (328 ft).

￭ PC tool cable

„ Connect the Drive Composer PC tool to the drive through the USB port of the control
panel. Use a USB Type A (PC) - Type Mini-B (control panel) cable. The maximum length
of the cable is 3 m (9.8 ft).
 Guidelines for planning the electrical installation 101

Routing the cables

￭ General guidelines – IEC
• Route the motor cable away from other cables. Motor cables of several drives can
be run in parallel installed next to each other.
• Install the motor cable, input power cable and control cables on separate trays.
• Avoid long parallel runs of motor cables with other cables.
• Where control cables must cross power cables, make sure that they are arranged
at an angle as near to 90 degrees as possible.
• Do not run extra cables through the drive.
• Make sure that the cable trays have good electrical bonding to each other and to
the grounding electrodes. Aluminum tray systems can be used to improve local
equalizing of potential.
The following figure illustrates the cable routing guidelines with an example drive.

1
min. 300 mm (12 in)
2 4

4
min. 300 mm (12 in) min. 500 mm (20 in)
2
3

90°
3 1
min. 200 mm (8 in)
min. 500 mm (20 in)
2
3

1 Motor cable
2 Input power cable
3 Control cable
4 Brake resistor or chopper cable (if any)

￭ Continuous motor cable shield/conduit and metal enclosure for

equipment on the motor cable
To minimize the emission level when safety switches, contactors, connection boxes
or similar equipment are installed on the motor cable between the drive and the motor:
• Install the equipment in a metal enclosure.
• Use either a symmetrical shielded cable, or install the cabling in a metal conduit.
• Make sure that there is a good and continuous galvanic connection in the
shield/conduit between drive and motor.
• Connect the shield/conduit to the protective ground terminal of the drive and the
motor.
102 Guidelines for planning the electrical installation

￭ Separate control cable ducts

Put 24 V DC and 230 V AC (120 V AC) control cables in separate ducts, unless the 24 V DC
cable is insulated for 230 V AC (120 V AC) or insulated with an insulation sleeving for
230 V AC (120 V AC).

230 V AC 24 V DC
(120 V AC)
230 V AC
24 V DC (120 V AC)

Protecting the drive, input power cable, motor and motor

cable in short circuit situations and against thermal
overload
￭ Protecting the input cabling and the drive upon a short-circuit
To protect the input cable in short-circuit situations, install fuses or a suitable circuit
breaker at the supply side of the cabling.
The drive is equipped with fuses as standard. In case of a short-circuit inside the drive,
the fuses protect the drive, restrict drive damage, and prevent damage to adjoining
equipment.

￭ Protecting the motor and motor cable in short-circuits

The drive protects the motor cable and motor in a short-circuit situation when:
• the motor cable is sized correctly
• the motor cable type complies with the motor cable selection guidelines by ABB
• the cable length does not exceed the allowed maximum length specified for the
drive
• the setting of parameter 99.10 Motor nominal power in the drive is equal with the
value given on the motor rating plate.
The electronic power output short-circuit protection circuitry meets the requirements
of IEC 60364-4-41:2005 + AMD1:2017.

￭ Protecting the drive and the power cables against thermal overload
The drive protects itself and the input and motor cables against thermal overload
when the cables are sized according to the nominal current of the drive. No additional
thermal protection devices are needed.

WARNING!
If the drive is connected to multiple motors, use a separate circuit breaker or
fuses for protecting each motor cable and motor against overload. The drive
overload protection is tuned for the total motor load. It may not trip due to an
overload in one motor circuit only.
 Guidelines for planning the electrical installation 103

￭ Protecting the motor against thermal overload

According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive includes a
motor thermal protection function that protects the motor and switches off the
current when necessary. Depending on a drive parameter value, the function either
monitors a calculated temperature value (based on a motor thermal model) or an
actual temperature indication given by motor temperature sensors.
The motor thermal protection model supports thermal memory retention and speed
sensitivity. The user can tune the thermal model further by feeding in additional motor
and load data.
The most common temperature sensor types are PTC or Pt100.
For more information, see the firmware manual.

￭ Protecting the motor against overload without thermal model or

temperature sensors
Motor overload protection protects the motor against overload without using motor
thermal model or temperature sensors.
Motor overload protection is required and specified by multiple standards including
the US National Electric Code (NEC) and the common UL/IEC 61800-5-1 standard in
conjunction with UL/IEC 60947-4-1. The standards allow for motor overload protection
without external temperature sensors.
The protection feature of the drive allows the user to specify the class of operation
in the same manner as the overload relays are specified in standards UL/IEC 60947-4-1
and NEMA ICS 2.
The motor overload protection supports thermal memory retention and speed
sensitivity.
For more information, see drive firmware manual.

Protecting the drive against ground faults

The drive is equipped with an internal ground fault protective function to protect the
unit against ground faults in the motor and motor cable. This function is not a
personnel safety or a fire protection feature. See the firmware manual for more
information.
An optional ground fault monitoring device (+Q954) is available for IT (ungrounded)
systems. The option includes a ground fault indicator on the drive cabinet door.

￭ Residual current device compatibility

The drive is suitable for use with residual current devices of Type B.

Note: As standard, the drive contains capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the ground leakage
current and may cause nuisance faults in residual current devices.

Implementing the emergency stop function

You can order the drive with an emergency stop function (option).
See the appropriate option manual for more information.
104 Guidelines for planning the electrical installation

Option User’s manual Manual code

code (English)
+Q951 Emergency stop, stop category 0 (using main contactor/breaker) 3AUA0000119895
+Q952 Emergency stop, stop category 1 (using main contactor/breaker) 3AUA0000119896
+Q963 Emergency stop, stop category 0 (using Safe torque off) 3AUA0000119908
+Q964 Emergency stop, stop category 1 (using Safe torque off) 3AUA0000119909
+Q978 Emergency stop, stop category 0 or 1 (using main contactor/breaker 3AUA0000145920
and Safe torque off)
+Q979 Emergency stop, stop category 0 or 1 (using Safe torque off) 3AUA0000145921

Implementing the Safe torque off function

See chapter The Safe torque off function (page 287).

Implementing the Prevention of unexpected start-up

function
You can order the drive with a Prevention of unexpected start-up (POUS) function.
The POUS function disables the control voltage of the power semiconductors of the
drive (inverter) output stage. This prevents the drive from generating the torque
required to rotate the motor. POUS enables a short-time maintenance work (like
cleaning) on the non-electrical parts of the machinery without switching off and
disconnecting the drive.
See the appropriate option manual for more information.

Option User’s manual Manual code

code (English)
+Q950 Prevention of unexpected start-up, with FSO-xx safety functions module 3AUA0000145922
+Q957 Prevention of unexpected start-up, with safety relay 3AUA0000119910

Implementing an ATEX-certified motor thermal protection

With option +Q971, the drive provides ATEX-certified safe motor disconnection without
contactor using the drive Safe torque off function. To implement the thermal protection
of a motor in explosive atmosphere (Ex motor), you must also:
• use an ATEX-certified Ex motor
• order an ATEX-certified thermistor protection module for the drive (option +L537),
or acquire and install an ATEX-compliant protection relay
• do the necessary connections.
For cabinet-built drives, an ATEX-certified motor thermal protection function is also
available (option +L513+Q971, or +L514+Q971). The drive is equipped with an
ATEX-certified Safe motor disconnection function and with ATEX-compliant protection
relays for PTC or Pt100 temperature sensors.
For more information, see:
 Guidelines for planning the electrical installation 105

User's manual Manual code

(English)

ATEX-certified Safe disconnection function, Ex II (2) GD for ACS880 drives (+Q971) 3AUA0000132231
application guide

FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option 3AXD50000027782

+L537+Q971) for ACS880 drives user's manual

FPTC-02 ATEX-certified thermistor protection module, instructions for pairing the 3AXD50001096700
module with a drive with the ATEX-certified disconnection function (option +Q971)

ATEX-certified motor thermal protection functions for cabinet-built ACS880 drives 3AXD50000014979
(options +L513+Q971 and +L514+Q971) user’s manual

Implementing the functions provided by the FSO safety

functions module
You can order the drive with an FSO-12 safety functions module (option +Q973) or
FSO-21 safety functions module (option +Q972). An FSO module enables the
implementation of functions such as Safe brake control (SBC), Safe stop 1 (SS1), Safe
stop emergency (SSE), Safely limited speed (SLS) and Safe maximum speed (SMS).
The settings of the FSO module have default values when delivered from the factory.
The wiring of the external safety circuit and configuration of the FSO module are the
responsibility of the user.
The FSO module reserves the standard Safe torque off (STO) connection of the drive
(or inverter) control unit. STO can still be utilized by other safety circuits through the
FSO module.
See the appropriate manual for more information.

Name Code
FSO-12 safety functions module user's manual 3AXD50000015612
FSO-21 safety functions module user's manual 3AXD50000015614

Implementing the functions provided by the FSPS-21

PROFIsafe safety functions module
You can order the drive with an FSPS-21 PROFIsafe safety functions module (option
+Q986), which provides PROFINET and PROFIsafe connection to the drive and has two
safety functions integrated into it: Safe torque off (STO) and Safe stop 1, time
monitored (SS1-t). With the module, it is possible to control the drive via PROFINET
and safely stop the drive via PROFIsafe.
The Safe torque off function can be controlled with PROFIsafe. When using FSPS-21
PROFIsafe safety functions module, other safety functions are not available. Use of
PROFIsafe and PROFINET is also possible by using FPNO-21 and FSO option modules.
The settings of the module have default values when delivered from the factory. The
wiring and configuration of the FSPS-21 module are the responsibility of the user.
For more information, see FSPS-21 PROFIsafe safety functions module user's manual
(3AXD50000158638 [English]).
106 Guidelines for planning the electrical installation

Implementing the functions provided by the FSCS-21 CIP

Safety™ functions module
You can order the drive with FSCS-21 CIP Safety™ functions module (option +Q989).
The module has two safety functions integrated into it: Safe torque off (STO) and
Safe stop 1, time monitored (SS1-t). With the module, you can connect a drive to an
Ethernet network and a safety PLC. The module supports the CIP Safety™
communication technology through the EtherNet/IP communication protocol. The
intended use of the FSCS module is to safely stop the drive when necessary. A safety
PLC can activate the safety functions of the module.
The settings of the FSCS module have default values when delivered from the factory.
The wiring and configuration of the FSCS module are the responsibility of the user.
The FSCS module reserves the standard Safe torque off (STO) connection of the drive
(or inverter) control unit.
For more information, refer to FSCS-21 CIP Safety™ functions module user's manual
(3AXD50001065478 [English]).

Implementing the power loss ride-through function

If the incoming supply voltage is cut off, the drive will continue to operate by utilizing
the kinetic energy of the rotating motor. The drive will be fully operational as long as
the motor rotates and generates energy to the drive.
If the drive is equipped with a main contactor or breaker, it restores the drive input
power after a short break. The contactor re-connects after the break automatically.
If the drive is equipped an external uninterruptible auxiliary power supply (option
+G307), it keeps the main contactor closed in power-loss situations

Note: If the power loss lasts so long that the drive trips on undervoltage, a fault reset
and a fresh start command is required to continue operation.
Implement the power-loss ride-through function as follows:
1. Enable the power-loss ride-through function of the drive (parameter 30.31).
2. Enable the automatic restart of the motor after a short power supply break:
• Set the start mode to automatic (parameter 21.01 or 21.19, depending on the
motor control mode being used).
• Define the automatic restart time (parameter 21.18).

WARNING!
Make sure that a flying restart of the motor will not cause any danger. If you
are in doubt, do not implement the power loss ride-through function.

Implementing a bypass connection

If bypassing is required, employ mechanically or electrically interlocked contactors
between the motor and the drive and between the motor and the power line. Make
sure with interlocking that the contactors cannot be closed simultaneously. The
installation must be clearly marked as defined in IEC/EN/UL 61800-5-1, subclause
6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”.
Bypass connection is available as a factory-installed option for some cabinet-installed
drive types. Consult ABB for more information.
 Guidelines for planning the electrical installation 107

WARNING!
Do not connect the drive output to the electrical power network. The connection
may damage the drive.

Supplying power for the auxiliary circuits

The user must supply these options from external power sources:
• +G300/+G301: Cabinet heaters and/or lighting
• +G307: Connection for an external uninterruptible power supply
• +G313: Power supply connection for a motor space heater output
For the voltages and fuse sizes, refer to the circuit diagrams delivered with the drive.

Using power factor compensation capacitors with the

drive
Power factor compensation is not needed with AC drives. However, if a drive is to be
connected in a system with compensation capacitors installed, note the following
restrictions.

WARNING!
Do not connect power factor compensation capacitors or harmonic filters to
the motor cables (between the drive and the motor). They are not meant to be
used with AC drives and can cause permanent damage to the drive or
themselves.

If there are power factor compensation capacitors in parallel with the input of the
drive:
1. Do not connect a high-power capacitor to the power line while the drive is
connected. The connection will cause voltage transients that may trip or even
damage the drive.
2. If capacitor load is increased/decreased step by step when the AC drive is
connected to the power line, make sure that the connection steps are low enough
not to cause voltage transients that would trip the drive.
3. Make sure that the power factor compensation unit is suitable for use in systems
with AC drives, ie, harmonic generating loads. In such systems, the compensation
unit should typically be equipped with a blocking reactor or harmonic filter.

Using a safety switch between the drive and the motor

ABB recommends to install a safety switch between the permanent magnet motor
and the drive output. The switch is needed to isolate the motor from the drive during
maintenance work on the drive.
108 Guidelines for planning the electrical installation

Implementing the control of a contactor between drive

and motor
Implementing the control of the output contactor depends on the motor control mode
and stopping method selected.
When you select the DTC motor control mode and the motor ramp stop mode, use
this operation sequence to open the contactor:
1. Give a stop command to the drive.
2. Wait until the drive decelerates the motor to zero speed.
3. Open the contactor.

WARNING!
If DTC motor control mode is in use, do not open the output contactor while
the drive controls the motor. The motor control operates faster than the
contactor, and tries to maintain the load current. This can cause damage to
the contactor.

When you select the DTC motor control mode and the motor coast stop mode, you
can open the contactor immediately after the drive has received the stop command.
This is the case also if you use the scalar motor control mode.

Protecting the contacts of relay outputs

Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
The relay contacts on the drive control unit are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended that inductive loads are
equipped with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) to
minimize the EMC emission at switch-off. If not suppressed, the disturbances may
connect capacitively or inductively to other conductors in the control cable and form
a risk of malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not
install protective components at the relay outputs.
 Guidelines for planning the electrical installation 109

230 V AC

1
2

230 V AC

+ 24 V DC

1 Relay output
2 Varistor
3 RC filter
4 Diode

Implementing a motor temperature sensor connection

WARNING!
IEC 61800-5-1 requires double or reinforced insulation between live parts and
accessible parts when:
• the accessible parts are not conductive, or
• the accessible parts are conductive, but not connected to the protective
earth.
Obey this requirement when you plan the connection of the motor temperature
sensor to the drive.

You have these implementation alternatives:

1. If there is double or reinforced insulation between the sensor and the live parts
of the motor: You can connect the sensor directly to the analog/digital input(s)
of the drive. See the control cable connection instructions. Make sure that the
voltage is not more than the maximum allowed voltage over the sensor.
2. If there is basic insulation between the sensor and the live parts of the motor, or
if the insulation type is not known: You can connect the sensor to the drive via an
option module. The sensor and the module must form a double or reinforced
insulation between the motor live parts and the drive control unit. Refer
toConnecting a motor temperature sensor to the drive through an option
module (page 110). Make sure that the voltage does not exceed the maximum
allowed voltage over the sensor.
3. If there is basic insulation between the sensor and the live parts of the motor, or
if the insulation type is not known: You can connect a sensor to a digital input of
the drive via an external relay. The sensor and the relay must form a double or
reinforced insulation between the motor's live parts and the digital input of the
110 Guidelines for planning the electrical installation

drive. Make sure that the voltage does not exceed the maximum allowed voltage
over the sensor.

￭ Connecting a motor temperature sensor to the drive through an

option module
This table shows:
• option module types that you can use for the motor temperature sensor connection
• insulation or isolation level that each option module forms between its temperature
sensor connector and other connectors
• temperature sensor types that you can connect to each option module
• temperature sensor insulation requirement in order to form, together with the
insulation of the option module, a reinforced insulation between the motor live
parts and the drive control unit.

Option module Temperature sensor type Temperature sensor in-

sulation requirement
Type Insulation/Isolation PTC KTY Pt100,
Pt1000

FIO-11 Galvanic isolation between sensor x x x Reinforced insulation

connector and drive control unit
connector. No isolation between
sensor connector and other I/O
connectors.

FEN-01 Galvanic isolation between sensor x - - Reinforced insulation

connector and drive control unit
connector. No isolation between
sensor connector and TTL encoder
emulation output.

FEN-11 Galvanic isolation between sensor x x - Reinforced insulation

connector and drive control unit
connector. No isolation between
sensor connector and TTL encoder
emulation output.

FEN-21 Galvanic isolation between sensor x x - Reinforced insulation

connector and drive control unit
connector. No isolation between
sensor connector and TTL encoder
emulation output.

FEN-31 Galvanic isolation between sensor x x - Reinforced insulation

connector and drive control unit
connector. No isolation between
sensor connector and other connect-
ors.

FAIO-01 Basic insulation between sensor x x x Reinforced or basic insu-

connector and drive control unit lation. With basic insula-
connector. No insulation between tion, the other I/O con-
sensor connector and other I/O nectors of the option
connectors. module must be kept
disconnected.
 Guidelines for planning the electrical installation 111

Option module Temperature sensor type Temperature sensor in-

sulation requirement
Type Insulation/Isolation PTC KTY Pt100,
Pt1000

FPTC- Reinforced insulation between x - - No special requirement

01/02 1) sensor connector and other connect-
ors (including drive control unit
connector).

1) Suitable for use in safety functions (SIL2 / PL c classified).

112
 Electrical installation 113

6
Electrical installation

Contents of this chapter

This chapter gives instructions on the wiring of the drive.

Measuring the insulation

￭ Measuring the insulation resistance of the drive 11

WARNING!
Do not do voltage withstand or insulation resistance tests on the drive. The
tests can cause damage to the drive. Every drive is tested for insulation between
the main circuit and the chassis at the factory. Also, there are voltage-limiting
circuits inside the drive which cut down the testing voltage automatically.

￭ Measuring the insulation resistance of the motor and motor cable

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

1. Do the steps in section Electrical safety precautions (page 22) before you start
the work.
2. Make sure that the motor cable is disconnected from the drive output terminals.
3. Measure the insulation resistance between each phase conductor and the
protective earth conductor. Use a measuring voltage of 1000 V DC. The insulation
resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C
114 Electrical installation

[77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s
instructions.

Note: Moisture inside the motor reduces the insulation resistance. If you think
that there is moisture in the motor, dry the motor and do the measurement again.

U1
M
U1-PE, V1-PE, W1-PE
V1
1000 V DC, 3~
ohm W1
> 100 Mohm PE

￭ Measuring the insulation resistance of the input power cable

Before you connect the input power cable to the drive, measure its insulation resistance
according to local regulations.

Compatibility check - IT (ungrounded) earthing system

Drives with a category 2, 1st environment EMC filter (option +E202) are not suitable
for use in an IT (ungrounded) supply network system. If the drive is equipped with
option +E202, disconnect the filter before connecting the drive to the IT supply network.
Contact ABB for instructions.

WARNING!
Do not install a drive equipped with EMC filter +E202 on an IT system (an
ungrounded power system or a high-resistance-grounded [over 30 ohms] power
system). The system will be connected to ground potential through the EMC
filter capacitors of the drive. This can cause danger, or damage the drive.

Attaching the device stickers to the cabinet door

A multilingual device label sticker is delivered with the drive. Attach the stickers in the
appropriate language on the English texts; see section Door devices (page 43).

Checking the settings of transformers T21, T101 and T111

Check the tap settings of all auxiliary voltage transformers. Transformer T21 is standard
equipment; T101 and T111 are present depending on drive configuration.
The voltage settings of transformers T21 and T101 are made at terminal blocks
T21_X1/X2 and T101_X1/X2 respectively. The settings of transformer T111 are made
on the transformer itself. The locations of the transformers and the terminal blocks
are shown in section Operation principle and hardware description (page 31).
 Electrical installation 115
„

„ ￭ T21 and T101 tap settings (400…500 V units)

T21_X1 T21_X2
T101_X1 T101_X2

500 V 1 1 230 V
480 V 2
460 V 3
440 V 4
2
415 V 5
Ĭ 3
400 V 6
380 V 7

4 N
U1 8 5
TP1 9
TP2 10

„ ￭ T21 and T101 tap settings (690 V units)

T21_X1 T21_X2
„ T101_X1 T101_X2
11
690 V 1 1 230 V
660 V 2
600 V 3
575 V 4
2
540 V 5
Ĭ 3
525 V 6
7

4 N
U1 8 5
TP1 9
TP2 10
116 Electrical installation

￭ T111 tap settings

3~ input

3~ output

3~ input 3~ output
Tap settings Terminals
Supply
Terminals 400 V 320/340 V
voltage A1– B1– C1–
(50 Hz) (60 Hz)
690 V A1, B1, C1 C2 A2 B2 a1, b1, c1 a2, b2, c2
660 V A1, B1, C1 C2 A2 B2 a1, b1, c1 a2, b2, c2
600 V A1, B1, C1 C3 A3 B3 a1, b1, c1 a2, b2, c2
575 V A1, B1, C1 C3 A3 B3 a1, b1, c1 a2, b2, c2
540 V A1, B1, C1 C4 A4 B4 a1, b1, c1 a2, b2, c2
525 V A1, B1, C1 C4 A4 B4 a1, b1, c1 a2, b2, c2
500 V A1, B1, C1 C4 A4 B4 a1, b1, c1 a2, b2, c2
480 V A1, B1, C1 C5 A5 B5 a1, b1, c1 a2, b2, c2
460 V A1, B1, C1 C5 A5 B5 a1, b1, c1 a2, b2, c2
440 V A1, B1, C1 C5 A5 B5 a1, b1, c1 a2, b2, c2
415 V A1, B1, C1 C6 A6 B6 a1, b1, c1 a2, b2, c2
400 V A1, B1, C1 C6 A6 B6 a1, b1, c1 a2, b2, c2
380 V A1, B1, C1 C6 A6 B6 a1, b1, c1 a2, b2, c2
 Electrical installation 117

Connecting the control cables

The default I/O connections can be different with some hardware options. See the
circuit diagrams delivered with the drive for the actual wiring. For other control
programs, see their firmware manuals.

￭ Control cable connection procedure

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur.

1. Do the steps in section Electrical safety precautions (page 22) before you start
the work.
2. Run the control cables into the cabinet as described in section Grounding the
outer shields of the control cables 360° at the cabinet entry (page 117).
3. Route the control cables as described in section Routing the control cables inside
the cabinet (page 119).
4. Connect the control cables as described in section Connecting control
cabling (page 119).

Grounding the outer shields of the control cables 360° at the cabinet entry
Ground the outer shields of all control cables 360° with the EMI conductive cushions
at the cabinet entry. The grounding principle is the same for top and bottom entry
cables. The figures show the bottom entry. The actual design details can vary.
1. If necessary, temporarily remove the shrouding in front of the cable entry.
2. 11
Put the cables in sequence from the smallest to the largest. This will help to achieve
a good contact with the cushions.
3. Loosen the tightening bolts of the EMI conductive cushions and pull them apart.
4. Cut holes in the grommets and put the cables through the grommets.
5. Peel the insulation from the part of the cable that will be in contact with the EMI
conductive cushion.
6. Put the cables between the cushions and attach them with cable ties for strain
relief.
7. Move the cushions back together.
8. Tighten the bolts to make sure that the EMI conductive cushions press tightly
around the peeled part of the cables.
118 Electrical installation

If the outer surface of the shield is non-conductive:

• Cut the shield at the midpoint of the peeled part. Be careful not to cut the
conductors or the grounding wire.
• Turn the conductive side of the shield inside out over the insulation.
• Cover the exposed shield and the peeled cable with copper foil to keep the shielding
continuous.

A Stripped cable
A B C
B Conductive surface of the shield exposed

C Stripped part covered with copper foil

1 Cable shield

2 Copper foil
2 2
1
3 3 Shielded twisted pair
4 4 Grounding wire
 Electrical installation 119

Routing the control cables inside the cabinet

Use the existing trunking in the cabinet where possible. Use sleeving if cables are laid
against sharp edges. When running cables to or from a swing-out frame, leave enough
slack at the hinge to allow the frame to open fully.

Connecting control cabling

Connect the conductors to the appropriate terminals. Refer to the wiring diagrams
delivered with the drive.
With option +L504, the terminals of the inverter control unit are available on terminal
block X504.
Obey these instructions:
• Connect the inner twisted pair shields and all separate grounding wires to the
grounding clamps near the terminals.
• 11
Ground the outer shield of the cable at the cable entry, not at the grounding clamps
near the terminals.
• Keep any signal wire pairs twisted as close to the terminals as possible. Twisting
the wire with its return wire reduces disturbances caused by inductive coupling.
• At the other end of the cable, leave the shields unconnected or ground them
indirectly via a high-frequency capacitor with a few nanofarads, eg. 3.3 nF / 630 V.
The shield can also be grounded directly at both ends if they are in the same
ground line with no significant voltage drop between the end points.
120 Electrical installation

The drawing below represents the grounding of the control cabling when connecting
to a terminal block inside the cabinet. The grounding is done in the same way when
connecting directly to a component such as the control unit.

Connecting the motor cables (units without common

motor terminal cubicle or sine output filter)
On units without a common motor terminal cubicle or a sine output filter, the motor
cables connect to busbars located behind the inverter module(s). The location and
dimensions of the busbars are shown in the dimension drawings delivered with the
drive and in the example drawings in this manual.

￭ Motor connection diagram (without option +H366)

All parallel-connected inverter modules are to be cabled separately to the motor.
360° grounding must be used at the cable entries.
„
Electrical installation 121

PE
U2
V2
W2

U1
V1
M
W1 3~
U2 PE
V2
W2

Inverter unit cubicle(s)

The recommended cable types are given in the technical data.

WARNING!
The cabling from all inverter modules to the motor must be physically identical
considering cable type, cross-sectional area, and length.

PE
U2
V2
W2

U1
V1
M
W1 3~
U2 PE
V2 11
W2

Inverter unit cubicle(s)

￭ Motor connection diagram (with option +H366)

„
With option +H366, the output busbars of the inverter modules within the same cubicle
are connected by bridging busbars. The bridging balances the motor current between
the modules, which allows more cabling options. For example, it is possible to use a
„
122 Electrical installation

number of cables that could not otherwise be evenly distributed between the inverter
modules.

PE

W2
V2
U2

Bridging busbars W1
V1
M
U1 3~
W2 PE
V2
U2

Inverter unit cubicle(s)

The recommended cable types are given in the technical data.

WARNING!
The bridging can carry the nominal output of one inverter module. In case of
three parallel modules, make sure 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.

Note: The +H366 option only interconnects the outputs of inverter modules within
the same cubicle, not modules installed in different cubicles. Therefore, when the drive
has multiple inverter cubicles (ie. two cubicles of two modules each), make sure that
the motor cabling is identical for both cubicles.

￭ Procedure
To get more space for cabling work, you can remove the inverter modules or the fan
carriages of each module. Especially in the case of multiple inverter modules in the
same cubicle, you can consider only removing the fan carriages. This is faster than
removing the entire module, but gives less free space for the work than removing the
module.

Removing an inverter module

Refer to section Removing a supply or inverter module (page 191).

Removing the fan carriage of an inverter module

Refer to the drawings below.

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur.
 Electrical installation 123

1. Do the steps in section Electrical safety precautions (page 22) before you start
the work.
2. Open the inverter module cubicle door.
3. Remove the screws holding the front cover plate. Lift the cover plate somewhat
to release it.
4. Disconnect the wiring at the top of the fan carriage.
5. Remove the two screws at the bottom of the fan carriage.

WARNING!
Before you proceed, make sure that the two screws holding the top of the
inverter module are in place.

6. Remove the two screws at the top of the fan carriage. (During reassembly, tighten
these screws to 22 N·m [16 lbf·ft].)

Note: Units with marine or seismic design have an additional transverse bracket
that is attached to the module with these screws. At this point, loosen the retaining
screws of the bracket at the left and the right ends and remove it. (During
reassembly, tighten the bracket retaining screws to 9 N·m [6.6 lbf·ft].)
7. Pull the fan carriage out.
8. Repeat the procedure for other fan carriages in the same cubicle.

11
 Electrical installation 113
124 Electrical installation

6
 Electrical installation 125

Connecting the motor cables

Refer to the drawings below.

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur.

1. Do the steps in section Electrical safety precautions (page 22) before you start
the work.
2. Remove the shroud in front of the output busbars.
3. For 360° grounding of the shield at the cable entry, remove the outer jacket of
each cable where they pass through the cable entry (a).
4. Cut the cable to suitable length and strip the ends of the individual conductors.
Twist the shield strands together to form a separate conductor and wrap it with
tape.
5. Crimp suitable lug terminals onto the phase conductors and the ground conductor.
The dimensions of the output busbars are shown in chapter Technical data.
6. Connect the phase conductors of the motor cable to the U2, V2 and W2 terminals.
Refer to section Use of fasteners in cable lug connections (page 132). You can
temporarily remove the plastic insulators (b) between the busbars to make the
installation work easier.

WARNING!
The plastic insulators (b) between the busbars must be in place when the
inverter is powered.

7. Connect the shield (and any grounding conductors) of the cable to the PE busbar
11
close to the cable entries.
8. Secure the cable mechanically.
9. Repeat the procedure for other modules (if any).
10. Install the shroud removed earlier.
11. At the motor, connect the cables according to instructions from the motor
manufacturer. Pay special attention to the phase order. For minimum
radio-frequency interference, ground the cable shield 360° at the cable entry of
the motor terminal box, or ground the cable by twisting the shield so that the
flattened shield is wider than 1/5 of its length.
126 Electrical installation

360° grounding detail

6
5

b 7

PE

10
2

11
 Electrical installation 127

Installing the fan carriage of an inverter module

If the inverter module was removed completely instead of only the fan carriage, proceed
to section Installing an inverter module.
The installation of the fan carriage is the removal procedure in reverse. See section
Removing the fan carriage of an inverter module (page 122).

Installing an inverter module

Refer to section Installing a supply or inverter module (page 196).

Connecting the motor cables (units with common motor

terminal cubicle or sine output filter)
￭ Output busbars
„
If the drive is equipped with option +H359, the motor cables connect to a common
motor terminal cubicle. Similarly, if the drive is equipped with option +E206 (sine
output filter), the motor cables connect to the output busbars in the sine filter cubicle.
The location and dimensions of the busbars are visible in the dimensional drawings
delivered with the drive.

￭„ Connection diagram

PE

U2
V2
U1
M 11
V1
W2
W1 3~
PE

Inverter unit cubicle Common motor terminal or

sine filter cubicle

The recommended cable types are given in the technical data.

￭ Procedure

„ WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur.

1. Do the steps in section Electrical safety precautions (page 22) before you start
the work.
2. Open the door of the cubicle and remove the shrouding.
3. Lead the cables into the cubicle. Make the 360° grounding arrangement at the
cable entry as shown.
128 Electrical installation

Grommet

4. Cut the cables to suitable length. Strip the cables and conductors.
5. Twist the cable screens into bundles and connect the bundles to the PE busbar
in the cubicle.
6. Connect any separate ground conductors/cables to the PE busbar in the cubicle.
Refer to section Use of fasteners in cable lug connections (page 132).
7. Connect the phase conductors to the output terminals. Use the tightening torques
specified in section Tightening torques (page 244).
8. Install the shrouding that was removed earlier and close the cubicle doors.
9. At the motor, connect the cables according to instructions from the motor
manufacturer. Pay special attention to the phase order. For minimum
radio-frequency interference, ground the cable shield 360° at the cable entry of
the motor terminal box, or ground the cable by twisting the shield so that the
flattened shield is wider than 1/5 of its length.
 Electrical installation 129

Connecting the input power cables

„
￭ Connection diagram

LCL filter IGBT supply modules

1)

2b)

2a)
Components
for charging
circuit

ICU cubicle ISU cubicle

Notes:
1) Fuses or other protection means.
Use a separate grounding (PE) cable (2a) or a cable with separate PE conductor (2b)
if the conductivity of the shield does not meet the requirement for the PE conductor.
See section Selecting the power cables (page 95).

￭ Layout of the input cable connection terminals and cable entries

The location and dimensions of the busbars are visible in the dimensional drawings
delivered with the drive. Alternatively, see the example dimension drawings in the
manual. 11

￭ Connection procedure

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur.

1. Do the steps in section Electrical safety precautions (page 22) before you start
the work.
2. Open the door of the incoming cubicle. In case of frame 1×R8i + 1×R8i, open the
door of the supply and inverter module cubicle.
3. Frame 1×R8i + 1×R8i only: Remove the LCL filter module as described under
Replacing the LCL filter (page 202).
4. Remove the shrouding covering the input terminals.
5. Peel off 3…5 cm (1.2 … 2 inches) of the outer insulation of the cables above the
cable entry plate for 360° high-frequency grounding.
6. Prepare the ends of the cables.
130 Electrical installation

WARNING!
Apply grease to stripped aluminum conductors before you attach them to
non-coated aluminum cable lugs. Obey the grease manufacturer’s
instructions. Aluminum-aluminum contact can cause oxidation in the
contact surfaces.

PE PE

7. Remove rubber grommets from the cable entries for the cables to be connected.
Cut adequate holes into the rubber grommets. Slide the grommets onto the cables.
Slide the cables into the cubicle through the conductive sleeves and attach the
grommets to the holes.

8. Attach the conductive sleeves to the cable shields with cable ties. Tie up the unused
conductive sleeves with cable ties.
 Electrical installation 131

9. Connect the twisted shields of the cables to the PE busbar of the cabinet.
10. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals.
See Use of fasteners in cable lug connections (page 132). Tighten the screws to
the torque given under Tightening torques (page 244).
11. Reinstall the shrouding removed earlier.
12. Frame 1×R8i + 1×R8i only: Reinstall the LCL filter module as described under
Replacing the LCL filter (page 202).
13. Close the cubicle door.

Connecting an external brake resistor assembly 11

See chapter Resistor braking (page 309).
For the location of the terminals, refer to the dimension drawings delivered with the
unit or the dimension drawing examples in this manual.
132 Electrical installation

Use of fasteners in cable lug connections

Use the bolts, nuts and washers delivered with the drive. Install all the fasteners in the
correct order. See the figure below. Tighten the cable lug to the torque specified for
the connection.

Cable lug on one side of the busbar

1 2 3 4 2 5 6

Cable lugs on both sides of the busbar

1 5 2 4 3 4 2 5 6

1 Bolt 4 Cable lug

2 Plain washer 5 Spring washer
3 Busbar 6 Nut
 Electrical installation 133

Connecting a PC

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

A PC (with, for example, the Drive Composer PC tool) can be connected as follows:
1. To connect a control panel to the unit, either
• insert the control panel into the panel holder or platform, or
• use an Ethernet (eg, Cat 5e) networking cable.
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.
5. Refer to the documentation of the PC tool for setup instructions.

USB connected 4
2
?

Stop Loc/Rem Start

Stop Loc/Rem Start

2 3a 3b 11

Panel bus (control of several units from one control panel)

One control panel (or PC) can be used to control several drives (or inverter units, supply
units etc.) by constructing a panel bus. This is done by daisy-chaining the panel
connections of the drives. Some drives have the necessary (twin) panel connectors in
the control panel holder; those that do not require the installation of an FDPI-02 module
(available separately). For further information, see the hardware description and
FDPI-02 diagnostics and panel interface user’s manual (3AUA0000113618 [English]).
The maximum allowed length of the cable chain is 100 m (328 ft).
Do the steps in section Electrical safety precautions (page 22) before you start the
work.
1. Connect the panel to one drive using an Ethernet (for example Cat 5e) cable.
• Use Menu - Settings - Edit texts - Drive to give a descriptive name to the drive
• Use parameter 49.01* to assign the drive with a unique node ID number
• Set other parameters in group 49* if necessary
• Use parameter 49.06* to validate any changes.
*The parameter group is 149 with supply (line-side), brake or DC/DC converter
units.
134 Electrical installation

Repeat the above for each drive.

2. With the panel connected to one unit, link the units using Ethernet cables.
3. Switch on the bus termination on the drive that is farthest from the control panel
in the chain.
• With drives that have the panel mounted on the front cover, move the
terminating switch into the outer position.
• With the FDPI-02 module and BCU-02 control unit: move termination switch
S1 on the FDPI-02 module into the TERMINATED position.
• With the FDPI-02 module and UCU-22…24 control unit: move termination
switch S1 on the FDPI-02 module into the OPEN position. Move control panel
connection termination switch XPAN TERM on the UCU-22…24 control unit
to ON position.
Make sure that bus termination is off on all other drives.
4. On the control panel, switch on the panel bus functionality (Options - Select drive
- Panel bus). The drive to be controlled can now be selected from the list under
Options - Select drive.
If a PC is connected to the control panel, the drives on the panel bus are automatically
displayed in the Drive Composer PC tool.

With twin connectors in the control panel holder:

2 3 4

1
 Electrical installation 135

With FDPI-02 modules and BCU control unit:

2 IN
AT
ED

RM
TE EN
OP

3 3

11

ED
AT
IN
RM
TE EN
OP
136 Electrical installation

Installing option modules

￭ Installing an I/O extension, fieldbus adapter or pulse encoder option
module
Refer to the option module manual. For installation on the UCU-22…24 control unit,
refer to UCU-22, -23 and -24 control units hardware manual (3AXD50000817726
[English]). For installation on the BCU-02, BCU-12 or BCU-22 control unit, refer to
BCU-02, -12 and -22 control units Hardware manual (3AUA0000113605 [English]).

￭ Installing an FSO safety functions module

Refer to FSO-12 safety functions module user's manual or FSO-21 safety functions
module user’s manual. For installation on the UCU-22…24 control unit, refer to UCU-22,
-23 and -24 control units hardware manual (3AXD50000817726 [English]). If you install
the module onto BCU-02, BCU-12 or BCU-22 control unit, refer to BCU-02, -12 and -22
control units Hardware manual (3AUA0000113605 [English]).

￭ Installing the FSPS-21 PROFIsafe safety functions module

To install the FSPS-21 PROFIsafe safety functions module onto the drive control unit,
refer to FSPS-21 PROFIsafe safety functions module user's manual (3AXD50000158638
[English]).

￭ Installing the FSCS-21 CIP Safety™ functions module

To install the FSCS-21 CIP Safety™ functions module onto the drive control unit, refer
to FSCS-21 CIP Safety™ functions module user's manual (3AXD50001065478 [English]).
 Control unit (UCU) 137

7
Control unit (UCU)

Contents of this chapter

This chapter
• describes the connections of the control unit(s) used in the drive,
• contains the specifications of the inputs and outputs of the control unit(s).

General
The UCU control units are used for controlling power modules (drive, inverter, supply,
converter, etc) via fiber optic links. UCU-22 has two, UCU-23 has eight and UCU-24 has
14 power module connections. The UCU control units have integrated branching unit
functionality for collecting and storing real-time data from the power modules to help
fault tracing and analysis. The data is stored on a memory card which can be analyzed
by ABB service personnel.

Layout
The figures below show an example UCU-24 control unit.
138 Control unit (UCU)

Description
I/O I/O terminals
SLOT 1
I/O extension, encoder interface or fieldbus
SLOT 2 adapter module connection. For F-type
modules with USCA-02 adapter.
SLOT 3
SLOT 4 RDCO-0x DDCS communication option
module connection
MEM UMU-01 memory unit connection. Data logger
microSDHC memory card for inverter module
communication is inside the memory unit.
BAT Holder for real-time clock battery (BR2032)
XD2D TERM Termination switches for drive-to-drive link
(XD2D)
X485 TERM RS-485 link termination switch
X485 BIAS RS-485 link bias switch.
DICOM= Ground selection. Determines whether DICOM
DIOGND is separated from DIOGND (ie. the common
reference for the digital inputs floats). Refer
to the ground isolation diagram.

LED Description
PWR When the PWR LED is on, the voltage supply
is sufficient.
BAT When the BAT LED is on, the real-time clock
battery voltage is higher than 2.5 V. If the LED
is off, replace the battery.
WRITE When the WRITE LED is on, writing to
microSDHC memory card is in progress. Do
not remove the microSDHC memory card.
FAULT The control program has generated a fault.
Refer to the firmware manual.
FS COMM Reserved.
FS STATUS Reserved.
 Control unit (UCU) 139

Description
XAI Analog input
XAO Analog output
XCAN Not in use
XCAN TERM CAN bus termination switch
XDI Digital input
XDIO Digital input/output
XD2D Drive-to-drive link
XD24 +24 V output (for digital input)
XETH1 Ethernet ports for fieldbus, internal switch
XETH2
XETH3 Ethernet ports for tool communication, internal
switch
XETH4
XPAN Control panel connection
XPAN TERM Panel bus termination switch
XPOW External power input
XRO1 Relay output RO1
XRO2 Relay output RO2
XCAN XD2D XRO3 Relay output RO3
XRO4 Relay output RO4, reserved.

XSTO XSTO X485

XSTO Safe torque off connection (input signals)
OUT XSTO OUT Safe torque off connection (to inverter modules)
X485 RS-485 link
XRO1 V1T/V1R Fiber optic connections to converter modules
XAI XDI … (VxT = transmitter, VxR = receiver)
V14T/V14R

XRO2

XAO XDIO
XRO3

XPOW XD24
XRO4
140 Control unit (UCU)

Description
1
XFSO Optional connection for FSO safety functions
module
1 Humidity and temperature measurements

XFSO
 Control unit (UCU) 141

Default I/O diagram of the supply control unit

This table describes the use of the default connections in the IGBT supply unit.

Terminal Description
XD2D Drive-to-drive link
1 1 B
2
3 2 A
4 Not supported
3 BGND
4 SHIELD
ON

XD2D.TERM Drive-to-drive link termination switch

1

X485 RS485 connection

5 5 B
6
7 6 A
8 Not in use by default
7 BGND
8 SHIELD
ON

X485 BIAS X485 bias selection switch

1

ON

X485 TERM X485 termination switch

1

XCAN CAN bus

9 CANH
9
10 10 CANL Not supported
11 11 CGND
12 12 SHIELD Control cable shield

1
XCAN TERM CANopen termination switch
ON

XRO1 Relay output 1

11 11 NC1 Norm. closed

XRO1: Charging 1) (Energized = Closes
12 12 COM1 Common charging contactor.)
13 13 NO1 Norm. open 250 V AC / 30 V DC, 2 A

XRO2 Relay output 2

21 21 NC2 Norm. closed

XRO2: Fault (-1) 2)
22 22 COM2 Common
250 V AC / 30 V DC, 2 A
23 23 NO2 Norm. open
XRO3 Relay output 3

31 31 NC3 Norm. closed XRO3: MCB ctrl1) (Energized = Closes

32 32 COM3 Common main contactor/breaker.)
33 33 NO3 Norm. open 250 V AC / 30 V DC, 2 A

XRO4 Relay output 4

142 Control unit (UCU)

Terminal Description

41 41 NC4 Norm. closed

XRO4: Not supported
42 42 COM4 Common
250 V AC / 30 V DC, 2 A
43 43 NO4 Norm. open
XSTO Safe torque off input connection
1 OUT
1
2 2 SGND XSTO: STO1 and STO2 are connected to OUT at the factory. To enable start
3 3 STO1 and operation, STO1 and STO2 must be connected to OUT.
4 4 STO2
XSTO OUT Safe torque off output connection (to inverter modules)
5 OUT1
5
6 6 SGND
XSTO OUT: Not in use
7 7 OUT2
8 8 SGND
XDI Digital inputs
1 DI1 Temp fault 3) (0 = overtemperature)
1
2 DI2 Run / enable3) (1 = run / enable)
2
3 3 DI3 MCB feedback1) (0 = main contactor/breaker open)
4 4 DI4 Not in use by default. Can be used for eg, auxiliary circuit breaker fault.
5 5 DI5 Not in use by default. Can be used for eg, earth fault monitoring.
6
6 DI6 Reset3) (0 -> = fault reset)
7
7 DIIL Not in use by default. DIIL is connected to XD24:5 at the factory.
XDIO Digital input/outputs
1 DIO1 Not in use by default
1
2 2 DIO2 Not in use by default
3 3 DIOGND Digital input/output ground
4 4 DIOGND Digital input/output ground
XD24 Auxiliary voltage output

5
5 +24VD +24 V DC 200 mA 4)
6 6 DICOM Digital input ground
7 7 +24VD +24 V DC 200 mA4)
8
8 DIOGND Digital input/output ground
Ground selection switch. Determines whether DICOM is separated from
1
DICOM=DIOGND DIOGND (ie, common reference for digital inputs floats). ON: DICOM con-
ON nected to DIOGND. OFF: DICOM and DIOGND separate.
XAI Analog inputs, reference voltage output
1 +VREF 10 V DC, RL 1…10 kohm
1
2 -VREF -10 V DC, RL 1…10 kohm
2
3 3 AGND Ground
4 4 AI1+
Not in use by default. 0(2)…10 V, Rin > 200 kohm 5)
5 5 AI1-
6
6 AI2+
7 Not in use by default. 0(4)…20 mA, Rin = 100 ohm 6)
7 AI2-
 Control unit (UCU) 143

Terminal Description
XAO Analog outputs
1 AO1
1 Zero (no signal indicated)3) 0…20 mA, RL < 500 ohm
2 2 AGND
3 3 AO2
4
Zero (not signal indicated)3) 0…20 mA, RL < 500 ohm
4 AGND
XPOW External power input
1 +24VI
1
19…32 V DC, 1.5…2.9 A (depends on the load and supply voltage)
2 2 GND
External power input
3 3 +24VI
Two supplies can be connected to the control unit for redundancy.
4 4 GND
XFSO Safety functions module connection. Not supported in supply unit.
XETH1 Ethernet ports for fieldbus. Support depends on the firmware. Refer to
XETH2 the firmware manual.

XETH3 Ethernet ports for tool communication. Support depends on the firmware.
XETH4 Refer to the firmware manual.

XPAN Control panel connection

Control panel connection termination switch. Used for panel bus configur-
1
XPAN TERM
ON
ation.

MEM Memory unit connection

1) Use of the signal in the control program. When parameter 120.30 External charge enable has value Yes (default
setting), the control program reserves this I/O terminal for external charging circuit control and monitoring, and
parameters 110.24 RO1 source and 110.30 RO3 source are write-protected. If the value is No, you can use the I/O
terminal for other purposes.
2) Use of the signal in the control program (fixed). See also the delivery-specific circuit diagrams.
3) Use of the signal in the control program (fixed). See also the delivery-specific circuit diagrams.
4) Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and DIO2.
5) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm]. Change of setting requires reboot of
control unit.
6) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm]. Change of setting requires reboot of
control unit.

Default I/O diagram of the inverter control unit

This diagram shows the default control connections of the inverter control unit. The
ACS880 primary control program is in use. Under normal circumstances, the
factory-made wiring should not be changed.

Terminal Description
XD2D Drive-to-drive link
1 1 B
2
3 2 A
4 Not in use by default
3 BGND
4 SHIELD
ON

XD2D.TERM Drive-to-drive link termination switch

1

X485 RS485 connection

144 Control unit (UCU)

Terminal Description
5 5 B
6
7 6 A
8 Not in use by default
7 BGND
8 SHIELD
ON

X485 BIAS X485 bias selection switch

1

ON

X485 TERM X485 termination switch

1

XCAN CAN bus

9 CANH
9
10 10 CANL Not supported
11 11 CGND
12 12 SHIELD Control cable shield

1
XCAN TERM CANopen termination switch
ON

XRO1 Relay output 1

11 11 NC1 Norm. closed

XRO1: Ready (Energized = Ready)
12 12 COM1 Common
250 V AC / 30 V DC, 2 A
13 13 NO1 Norm. open
XRO2 Relay output 2

21 21 NC2 Norm. closed

XRO2: Running (Energized = Running)
22 22 COM2 Common
250 V AC / 30 V DC, 2 A
23 23 NO2 Norm. open
XRO3 Relay output 3

31 31 NC3 Norm. closed

XRO3: Fault (-1) (Energized = No fault)
32 32 COM3 Common
250 V AC / 30 V DC, 2 A
33 33 NO3 Norm. open
XRO4 Relay output 4

41 41 NC4 Norm. closed

XRO4: Not supported
42 42 COM4 Common
250 V AC / 30 V DC, 2 A
43 43 NO4 Norm. open
XSTO Safe torque off input connection
1 OUT
1
XSTO: STO1 and STO2 are connected to OUT at the factory. To enable start
2 2 SGND
and operation, STO1 and STO2 must be connected to OUT. Refer to chapter
3 3 STO1 The Safe torque off function (page 287).
4 4 STO2
XSTO OUT Safe torque off output connection (to inverter modules)
5 OUT1
5
6 6 SGND
XSTO OUT: Safe torque off output to inverter modules
7 7 OUT2
8 8 SGND
 Control unit (UCU) 145

Terminal Description
XDI Digital inputs
1 DI1 Stop (0) / Start (1)
1 2 DI2 Forward (0) / Reverse (1)
2
3 DI3 Reset
3
4 4 DI4 Acceleration & deceleration select 1)
5 5 DI5 Constant speed 1 select (1 = on) 2)
6
6 DI6 Not in use by default.
7
7 DIIL Run enable. DIIL is connected to XD24:5 at the factory. 3)
XDIO Digital input/outputs
1 DIO1 Output: Ready
1
2 2 DIO2 Output: Running
3 3 DIOGND Digital input/output ground
4 4 DIOGND Digital input/output ground
XD24 Auxiliary voltage output

5
5 +24VD +24 V DC 200 mA 4)
6 6 DICOM Digital input ground
7 7 +24VD +24 V DC 200 mA4)
8
8 DIOGND Digital input/output ground
Ground selection switch. Determines whether DICOM is separated from
1
DICOM=DIOGND DIOGND (ie, common reference for digital inputs floats). ON: DICOM con-
ON nected to DIOGND. OFF: DICOM and DIOGND separate.
XAI Analog inputs, reference voltage output
1 +VREF 10 V DC, RL 1…10 kohm
1
2 -VREF -10 V DC, RL 1…10 kohm
2
3 3 AGND Ground
4 4 AI1+
Speed reference. 0(2)…10 V, Rin > 200 kohm 5)
5 5 AI1-
6
6 AI2+
7 Not in use by default. 0(4)…20 mA, Rin = 100 ohm 6)
7 AI2-
XAO Analog outputs
1 AO1
1 Motor speed rpm 0 … 20 mA, RL < 500 ohm
2 2 AGND
3 3 AO2
4
Motor current 0 … 20 mA, RL < 500 ohm
4 AGND
XPOW External power input
1 +24VI
1
19…32 V DC, 1.5…2.9 A (depends on the load and supply voltage)
2 2 GND
External power input
3 3 +24VI
Two supplies can be connected to the control unit for redundancy.
4 4 GND
Safety functions module connection. Support depends on the control
XFSO
program. Refer to the firmware manual.
146 Control unit (UCU)

Terminal Description
XETH1 Ethernet ports for fieldbus. Support depends on the control program. Refer
XETH2 to the firmware manual.

XETH3 Ethernet ports for tool communication. Support depends on the control
XETH4 program. Refer to the firmware manual.

XPAN Control panel connection

Control panel connection termination switch. Used for panel bus configur-
1
XPAN TERM
ON
ation.

MEM Memory unit connection

1) 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.
2) Constant speed 1 is defined by parameter 22.26.
3) The DIIL input is configured to stop the unit when the input signal is removed. This input does not have a SIL or PL
classification.
4) Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and DIO2.
5) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm]. Change of setting requires reboot of
control unit.
6) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm]. Change of setting requires reboot of
control unit.
 Control unit (UCU) 147

This is an I/O connection example for the inverter control unit.

XRO1…XRO4
NC1 11
COM1 12
NO1 13
NC2 21
COM2 22
NO2 23
1)
NC3 31
COM3 32
NO3 33
NC4 41
COM4 42
NO4 43
XSTO
OUT 1
2)
SGND 2
STO1 3
STO2 4
XDI
DI1 1
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
DIIL 7 3)
XD24
+24VD 5
DICOM 6
+24VD 7
DIOGND 8
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5
AI2+ 6
AI2- 7
XAO
AO1 1
AGND 2
AO2 3
AGND 4

1) Fault
2) Connected at the factory. If necessary, you can connect a safety device (eg, a safety
relay) to the XSTO terminal.
3) DIIL is connected to XD24:5 at the factory.
148 Control unit (UCU)

Additional information on the connections

￭ Connecting motor temperature sensors to the drive
Refer to the electrical planning instructions.

￭ Power supply for the control unit (XPOW)

Power to the control unit is supplied internally through terminal block XPOW.
Refer to the control unit connector data for the current and voltage ratings of the
power supply.
Connect an additional external power supply to the free +24 V and GND terminals of
the XPOW terminal block if:
• the control unit must be kept operational during input power breaks, for example,
because of continuous fieldbus communication
• immediate restart is necessary after a power break (that is, no control unit
power-up delay is permitted).

￭ Digital interlock (DIIL)

Digital interlock input (DIIL) terminal is originally intended for interlock signals that
stop the drive/unit when necessary. In the ACS880 primary control program, DIIL
terminal is the source for the run enable signal by default. The inverter unit or drive
cannot start, or it stops when there is no DIIL signal. In other control programs (and
units), the default use of the DIIL terminal varies. Refer to firmware manual for more
information.

Note: This input is not SIL or PL classified.

￭ Control panel connection (XPAN)

The XPAN connector can be used to connect an assistant control panel or FDPI-02
diagnostics and panel interface unit to the control unit. With FDPI-02, it is possible to
connect one control panel to two or more control units in a chain topology, also known
as a panel bus. For more information, refer to FDPI-02 diagnostics and panel interface
user's manual (3AUA0000113618 [English]).
The XPAN TERM switch sets the termination for the panel bus. Must be set to ON if
there is no panel bus, or if the control unit is the last one in a panel bus. On intermediate
units in a panel bus, set termination to OFF (1).

￭ The XD2D connector

The XD2D connector has an RS-485 connection that can be used for
• basic master/follower communication with one master drive/unit and multiple
followers
• fieldbus control through the embedded fieldbus interface (EFB)
• drive-to-drive (D2D) communication implemented by application programming.
Refer to the firmware manual for the availability of these features and related
parameter settings.
Terminate the bus on the units at the ends of the drive-to-drive link. Disable bus
termination on the intermediate units.
 Control unit (UCU) 149

Use a shielded twisted-pair cable for data, and another pair or a wire for signal ground
(nominal impedance 100…165 ohm, for example Belden 9842). For the best immunity,
use high quality cable. Keep the cable as short as possible. Avoid unnecessary loops
and parallel runs near power cables such as motor cables.
The following diagram shows the wiring between control units.
XD2D

XD2D

XD2D
B 1
A 2
BGND 3
SHIELD 4

B 1
A 2
BGND 3
SHIELD 4

B 1
A 2
BGND 3
SHIELD 4
Termination ON Termination OFF Termination ON

￭ Safe torque off (XSTO, XSTO OUT)

Refer to chapter The Safe torque off function.
The XSTO input only acts as a true Safe torque off input on the inverter control unit.
De-energizing the STO input terminals of other control units (supply, DC/DC converter,
or brake unit) stops the unit but does not constitute a SIL/PL classified safety function.

￭ Safety functions module connection (XFSO)

In drives or inverter units with a compatible control program, an optional FSO safety
functions module can be connected to the XFSO connector. The control program in
supply, brake, and DC/DC converter units does not support the FSO module.
Before you connect an FSO module to the XFSO connector, make sure that the control
board revision is compatible with the FSO module. For more information, refer to the
applicable FSO module user's manual.

Note: Inverter modules that have a sticker with the text “No FSO support” are not
compatible with the FSO safety functions module.

￭ MicroSDHC memory card slot

The control unit has an on-board data logger that collects real-time data from the
power modules to help fault tracing and analysis. The data is stored onto the
microSDHC memory card inserted into the UMU-01 memory unit and can be analyzed
by ABB service personnel.

Connector data
The wire size accepted by all screw terminals (for both stranded and solid wire) is
0.5 … 2.5 mm2 (22…12 AWG). Connector pitch is 5 mm.
Maximum tightening torque of the screw terminals is 0.45 N·m (4 lbf·in).
150 Control unit (UCU)

Power supply (XPOW) 19…32 V DC, 1.5 … 2.9 A (depends on the load and supply voltage)
External power input.
Two supplies can be connected to the control unit for
redundancy.
Relay outputs XRO1…XRO4 250 V AC / 30 V DC, 2 A
Protected by varistors
+24 V output (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 24 V logic levels: “0” < 5 V, “1” > 15 V
(XDI:1…XDI:6) Rin: 2.0 kohm
Input type: NPN/PNP (DI1…DI5), PNP (DI6)
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
Imax: 15 mA (DI1…DI5), 5 mA (DI6)
Start interlock input DIIL (XDI:7) 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 As inputs: 24 V logic levels: "0" < 5 V, "1" > 15 V. Rin: 2.0 kohm.
(XDIO:1 and XDIO:2) Filtering: 1 ms.
Input/output mode selection by As outputs: Total output current from +24VD is limited to 200
parameters. mA
DIO1 can be configured as a frequency +24VD
input (0…100 kHz with hardware
filtering of 4 microseconds) for 24 V
level square wave signal (sinusoidal or
other wave form cannot be used).
DIOx
In some control programs, DIO2 can be
configured as a 24 V level square wave RL
frequency output. Refer to the
firmware manual, parameter group 11.
DIOGND

Reference voltage for analog inputs 10 V ±1% and -10 V ±1%, Rload 1…10 kohm
+VREF and -VREF (XAI:1 and XAI:2) Maximum output current: 10 mA
Analog inputs AI1 and AI2 Current input: -20…20 mA, Rin = 100 ohm
(XAI:4 … XAI:7). Voltage input: -10…10 V, Rin > 200 kohm
Current/voltage input mode selection Differential inputs, common mode range ±30 V
by parameters 12.15 AI1 unit selection
Sampling interval per channel: 0.25 ms
and 12.25 AI2 unit selection
Hardware filtering: 0.25 ms
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
Analog outputs AO1 and AO2 (XAO) 0…20 mA, Rload < 500 ohm
Frequency range: 0…500 Hz
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
XD2D connector Physical layer: RS-485
Transmission rate: 8 Mbit/s
Cable type: Shielded twisted-pair cable with a twisted pair for
data and a wire or another pair for signal ground (nominal
impedance 100 … 165 ohm, for example Belden 9842)
Maximum length of link: 50 m (164 ft)
Termination by switch
 Control unit (UCU) 151

RS-485 connection (X485) Physical layer: RS-485

Cable type: Shielded twisted-pair cable with a twisted pair for
data and a wire or another pair for signal ground (nominal
impedance 100 … 165 ohm, for example Belden 9842)
Maximum length of link: 50 m (164 ft)
Termination and bias by switch (X485 TERM and X485 BIAS)
CAN connection (XCAN) Termination by switch (XCAN TERM)
This connection is not supported by the ACS880 control
programs.
Safe torque off connection (XSTO) Input voltage range: -3…30 V DC
Logic levels: "0" < 5 V, "1" > 17 V.

Note: Both circuits must be closed to enable start and operation

(STO1 and STO2 must be connected to OUT). This applies to all
control units (including drive, inverter, supply, brake, DC/DC
converter etc. control units), but SIL/PL classified Safe torque
off functionality is only achieved through the XSTO connector
of the drive/inverter control unit.
Current consumption (continuous) per STO channel: 10 mA. The
number of parallel inverter modules does not have an effect on
the current consumption.
EMC (immunity) according to IEC 61326-3-1 and IEC 61800-5-2
See also chapter The Safe torque off function (page 287).
Safe torque off output (XSTO OUT) To STO connector of inverter module.
Control panel connection (XPAN) Connector: RJ-45
Cable length < 50 m (164 ft)
Termination by switch (XPAN TERM)
Fieldbus Ethernet connection with Connector: RJ-45
internal switch (XETH1 and XETH2) Cable type: minimum requirement CAT5e
microSDHC memory card slot Memory card type: microSDHC (minimum of class 4 speed grade)
(microSDHC CARD) Supported memory size: 4 GB…32 GB
Battery Real-time clock battery type: BR2032
The terminals of the control unit fulfill 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.
152 Control unit (UCU)

￭ Ground isolation diagram

XPOW

XAI *
XAO

XD2D

X485

XCAN

XETH1

XETH2

XETH3

XETH4

XPAN

XRO1-XRO4
NC1 11
COM1 12
NO1 13
…
NC4 41
COM4 42
NO4 43

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

XSTO OUT

Power supply ground

*The maximum common mode voltage between each AI input and AGND is ±30 V.
**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.
 Control unit (BCU) 153

8
Control unit (BCU)

Contents of this chapter

This chapter
• describes the connections of the control unit(s) used in the drive,
• contains the specifications of the inputs and outputs of the control unit(s).

General
The drive utilizes BCU-02 control units. The BCU-02 consists of a BCON-12 control
board (and a BIOC-01 I/O connector board and power supply board) built in a metal
housing.
The supply and inverter units of the drive are each controlled by a dedicated BCU-02
control unit. The designation of the supply control unit is A51; the inverter control unit
is A41. Both are connected to the power modules (i.e. supply and inverter modules
respectively) by fiber optic cables.
154 Control unit (BCU)

Layout
„
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, field-
bus adapter or FSO safety functions
module connection
SLOT 4 RDCO DDCS communication option
module connection

X205 Memory unit connection

BATTERY Holder for real-time clock battery
(BR2032)

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 in-
puts floats). See the ground isolation
diagram.

7-segment display
Multicharacter indications are displayed as repeated
sequences of characters
(“U” is indicated briefly before “o”.)
Control program running
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 immedi-
ately after power-up. If the display ends
up showing any other value than those
described, it indicates a hardware failure.
 Control unit (BCU) 155

Description
XAI Analog inputs
XAO Analog outputs
XDI Digital inputs, Digital input interlock (DIIL)
XRO3
XD24 XPOW XDIO Digital input/outputs
XD2D Drive-to-drive link
XRO2 XD24 +24 V output (for digital inputs)
XDIO XAO
XETH Ethernet port – Not in use

XRO1 XPOW External power input

XRO1 Relay output RO1
XDI XAI XRO2 Relay output RO2
X485
XRO3 Relay output RO3
XSTO Safe torque off connection (input signals)
XSTO OUT Safe torque off connection (to inverter
XD2D XSTO XSTO
OUT modules)
X12 (On the opposite side) Optional connection
for FSO safety functions module
X13 Control panel, PC connection through the
control panel
X485 Not in use by default

V1T/V1R, Fiber optic connection to modules 1 and 2

V2T/V2R (VxT = transmitter, VxR = receiver)
V3T/V3R Fiber optic connection to modules 3…7
… (BCU-12 and BCU-22 only)
V7T/V7R (VxT = transmitter, VxR = receiver)
V8T/V8R Fiber optic connection to 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 con-
trol unit is powered, replace the battery.
FAULT The control program has generated a fault.
See the firmware manual of the supply/in-
verter unit.
PWR OK Internal voltage is sufficient
WRITE Writing to memory card in progress. Do
not remove the memory card.
156 Control unit (BCU)

Default I/O diagram of the supply control unit

This table describes the use of default connections in the IGBT supply unit.

Terminal Description
XD2D Drive-to-drive link
1 1 B
2
3 2 A
4 Not supported
3 BGND
4 Shield
OFF
ON

D2D.TERM Drive-to-drive link termination switch

X485 RS485 connection
5 5 B
6
7 6 A
8 Not in use by default
7 BGND
8 Shield
XRO1, XRO2, XRO3 Relay outputs
11 NC Norm. closed
XRO1: Charging 1) (Energized = Closes
11
12 COM Common charging contactor.)
12 250 V AC / 30 V DC, 2 A
13 NO Norm. open
13
21 21 NC Norm. closed
XRO2: Fault (-1) 2) (Energized = Indicates
22 22 COM Common no fault.)
23 23 NO Norm. open
250 V AC / 30 V DC, 2 A
31
31 NC Norm. closed
32 XRO3: MCB ctrl1) (Energized = Closes
32 COM Common main contactor/breaker.)
33
250 V AC / 30 V DC, 2 A
33 NO Norm. open
XSTO Safe torque off input connection
1 OUT
1
2 2 SGND XSTO: IN1 and IN2 are connected to OUT at the factory. To enable start and
3 3 IN1 operation, IN1 and IN2 must be connected to OUT.
4 4 IN2
XSTO OUT Safe torque off output connection (to inverter modules)
5 IN1
5
6 6 SGND
XSTO OUT: Not in use
7 7 IN2
8 8 SGND
XDI Digital inputs
1 DI1 Temp fault2) (0 = overtemperature)
1
2 DI2 Run / enable2) (1 = run / enable)
2
3 3 DI3 MCB feedback1) (0 = main contactor/breaker open)
4 4 DI4 Not in use by default. Can be used for eg, auxiliary circuit breaker fault.
5 5 DI5 Not in use by default. Can be used for eg, earth fault monitoring.
6
6 DI6 Reset2) (0 -> 1 = fault reset)
7
7 DIIL Not in use by default. DIIL is connected to XD24:5 at the factory.
 Control unit (BCU) 157

Terminal Description
XDIO Digital input/outputs
1 DIO1 Not in use by default
1
2 2 DIO2 Not in use by default
3 3 DIOGND Digital input/output ground
4 4 DIOGND Digital input/output ground
XD24 Auxiliary voltage output

5
1 +24VD +24 V DC 200 mA 3)
6 2 DICOM Digital input ground
7 3 +24VD +24 V DC 200 mA3)
8
4 DIOGND Digital input/output ground
Ground selection switch. Determines whether DICOM is separated from
OFF
ON

DICOM=DIOGND DIOGND (ie, common reference for digital inputs floats). ON: DICOM con-
nected to DIOGND. OFF: DICOM and DIOGND separate.
XAI Analog inputs, reference voltage output
1 +VREF 10 V DC, RL 1…10 kohm
1
2 -VREF -10 V DC, RL 1…10 kohm
2
3 3 AGND Ground
4 4 AI1+
Not in use by default. 0(2)…10 V, Rin > 200 kohm 4)
5 5 AI1-
6
6 AI2+
7 Not in use by default. 0(4)…20 mA, Rin = 100 ohm 5)
7 AI2-
AI1 AI1 current/voltage selection switch
U
I

AI2 AI2 current/voltage selection switch

U
I

XAO Analog outputs

1 AO1
1 Zero (no signal indicated)2) 0…20 mA, RL < 500 ohm
2 2 AGND
3 3 AO2
4
Zero (not signal indicated)2) 0…20 mA, RL < 500 ohm
4 AGND
XPOW External power input
1 +24VI
1
24 V DC (±10%), 2 A
2 2 GND
External power input
3 3 +24VI
Two supplies can be connected to the control unit for redundancy.
4 4 GND
Safety functions module connection. Not in use by default in IGBT supply
X12
unit.
X13 Control panel connection
X205 Memory unit connection

1) Use of the signal in the control program. When parameter 120.30 External charge enable has value Yes (default
setting), the control program reserves this I/O terminal for external charging circuit control and monitoring, and
parameters 110.24 RO1 source and 110.30 RO3 source are write-protected. If the value is No, you can use the I/O
terminal for other purposes.
2) Use of the signal in the control program (fixed). See also the delivery-specific circuit diagrams.
3) Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and DIO2.
4) 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.
158 Control unit (BCU)

5) 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.

Default I/O diagram of the inverter control unit

This diagram shows the default control connections of the inverter control unit. The
ACS880 primary control program is in use.
Under normal circumstances, the factory-made wiring should not be changed.

Terminal Description
XD2D Drive-to-drive link
1 1 B
2
3 2 A
4 Not in use by default
3 BGND
4 Shield
OFF
ON

D2D.TERM Drive-to-drive link termination switch

X485 RS485 connection
5 5 B
6
7 6 A
8 Not in use by default
7 BGND
8 Shield
XRO1, XRO2, XRO3 Relay outputs
11 NC Norm. closed
11 XRO1: Ready (Energized = Ready)
12 COM Common
12 250 V AC / 30 V DC, 2 A
13 NO Norm. open
13
21 21 NC Norm. closed
XRO2: Running (Energized = Running)
22 22 COM Common
250 V AC / 30 V DC, 2 A
23 23 NO Norm. open
31
31 NC Norm. closed
32 XRO3: Fault (-1) (Energized = No fault)
32 COM Common
33 250 V AC / 30 V DC, 2 A
33 NO Norm. open
XSTO Safe torque off input connection
1 OUT
1
XSTO: IN1 and IN2 are connected to OUT at the factory. To enable start and
2 2 SGND
operation, IN1 and IN2 must be connected to OUT. Refer to chapter The
3 3 IN1 Safe torque off function (page 287).
4 4 IN2
XSTO OUT Safe torque off output connection (to inverter modules)
5 IN1
5
6 6 SGND
XSTO OUT: Safe torque off output to inverter modules
7 7 IN2
8 8 SGND
 Control unit (BCU) 159

Terminal Description
XDI Digital inputs
1 DI1 Stop (0) / Start (1)
1 2 DI2 Forward (0) / Reverse (1)
2
3 DI3 Reset
3
4 4 DI4 Acceleration & deceleration select 1)
5 5 DI5 Constant speed 1 select (1 = on) 2)
6
6 DI6 Not in use by default.
7
7 DIIL Run enable. DIIL is connected to XD24:5 at the factory. 3)
XDIO Digital input/outputs
1 DIO1 Output: Ready
1
2 2 DIO2 Output: Running
3 3 DIOGND Digital input/output ground
4 4 DIOGND Digital input/output ground
XD24 Auxiliary voltage output

5
5 +24VD +24 V DC 200 mA 4)
6 6 DICOM Digital input ground
7 7 +24VD +24 V DC 200 mA
4)

8
8 DIOGND Digital input/output ground
Ground selection switch. Determines whether DICOM is separated from
OFF
ON

DICOM=DIOGND DIOGND (ie, common reference for digital inputs floats). ON: DICOM con-
nected to DIOGND. OFF: DICOM and DIOGND separate.
XAI Analog inputs, reference voltage output
1 +VREF 10 V DC, RL 1 … 10 kohm
1
2 -VREF -10 V DC, RL 1 … 10 kohm
2
3 3 AGND Ground
4 4 AI1+
Speed reference. 0(2)…10 V, Rin > 200 kohm 5)
5 5 AI1-
6
6 AI2+
7 Not in use by default. 0(4)…20 mA, Rin = 100 ohm 6)
7 AI2-
AI1 AI1 current/voltage selection switch
U
I

AI2 AI2 current/voltage selection switch

U
I

XAO Analog outputs

1 AO1
1 Motor speed rpm 0 … 20 mA, RL < 500 ohm
2 2 AGND
3 3 AO2
4
Motor current 0 … 20 mA, RL < 500 ohm
4 AGND
XPOW External power input
1 +24VI
1
24 VDC (±10%), 2 A
2 2 GND
External power input
3 3 +24VI
Two supplies can be connected to the control unit for redundancy.
4 4 GND
160 Control unit (BCU)

Terminal Description
X12 Safety functions module connection. Not in use by default.
X13 Control panel connection
X205 Memory unit connection

1) 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.
2) Constant speed 1 is defined by parameter 22.26.
3) The DIIL input is configured to stop the unit when the input signal is removed. This input does not have a SIL or PL
classification.
4) Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and DIO2.
5) 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.
6) 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.
 Control unit (BCU) 161

This is an I/O connection example for the inverter control unit.

XRO1…XRO3
NC 11
COM 12
NO 13
NC 21
COM 22
NO 23
1)
NC 31
COM 32
NO 33
XSTO
OUT 1
2)
SGND 2
IN1 3
IN2 4
XDI
DI1 1
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
DIIL 7 3)
XD24
+24VD 5
DICOM 6
+24VD 7
DIOGND 8
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5
AI2+ 6
AI2- 7
XAO
AO1 1
AGND 2
AO2 3
AGND 4

1) Fault
2) Connected at the factory. If necessary, you can connect a safety device (for example, a safety relay)
to the XSTO terminal.
3) DIIL is connected to XD24:5 at the factory.
162 Control unit (BCU)

Additional information on the connections

￭ Connecting motor temperature sensors to the drive
Refer to the electrical planning instructions.

￭ Power supply for the control unit (XPOW)

Power to the control unit is supplied internally through terminal block XPOW.
Refer to the control unit connector data for the current and voltage ratings of the
power supply.
Connect an additional external power supply to the free +24 V and GND terminals of
the XPOW terminal block if:
• the control unit must be kept operational during input power breaks, for example,
because of continuous fieldbus communication
• immediate restart is necessary after a power break (that is, no control unit
power-up delay is permitted).

￭ Digital interlock (DIIL)

Digital interlock input (DIIL) terminal is originally intended for interlock signals that
stop the drive/unit when necessary. In the ACS880 primary control program, DIIL
terminal is the source for the run enable signal by default. The inverter unit or drive
cannot start, or it stops when there is no DIIL signal. In other control programs (and
units), the default use of the DIIL terminal varies. Refer to firmware manual for more
information.

Note: This input is not SIL or PL classified.

￭ The XD2D connector

The XD2D connector provides an RS-485 connection that can be used for
• basic master/follower communication with one master drive and multiple
followers,
• fieldbus control through the embedded fieldbus interface (EFB), or
• drive-to-drive (D2D) communication implemented by application programming.
See the firmware manual for the related parameter settings.
Terminate the bus on the units at the ends of the drive-to-drive link. Disable bus
termination on the intermediate units.
Use a shielded twisted-pair cable for data, and another pair or a wire for signal ground
(nominal impedance 100…165 ohm, for example Belden 9842). For the best immunity,
ABB recommends high quality cable. Keep the cable as short as possible. Avoid
unnecessary loops and parallel runs near power cables such as motor cables.
 Control unit (BCU) 163

The diagram that follows shows the wiring of the drive-to-drive link. The diagram is
applicable to these control units:
• XD2D BCU-02/12/22

XD2D

XD2D
B 1
A 2
BGND 3
SHIELD 4

B 1
A 2
BGND 3
SHIELD 4

B 1
A 2
BGND 3
SHIELD 4
Termination ON Termination OFF Termination ON

￭ Safe torque off (XSTO, XSTO OUT)

Refer to chapter The Safe torque off function.
The XSTO input only acts as a true Safe torque off input on the inverter control unit.
De-energizing the STO input terminals of other control units (supply, DC/DC converter,
or brake unit) stops the unit but does not constitute a SIL/PL classified safety function.

￭ Safety functions module connection (X12)

In drives or inverter units with a compatible control program, an optional FSO safety
functions module can be connected to the X12 connector. The control program in
supply, brake, and DC/DC converter units does not support the FSO safety functions
module.
For more information on the FSO safety functions module, refer to the applicable FSO
module user's manual.

Note: Inverter modules and control units that have a sticker with the text “No FSO
support” are not compatible with the FSO safety functions module.

￭ SDHC memory card slot

The control unit has an on-board data logger that collects real-time data from the
power modules 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.

Connector data
The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5
… 2.5 mm2 (22…12 AWG). Connector pitch is 5 mm.
The maximum tightening torque for screw terminals is 0.45 N·m (4 lbf·in).

Power supply (XPOW) 24 V DC (±10%), 2 A

External power input.
Two supplies can be connected to the BCU control unit for
redundancy.
164 Control unit (BCU)

Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A

(XRO1…XRO3) Protected by varistors
+24 V output (XD24:5 and XD24:7) 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 24 V logic levels: “0” < 5 V, “1” > 15 V
(XDI:1…XDI:6) Rin: 2.0 kohm (DI1…DI5)
Input type: NPN/PNP (DI1…DI5), PNP (DI6)
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
Imax: 15 mA (DI1…DI5), 5 mA (DI6)
Start interlock input DIIL (XDI:7) 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 As inputs: 24 V logic levels: "0" < 5 V, "1" > 15 V. Rin: 2.0 kohm.
(XDIO:1 and XDIO:2) Filtering: 1 ms.
Input/output mode selection by As outputs: Total output current from +24VD is limited to 200 mA
parameters.
+24VD
DIO1 can be configured as a frequency
input (0…16 kHz with hardware
filtering of 4 microseconds) for 24 V
level square wave signal (sinusoidal or
DIOx
other wave form cannot be used).
In some control programs, DIO2 can be RL
configured as a 24 V level square wave
frequency output. Refer to the
firmware manual, parameter group 11. DIOGND

Reference voltage for analog inputs 10 V ±1% and -10 V ±1%, Rload 1…10 kohm
+VREF and -VREF (XAI:1 and XAI:2) Maximum output current: 10 mA
Analog inputs AI1 and AI2 Current input: -20…20 mA, Rin = 100 ohm
(XAI:4 … XAI:7). Voltage input: -10…10 V, Rin > 200 kohm
Current/voltage input mode selection Differential inputs, common mode range ±30 V
by switches
Sampling interval per channel: 0.25 ms
Hardware filtering: 0.25 ms
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
Analog outputs AO1 and AO2 (XAO) 0…20 mA, Rload < 500 ohm
Frequency range: 0…500 Hz
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
XD2D connector Physical layer: RS-485
Transmission rate: 8 Mbit/s
Cable type: Shielded twisted-pair cable with a twisted pair for
data and a wire or another pair for signal ground (nominal
impedance 100 … 165 ohm, for example Belden 9842)
Maximum length of link: 50 m (164 ft)
Termination by switch
RS-485 connection (X485) Physical layer: RS-485
Cable type: Shielded twisted-pair cable with a twisted pair for
data and a wire or another pair for signal ground (nominal
impedance 100 … 165 ohm, for example Belden 9842)
Maximum length of link: 50 m (164 ft)
 Control unit (BCU) 165

Safe torque off connection (XSTO) Input voltage range: -3…30 V DC

Logic levels: "0" < 5 V, "1" > 17 V.

Note: Both circuits must be closed to enable start and operation

(IN1 and IN2 must be connected to OUT). This applies to all
control units (including drive, inverter, supply, brake, DC/DC
converter etc. control units), but SIL/PL classified Safe torque
off functionality is only achieved through the XSTO connector
of the drive/inverter control unit.
Current consumption: 66 mA (continuous) per STO channel per
drive/inverter module
EMC (immunity) according to IEC 61326-3-1 and IEC 61800-5-2
See also chapter The Safe torque off function (page 287).
Safe torque off output (XSTO OUT) To STO connector of inverter module.
Control panel connection (X13) Connector: RJ-45
Cable length < 100 m (328 ft)
Ethernet connection (XETH) Connector: RJ-45
This connection is not supported by the firmware
SDHC memory card slot (SD CARD) Memory card type: SDHC
Maximum memory size: 4 GB
Battery Real-time clock battery type: BR2032
The terminals of the control unit fulfill 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.
166 Control unit (BCU)

￭ BCU ground isolation diagram

XPOW
+24VI 1
GND 2
+24VI 3
GND 4
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5 **
AI2+ 6
AI2- 7
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
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 maximum common mode voltage between each AI input and AGND is +30 V
 Installation checklist 167

9
Installation checklist

Contents of this chapter

This chapter contains a checklist for the mechanical and electrical installation of the
drive.

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

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

WARNING!
Do the steps in section Electrical safety precautions (page 22) before you start
the work.
168 Installation checklist

Make sure that …

The ambient operating conditions meet the drive ambient conditions specification and enclosure
rating (IP code).
The supply voltage matches the nominal input voltage of the drive. Refer the type designation
label.
The insulation resistance of the input power cable, motor cable and motor is measured according
to local regulations and the manuals of the drive.
The drive cabinet is attached to the floor, and if necessary due to vibration etc, also by its top
to the wall or roof.
The cooling air can flow freely in and out of the drive.
If the drive is connected to a network other than a symmetrically grounded TN-S system: You
have done all the required modifications (for example, you may need to disconnect the EMC filter
or ground-to-phase varistor) the electrical installation instructions.
There is an adequately sized protective earth (ground) conductor(s) between the drive and the
switchboard, the conductor is connected to correct terminal, and the terminal is tightened to
the correct torque.
Grounding has also been measured according to the regulations.
The input power cable is connected to the correct terminals, the phase order is correct, and the
terminals are tightened to the correct torque.
There is an adequately sized protective earth (ground) conductor between the motor and the
drive. The conductor is connected to the correct terminal, and the terminal is tightened to the
correct torque.
Grounding has also been measured according to the regulations.
The motor cable is connected to the correct terminals, the phase order is correct, and the terminals
are tightened to the correct torque.
The motor cable is routed away from other cables.
No power factor compensation capacitors are connected to the motor cable.
If an external brake resistor is connected to the drive: There is an adequately sized protective
earth (ground) conductor between the brake resistor and the drive, and the conductor is connec-
ted to the correct terminal, and the terminals are tightened to the correct torque. Grounding
has also been measured according to the regulations.
If an external brake resistor is connected to the drive: The brake resistor cable is connected to
the correct terminals, and the terminals are tightened to the correct torque.
If an external brake resistor is connected to the drive: The brake resistor cable is routed away
from other cables.
The control cables are connected to the correct terminals, and the terminals are tightened to
the correct torque.
The voltage setting of the auxiliary voltage transformers (if any) is correct. See the electrical in-
stallation instructions.
If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive
output contactor are either mechanically and/or electrically interlocked, that is, they cannot be
closed at the same time. A thermal overload device must be used for protection when bypassing
the drive. Refer to local codes and regulations.
There are no tools, foreign objects or dust from drilling inside the drive.
The area in front of the drive is clean: the drive cooling fan cannot draw any dust or dirt inside.
The terminal box cover of the motor is in place. Cabinet shrouds are in place and doors are closed.
The motor and the driven equipment are ready for power-up.
 Start-up 169

10
Start-up

Contents of this chapter

This chapter contains the start-up and switch-off procedures of the drive.

Start-up procedure
The tasks which are needed in certain cases only are marked with underlining, and
option codes are given in brackets. Default device designations (if any) are given in
brackets after the name, for example “main switch-disconnector [Q1]”. The same
device designations are also used in the circuit diagrams.
12
These instructions cannot and do not cover all possible start-up tasks of a customized
drive. Always refer to the delivery-specific circuit diagrams when proceeding with the
start-up.

WARNING!
Only qualified electrical professionals are permitted to do the work described
in this chapter.

Note: For certain options (such as functional safety options +Q950, +Q951, +Q952,
+Q957, +Q963, +Q964, +Q978, +Q979), additional start-up instructions are given in
their separate manuals.

Action
Safety

WARNING!
Obey the safety instructions during the start-up procedure. See chapter Safety instruc-
tions (page 17).
170 Start-up

Action
Checks/Settings with no voltage connected
Make sure that the disconnector of the supply transformer is locked to the open position (i.e.,
voltage is not connected to the drive, and cannot be connected to the drive accidentally).
Make sure that the main switch-disconnector [Q1.1] is open, or the main breaker [Q1] is racked
out.
Close the grounding switch [Q9.1] (option +F259). Do not use too much force. Electrical interlock-
ing can prevent closing of the grounding switch.
Check the mechanical and electrical installation of the drive. See Installation checklist (page 167).
Check the settings of breakers/switches in the auxiliary circuits. See the circuit diagrams delivered
with the drive.
Check the tap settings of transformers T21, T101 (if present) and T111 (if present). See section
Checking the settings of transformers T21, T101 and T111 (page 114).
Disconnect any unfinished or uninspected auxiliary voltage (115/230 V AC) cables that lead from
the terminal blocks to the outside of the equipment.
Check that both channels of the Safe torque off circuit connected to the STO inputs of both the
supply control unit [A51] and the inverter control unit [A41] are closed. Refer to the wiring diagrams
delivered with the drive.
Drives with ground fault monitoring for IT (ungrounded) systems (option +Q954): If necessary,
adjust the settings of the device. See the circuit diagrams of the delivery and the manual of the
device.
Drives with Pt100 relays (option +(n)L506):
• Check the connections against the circuit diagrams of the delivery.
• Set the alarm and trip levels of the Pt100 relays.
Set the alarm and trip levels of the Pt100 relay as low as possible based on the operating temper-
ature and test results of the machine. The trip level can be set, for example, 10 °C higher than
what the temperature of the machine is at maximal load in the maximum environmental temper-
ature.
ABB recommends to set the operating temperatures of the relay, typically for example, as follows:
• 120…140 °C when only tripping is in use
• alarm 120…140 °C and trip 130…150 °C when both alarm and tripping are used.
Powering up the auxiliary circuit of the drive
Make sure that it is safe to connect voltage. Make sure that:
• nobody is working on the drive or circuits that have been wired from outside into the drive
cabinet
• the cover of the motor terminal box is in place.
Drives with a voltmeter (option +G334): Make sure that the circuit breaker of the measuring circuit
(F5.1) is closed.
Close the circuit breakers and/or fuse disconnectors supplying the auxiliary voltage circuits.
Close the cabinet doors.
Close the main breaker of the supply transformer.
Switch on the auxiliary voltage [Q21].
Drives of frame size 1×R8i + 1×R8i: Close the main switch-disconnector [Q1.1]. This will power up
the main circuit of the drive as well as the auxiliary voltage circuit.
Setting up the supply unit parameters
Check the voltage range setting in parameter 195.01 Supply voltage.
For more information on setting up the supply control program, refer to the applicable firmware
manual ACS880 IGBT supply control program firmware manual (3AUA0000131562 [English]) or
ACS880 IGBT supply control program (YISLX and YLHLX) firmware manual (3AXD50001019464
[English]).
If you need more information on the use of the control panel, refer to ACS-AP-I, -S, -W and ACH-
AP-H, -W Assistant control panels user's manual (3AUA0000085685 [English]).
 Start-up 171

Action
Setting up the inverter unit parameters, and performing the first start
Set up the inverter control program. See the appropriate start-up guide and/or firmware
manual. There is a separate start-up guide only for some control programs.
Make sure that parameter 95.09 Switch fuse controller is set to Disabled.
Drives with a brake chopper (option +D150): See chapter Resistor braking (page 309).
Drives with a sine output filter (option +E206): Check that bit 1 of parameter 95.15 Special HW
settings is activated.
Drives with an fieldbus adapter module (optional): Set the fieldbus parameters. Activate the
appropriate assistant (if present) in the control program, or see the user’s manual of the fieldbus
adapter module, and the drive firmware manual. Check that the communication works between
the drive and the PLC.
Drives with an encoder interface module (optional): Set the encoder parameters. Activate the
appropriate assistant (if present) in the control program, or see the user’s manual of the encoder
interface module, and the drive firmware manual.
Powering up the main circuit of the drive
Switch off the grounding switch [Q9.1] (option +F259).
Close the main switch-disconnector [Q1.1] or main breaker [Q1].

Note: Do not use excessive force. The main switch-disconnector (or main breaker) can only be
closed when:
• the main input terminals [L1, L2, L3] are powered, and
• auxiliary voltage is switched on [Q21], and
• the grounding switch [Q9.1, Q9.2] (option +F259) is open.
Turn the operating switch (S21) to the ON (1) position to activate the run enable signal. Depending
on control source settings, this may also close the main contactor (if present). If a main contactor
is present and does not close, refer to the circuit diagrams delivered by the drive as well as the
appropriate firmware manuals.
On-load checks
Start the motor to perform the ID run.
Check that the cooling fans rotate freely in the right direction, and the air flows upwards.
Check that the motor starts, stops and follows the speed reference in the correct direction when
controlled with the control panel. 12
Check that the motor starts, stops and follows the speed reference in the correct direction when
controlled through the customer-specific I/O or fieldbus.
Drives in which the Safe torque off control circuit is in use: Test and validate the operation of
the Safe torque off function. See section Start-up including validation test (page 298).
Drives with an emergency stop circuit (options +Q951, +Q952, +Q963, +Q964, +Q978, +Q979):
Test and validate the operation of the emergency-stop circuit. See the delivery specific circuit
diagrams and wiring, start-up and operating instructions of the option.
Drives with the Prevention of unexpected start-up with safety relay (option +Q957): Test and
validate the operation of the Prevention of unexpected start-up circuit. See the delivery specific
circuit diagrams and wiring, start-up and operating instructions of the option.
Drives with the Prevention of unexpected start with FSO safety functions module (option +Q950):
Test and validate the operation of the Prevention of unexpected start-up circuit. See the delivery
specific circuit diagrams and wiring, start-up and operating instructions of the option.
Drives with the Safely-limited speed with the encoder interface (option +Q965): Test and validate
the operation of the Safely-limited speed circuit. See the delivery specific circuit diagrams and
wiring, start-up and operating instructions of the option.
Drives with a motor thermal protection function (options +L513, +L514, +L536, +L537): Test and
validate the operation of the motor thermal protection function. See the delivery specific circuit
diagrams and wiring, start-up and operating instructions of the option.
172 Start-up

Switching off the drive

1. Stop the motor.
2. Turn the Run enable switch (S21) to the off (0) position to deactivate the Run
enable signal and to switch the main contactor/breaker off.
 Fault tracing 173

11
Fault tracing

Contents of this chapter

This chapter describes the fault tracing possibilities of the drive.

Control unit LEDs (UCU-22…24)

LED Indication

BAT Green Battery voltage of the real-time clock is sufficient (higher than
2.5 V).

Off Battery voltage is below 2.5 V, the battery is missing or the

control unit is not powered.

PWR Green Internal voltage is sufficient.

FAULT Red Control program indicates that the equipment is faulty. See
the appropriate firmware manual.

WRITE Yellow Writing to microSDHC card in progress.

FS COMM Green Reserved

FS STATUS Green Reserved

174 Fault tracing

Control unit LEDs (BCU-x2)

LED Color Indication

BATT OK Green Battery voltage of the real-time clock is OK (higher than 2.8 V).
When the LED is not lit,
• battery voltage is below 2.8 V,
• the battery is missing, or
• the control unit is not powered.

PWR OK Green Internal voltage is sufficient.

FAULT Red The control program indicates that the equipment is faulty.
See the appropriate firmware manual.

WRITE Yellow Writing to SD card in progress.

Control panel and panel platform/holder LEDs

The ACS-AP-… control panel has a status LED. The control panel mounting platform
or holder has two status LEDs. For status LED indications, see the following table.

Location LED Indication

Control panel Continuous green The unit operates normally.

Flickering green Data is transferred between the PC and the unit through the
USB connection of the control panel.

Flashing green There is an active warning in the unit.

Continuous red There is an active fault in the unit.

Flashing red There is a fault that requires the stopping and restarting of
the drive/converter/inverter.

Flashing blue (ACS- The Bluetooth interface is enabled, in discoverable mode, and
AP-W only) ready for pairing.

Flickering blue Data is transferred through the Bluetooth interface of the

(ACS-AP-W only) control panel.

Control panel Red There is an active fault in the unit.

mounting platform
or holder (with the Green Power supply for the control unit is OK.
control panel
removed)

Warning and fault messages

See the firmware manual for the descriptions, causes and remedies of the drive control
program warning and fault messages.
 Maintenance 175

12
Maintenance

Contents of this chapter

This chapter contains maintenance instructions.

Handling fiber optic cables

WARNING!
Obey these instructions. If you ignore them, damage to the equipment can
occur.

• Handle the fiber optic cables with care.

• When you disconnect the fiber optic cables, always hold the connector, not the
cable.
• Do not touch the ends of the fibers. They are sensitive to dirt.
• Do not bend the fiber optic cables too tightly. The minimum allowed bend radius
is 35 mm (1.4 in).

Maintenance intervals
The tables show the maintenance tasks that can be done by the end user. For the ABB
Service offering, contact your local ABB Service representative
(new.abb.com/contact-centers).

￭ Description of symbols

Action Description

I Inspection (visual inspection and maintenance action if needed)

176 Maintenance

Action Description

P Performance of on/off-site work (commissioning, tests, measurements or other work)

R Replacement

￭ Recommended maintenance intervals after start-up

Years from start-up

Maintenance task/object
0 1 2 3 4 5 6 7 8 9 10 11 12 …

Cooling
Supply/Inverter module main cooling fan R
Supply/Inverter module circuit board compart-
R
ment fan
LCL filter cooling fan (50 Hz) R
LCL filter cooling fan (60 Hz) R R
Sine filter cooling fan R
Door fan R
Other cabinet cooling fans (50 Hz) R
Other cabinet cooling fans (60 Hz) R R
Batteries
Control unit battery R R
Control panel battery R
Connections and environment
Air inlet and outlet cleaning (IP22/IP42) I I I I I I I I I I I I I
Cabinet door filter change (IP54) R R R R R R R R R R R R R
Checking tightness of cable and busbar ter-
I I I I I I I I I I I I I
minals. Tightening if needed.
Checking ambient conditions (dustiness,
I I I I I I I I I I I I I
corrosion, temperature)
Cleaning of heatsinks I I I I I I I I I I I I I
Quality of supply voltage P P P P P P P P P P P P P
Air circuit breaker maintenance (if present) I I I I I I I I I I I I I
Spare parts
Spare parts I I I I I I I I I I I I I
DC circuit capacitor reforming (spare mod-
P P P P P P P P P P P P P
ules and spare capacitors)
Functional safety
I
Safety function test
See the maintenance information of the safety function.
Safety component expiry (Mission time, TM) 20 years
 Maintenance 177

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

Cabinet
￭ Cleaning the interior of the cabinet

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

WARNING!
Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding
wristband. Using a normal vacuum cleaner creates static discharges which can
damage circuit boards.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
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 of the fans and air outlets of the modules (top).
5. Clean the air inlet gratings (if any) on the door.
6. Close the door.

￭ Cleaning the exterior of the drive

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Clean the exterior of the drive. Use:
• vacuum cleaner with an antistatic hose and nozzle
• soft brush
• dry or damp (not wet) cleaning cloth. Moisten with clean water, or mild
detergent (pH 5…9 for metal, pH 5…7 for plastic).

WARNING!
Prevent water from entering the drive. Never use excessive amount of water,
a hose, steam, etc.
 Maintenance 179

￭ Cleaning the door air inlets (IP22 and IP42)

Check the dustiness of the air inlet meshes. If the dust cannot be removed by vacuum
cleaning from outside through the grating holes with a small nozzle, proceed as follows:
1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
„
2. Remove the fasteners at the top of the grating.
3. Lift the grating and pull it away from the door.
4. Vacuum clean or wash the grating on both sides.
5. Reinstall the grating in reverse order.
180 Maintenance

￭ Replacing the inlet door filters (IP54)

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
„
2. Remove the fasteners at the top of the grating.
3. Lift the grating and pull it away from the door.
4. Remove the air filter mat.
5. Place the new filter mat in the grating the metal wire side facing the door.
6. Reinstall the grating in reverse order.

„
￭ Cleaning the roof outlet filters (IP54)
The outlet filters on the roof of IP54 units can be accessed by pulling the gratings
upwards.
„
￭ Replacing the roof outlet filters (IP54)
1. Remove the front and back gratings of the fan cubicle by lifting them upwards.
2. Remove the air filter mat.
3. Place the new filter mat in the grating.
4. Reinstall the gratings in reverse order.
 Maintenance 181

Fans
The lifespan of the cooling fans of the drive depends on running time, ambient
temperature and dust concentration. See the firmware manual for the actual signal
which indicates the running time of the cooling fan. Reset the running time signal
after fan replacement.
Replacement fans are available from ABB. Do not use other than ABB-specified spare
parts.

￭ Replacing R8i module cooling fan (speed-controlled version)

The module is equipped with a fan unit that contains two cooling fans.

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

WARNING!
Use the required personal protective equipment. Wear protective gloves and
long sleeves. Some parts have sharp edges.

Before you start replacing the fan kit of the converter module, make sure that the
connector at the end of the fan kit cable is compatible with the counterpart in the
module. Black connector is compatible only with the black counterpart, and gray
connector only with the gray counterpart. If the connectors are not compatible, replace
the connector at the end of the fan kit cable. Use the connector in the old fan kit, or
order a suitable connector from ABB.
1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the cubicle door.
3. Remove the shroud in front of the fan (if any).
4. Remove the screws holding the front cover plate. Lift the cover plate somewhat
to release it.
5. Disconnect the fan wiring.
6. Remove the unit below the fan.
7. Remove the screws of the fan unit.
8. Pull out the fan unit.
9. Install a new fan in reverse order.
182 Maintenance





￭ Replacing R8i module cooling fan (direct-on-line version)

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

WARNING!
Use the required personal protective equipment. Wear protective gloves and
long sleeves. Some parts have sharp edges.

Before you start replacing the fan kit of the converter module, make sure that the
connector at the end of the fan kit cable is compatible with the counterpart in the
module. Black connector is compatible only with the black counterpart, and gray
connector only with the gray counterpart. If the connectors are not compatible, replace
the connector at the end of the fan kit cable. Use the connector in the old fan kit, or
order a suitable connector from ABB. Refer to Connector replacement guide for
ACS880-x04 R8i/D8T, BLCL-2X, BL-2X and BLHF DOL fan (3AXD50001059903 [English]).
1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the door.
3. Remove the shroud in front of the fan (if any).
4. Remove the screws holding the front cover plate. Lift the cover plate somewhat
to release it.
5. Remove the bracket.
6. Disconnect the wiring of the fan unit.
7. Remove the screws of the fan unit.
8. Pull out the fan unit.
9. Disconnect the fan wire from the fan unit.
10. Remove the screws of the fan.
11. Install a new fan in reverse order.
 Maintenance 183

10

10
6
184 Maintenance

￭ Replacing the fan of the LCL filter (BLCL-1x-x)

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
„
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

Note: Before you start replacing the fan kit of the converter module, make sure that
the connector at the end of the fan kit cable is compatible with the counterpart in the
module. Black connector is compatible only with the black counterpart, and gray
connector only with the gray counterpart. If the connectors are not compatible, replace
the connector at the end of the fan kit cable. Use the connector in the old fan kit, or
order suitable connector from ABB. Refer to +V112 connector replacement guide for
ACS880 BLCL-1X and BL-1X fan kit change, connector X55 (3AXD50001065140 [English]).
1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the door.
3. Remove the two locking screws of fan supply plug connector.
4. Pull the plug connector downwards to unplug the fan wiring.
5. Remove two screws in front of the fan unit.
6. Pull the fan unit out.
7. Install a new fan in reverse order.

4
 Maintenance 185

￭ Replacing the fan of the LCL filter (BLCL-2x-x)

WARNING!
„
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

Note: Before you start replacing the fan kit of the filter module, make sure that the
connector at the end of the fan kit cable is compatible with the counterpart in the
module. Black connector is compatible only with the black counterpart, and gray
connector only with the gray counterpart. If the connectors are not compatible, replace
the connector at the end of the fan kit cable. Use the connector in the old fan kit, or
order suitable connector from ABB. Refer to +V112 connector replacement guide for
ACS880-x04 R8i/D8T, BLCL-2X, BL-2X and BLHF DOL fan (3AXD50001059903 [English]).
1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the door.
3. Remove the two locking screws of fan supply plug connector.
4. Pull the plug connector downwards to unplug the fan wiring.
5. Remove the screws in front of the fan unit.
6. Pull the fan unit out.
7. Replace the fan of the fan unit. Install the fan unit in reverse order.

6
5
186 Maintenance

￭ Replacing the circuit board compartment fan

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

„ WARNING!
„
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the door of the module cubicle.
3. Remove the two M4×12 (T20) screws which lock the fan holder.
4. Pull the fan holder out of the module.
5. Disconnect the fan cable.

5
4

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

8. Put the fan onto the threaded studs on the fan holder with the airflow direction
arrow pointing towards the fan holder.
 Maintenance 187

9. Install and tighten the four nuts removed earlier.

10. Connect the fan cable.

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

10
11

12

￭ Replacing the cooling fan in the incoming cubicle

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Remove the shrouding (if any) in front of the fan.
3. Disconnect the fan wiring (a).
4. Remove the fastening screws (a) and finger guard (b) of the fan.
5. Install the new fan in reverse order. Make sure that the arrow indicating the air
flow direction points up.
188 Maintenance

3 4

4b
4a

3a

￭ Replacing the roof fan (IP54/UL type 12)

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Remove all ventilation covers (lift and pull) and filters.
3. Remove the roof plate on top of the outlet (if any).
4. Disconnect the fan supply wires.
5. Loosen the mounting screws of the fan.
6. Remove the fan.
7. Install the new fan in reverse order.
 Maintenance 189

Different roof fan models

￭ Replacing the common motor terminal cubicle fan

WARNING!
Use the required personal protective equipment. Wear protective gloves and
long sleeves. Some parts have sharp edges.

Fan attached to the cabinet door

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the cabinet door.
3. Disconnect the fan wiring.
4. Remove the connectors.
5. Remove the fastening screws.
6. Remove the fan.
7. Install the new fan in reverse order.

Roof fan (with options +C128 and +H353)

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the cabinet door.
3. Remove the finger guard.
4. Disconnect the fan wiring.
5. Remove the fastening screws.
6. Remove the fan.
7. Install a new fan in reverse order.
190 Maintenance

Floor fan (with options +C128 and +H353)

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the cabinet door.
3. Remove the finger guard.
4. Disconnect the fan wiring.
5. Remove the fastening screws.
6. Remove the fan.
7. Install a new fan in reverse order.

￭ Replacing the brake chopper and resistor cubicle fans (options +D150
and +D151)
See chapter Resistor braking (page 309).
 Maintenance 191

Supply and inverter modules

￭ Replacing a supply or inverter module
Removing a supply or inverter module

Note: As an alternative to using the extraction/installation ramp, a lifter is available

from ABB Service. See Lifter for air-cooled drive modules user's guide
(3AXD50000332588 [English]).

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur.
192 Maintenance

WARNING!
Use extreme caution when maneuvering the inverter module. It is heavy and
has a high center of gravity. Ignoring the following instructions can cause
physical injury, or damage to the equipment.
• Use the required personal protection equipment: safety shoes with metal
toe cap, protective gloves, etc.
• Do not use the module extraction/installation ramp with plinth heights
that exceed the maximum allowed height.
• Push the module into the cabinet and pull it from the cabinet carefully
preferably with help from another person. Keep a constant pressure with
one foot on the base of the module to prevent the module from falling on
its back. Keep your fingers away from the edges of the front flange of the
module.

max.

• Be careful when handling a tall module. The module overturns easily because
it is heavy and has a high center of gravity. Whenever possible, secure the
module with chains. Do not leave an unsupported module unattended
especially on a sloping floor.

1. Do the steps in section Electrical safety precautions (page 22) before you start
the work.
2. Open the inverter module cubicle door.
3. Remove the shroud at the top of the cubicle.
 Maintenance 193

4. Detach the terminal block [X50] at the top of the module.

5. Detach the DC busbars from the module. Make note of the order and position of
the screws and washers.
6. Detach the wiring connected to the terminals on the front of the module (including
fiber optic cabling). Move the disconnected wiring aside.
7. Drives with option +C121 (Marine construction) or +C180 (Seismic design):
a. Loosen the bolts holding the transverse retaining bracket both on the left
and the right. (During reassembly, tighten these screws to 9 N·m [6.6 lbf·ft].)
b. Remove the bolts holding the retaining bracket to the module.
c. Remove the retaining bracket.
d. Reinstall the bolts to the module. Tighten to 22 N·m (16 lbf·ft).

WARNING! Do not proceed before the bolts are securely in place.

Otherwise, the parts of the module can become separated and cause
injury or damage.

8. Attach the module extraction/installation ramp (included) to the base of the

cabinet so that the tabs on the mounting bracket enter the slots on the ramp.

WARNING!
Make sure that the markings on the ramp agree with the plinth height. An
incorrect ramp can cause the module to fall over when removing it from
the cabinet.

9. Remove the two retaining screws at the bottom front of the module.

WARNING!
Before you proceed, make sure the cabinet is level, or chock the wheels of
the module.

10. Remove the two retaining screws at the top front of the module.
11. Pull the module carefully out along the ramp. While pulling on the handle with your
right hand, keep a constant pressure with one foot on the base of the module to
prevent the module from falling on its back.
12. Move the module into a safe location outside the immediate work area and make
sure it cannot topple over. Chock the wheels of the module if the floor is not
completely level.
13. Repeat the procedure for the other inverter modules.
 Electrical installation 109
194 Maintenance

6
 Maintenance 195

b
d

110 Electrical installation

87

9
8
9
8
 Electrical installation 111
196 Maintenance

10
9

11
10

Installing a supply or inverter module

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

Before you replace an inverter module with a new one, make sure that the connector
of the auxiliary power supply cable in the cabinet is compatible with the counterpart
in the module (X50). Black connector is compatible only with the black counterpart,
and gray connector only with the gray counterpart. If the connectors are not
compatible, replace the connector in the new module. Use the connector from the old
module, or order suitable connector from ABB. Refer to Connector replacement guide,
auxiliary power supply for ACS880-104 R8i, ACS880-304 D8T and D7T
 Maintenance 197

(3AXD50001060015 [English]) or Connector replacement guide, auxiliary power supply

for ACS880-104 R8i with +C183, ACS880-304 D8T with +C183 (3AXD50001060022
[English]).
If you replace a module with a new one, make sure that the new module has the same
type code as the old one.
1. Make sure there are no tools, debris or any other foreign objects in the cubicle.
2. If not already in place, attach the module extraction/installation ramp (included)
to the base of the cabinet so that the tabs on the mounting bracket enter the
slots on the ramp.
3. 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.
• Keep a constant pressure with one foot on the base of the module to prevent
the module from falling on its back.
4. Attach the top front of the module with two screws. Tighten to 22 N·m (16 lbf·ft).
5. Attach the bottom front of the module with two screws. Tighten to 22 N·m
(16 lbf·ft).
6. Remove the ramp.
7. Drives with option +C121 (Marine construction) or +C180 (Seismic design):
a. Remove the bolts holding the fan carriage (two bolts per module).

WARNING! The module retaining screws (two at top, two at bottom

per module) must be in place before removing these screws. Otherwise,
the parts of the module can become separated and cause injury or
damage.

b. Install the transverse retaining bracket. At the ends of the bracket, tighten
the screws to 9 N·m [6.6 lbf·ft]. Install the fan carriage bolts removed at
previous step, and tighten to 22 N·m (16 lbf·ft).
8. Attach the DC busbars to the module. Tighten to 70 N·m (52 lbf·ft). See Use of
fasteners in cable lug connections (page 132).
9. Connect terminal block [X50] at the top of the module.
10. Connect the wiring and fiber optic cables to the terminals on the front of the
module.
198 Maintenance

11. Repeat the procedure for the other inverter modules.

12. Reinstall the shroud near the top of the cubicle.

￭ Cleaning the heatsink

The heatsink of the power module (drive, supply, inverter, converter, etc.) pick up dust
from the cooling air. This can cause overtemperature warnings and faults. When
necessary, clean the heatsink as follows.

WARNING!
Use the required personal protective equipment. Wear protective gloves and
long sleeves. Some parts have sharp edges.

WARNING!
Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding
wristband. Using a normal vacuum cleaner creates static discharges which can
damage circuit boards.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Remove the power module from the cabinet.
3. Remove the module cooling fan(s). Refer to the separate instructions.
4. Protect the adjacent equipment from dust.
5. Blow dry, clean and oil-free compressed air from bottom to top and simultaneously
use a vacuum cleaner at the air outlet to trap the dust.
6. Reinstall the cooling fan.

￭ Activating the reduced run function of the inverter unit

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.

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur.

Refer to the drawing below.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Remove the shrouding above the module bay (in front of the DC fuses).
3. Remove the DC fuses and the busbar assembly connecting the fuses to the inverter
module. Store these parts – they are to be reinstalled only with the inverter module.
Make note of the order of washers.
4. Remove the faulty module from its bay. See the module replacement instructions.
5. Install the air baffle (included) to the underside of the top module guide:
 Maintenance 199

• Fasten the front edge of the baffle to the module mounting holes using the
module mounting screws (2 × M8). Tighten to 9 N·m (6.6 lbf·ft).
• Fasten the left/right sides of the baffle using M4 screws wherever possible.
(This depends on the location of the module in the cubicle.) Tighten to 1…2 N·m
(0.7 … 1.5 lbf·ft).

6. If the inverter control unit (A41) is powered from the faulty module, connect the
power supply wiring to another module using the extension wire set included.
7. If the Safe torque off (STO) function is in use, install the jumper wire set included
in the STO wiring in place of the missing module. (This is not needed if the module
was the last on the STO wire chain.)
8. Reinstall all shrouding removed earlier.

Note: Do not reinstall the DC fuses or busbars but store them elsewhere until the
module can be reinstalled.
9. Switch on the power to the drive.
10. Enter the number of inverter modules present into parameter 95.13 Reduced run
mode.
11. Reset all faults and start the drive.
12. If the Safe torque off (STO) function is in use, perform a validation test. See the
STO instructions.
The maximum current is now automatically limited according to the new inverter
configuration. A mismatch between the number of detected modules and the value
set in parameter 95.13 will generate a fault.

Returning the module

1. Install the module in reverse order. Use the following tightening torques:
200 Maintenance

• DC busbar assembly to upper insulators (2 × M8): 9 N·m (6.6 lbf·ft)

• DC busbar assembly to lower insulators (2 × M10): 18 N·m (13.3 lbf·ft)
• Fuses to DC busbars: 50 N·m (37 lbf·ft) (Bussmann), 46 N·m (34 lbf·ft)
(Mersen/Ferraz-Shawmut)
• Module to cabinet frame (4 × M8): 22 N·m (16 lbf·ft)
• DC busbar assembly to module DC input (2 × M12): 70 N·m (52 lbf·ft)
2. Restore the original wiring (STO and control unit power supply whenever needed).
3. Set parameter 95.13 to 0 to disable the reduced run function.
4. If the Safe torque off (STO) function is in use, perform a validation test. See the
STO instructions.

￭ Activating the reduced run of the supply unit

A “reduced run” function is available for supply/rectifier units consisting of
parallel-connected 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 enough current. For allowed configurations when using reduced
run function, refer to the firmware manual of the supply unit.

Starting reduced run operation

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

WARNING!
Use the required personal protective equipment. Wear protective gloves and
long sleeves. Some parts have sharp edges.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. If the control unit is powered from the faulty module, connect the control unit to
another 24 V DC power supply. ABB strongly recommends using an external power
supply with supply/rectifier units consisting of parallel-connected modules.
3. Remove the module to be serviced from its bay.
4. Install an air baffle (for example, plexiglass) to the top module guide to block the
airflow through the empty module bay.
5. Switch on the power to the supply/rectifier unit.
6. Enter the number of supply/rectifier modules present into parameter 195.13
Reduced run mode.
7. Reset all faults and start the supply/rectifier unit. The maximum current limit is
now automatically set according to the new configuration. A mismatch between
the number of detected modules (parameter 195.14) and the value set in 195.13
will generate a fault.
 Maintenance 201

Resuming normal operation

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Remove the air baffle from the module bay.
3. Reinstall the module into its bay.
4. Switch on the power to the supply/rectifier unit.
5. Enter "0" into parameter 195.13 Reduced run mode.
202 Maintenance

LCL filter
￭ Replacing the LCL filter
Refer to the drawings below.

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.
 Maintenance 203

WARNING!
• Do not use the module extraction/installation ramp when the height of
the drive cabinet plinth is more than the maximum permitted height.
• Secure the module extraction/installation ramp carefully.
• Push the module into the cabinet and pull it from the cabinet carefully
preferably with help from another person. Keep a constant pressure with
one foot on the base of the module to prevent the module from falling on
its back. Keep your fingers away from the edges of the front flange of the
module.

max.

•
WARNING!
Do not move the module on its wheels for long distances. It can
cause damage to the wheels. Also, there is a risk of the module
falling over.

• Be careful when handling a tall module. The module overturns easily because
it is heavy and has a high center of gravity. Whenever possible, secure the
module with chains. Do not leave an unsupported module unattended
especially on a sloping floor.

• Wear protective gloves and long sleeves! Some parts have sharp edges.
204 Maintenance

Note: As an alternative to using the extraction/installation ramp, a lifter is available

from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled
drive modules user's guide (3AXD50000332588 [English]).

Note: Before you start replacing the filter module, make sure that the connector at
the end of the auxiliary power supply cable in the cabinet is compatible with the
counterpart in the module. Black connector is compatible only with the black
counterpart, and gray connector only with the gray counterpart. If the connectors are
not compatible, replace the connector in the new module. Use the connector in the
old module, or order suitable connector from ABB. Refer to +V112 connector
replacement guide for ACS880 BLCL-2X, BL-2X and BLHF module change, connector
X30 (3AXD50001065157 [English]).
1. Stop the drive (if running) and do the steps in section Electrical safety
precautions (page 22) before you start the work.
2. Open the cubicle door.
3. Undo the four screws of the shroud in the upper part of the cubicle. Remove the
shroud.
4. Unplug the signal connector cable on top of the module.
5. Remove the screws that connect the busbars to the top of the filter module. Be
careful not to drop the screws into the module.
Frame 1×R8i+1×R8i only: Loosen the screws (a) and slide the busbars (b) upwards
as far as they go. Tighten the screws (a) enough to hold the busbars in the up
position.

6. Remove the fan of the filter module. Unplug the signal connector cable and remove
the screws in front of the fan.
7. Remove the fastening screws in the busbar behind the module.
8. Remove the two screws that fasten the bottom of the module to the base of the
cabinet.
9. Install the module extraction/installation ramp: lift the ramp against the cabinet
base so that the hooks of the base go into the ramp’s holes.
10. Remove the two fastening screws that fasten the top of the module to the cabinet
frame.
 Maintenance 205

11. Pull the module carefully out of the cabinet 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.
12. Replace the module: install the module in reverse order. Mind you fingers. Keep a
constant pressure with one foot on the base of the module to prevent the module
from falling on its back.

Note: Be careful not to break the fastening screws: tighten the fastening screws
of the module to 22 N·m (16.2 lbf·ft) and fastening bolts of the DC output busbars
to 70 N·m (51.6 lbf·ft).
• Plug the module signal wire set to the module signal connector.
• Fasten the shrouds.
13. Remove the module extraction/installation ramp and close the cabinet doors.

7
206 Maintenance

11

10

Capacitors
The intermediate DC circuit of the drive contains several electrolytic capacitors.
Operating time, load, and surrounding air temperature have an effect on the life of
the capacitors. Capacitor life can be extended by decreasing the surrounding air
temperature.
Capacitor failure is usually followed by damage to the unit and an input cable fuse
failure, or a fault trip. If you think that any capacitors in the drive have failed, contact
ABB.
 Maintenance 207

￭ Reforming the capacitors

The capacitors must be reformed if the drive has not been powered (either in storage
or unused) for a year or more. The manufacturing date is on the type designation label.
For information on reforming the capacitors, refer to Capacitor reforming instructions
(3BFE64059629 [English]).
208 Maintenance

Fuses
￭ Replacing the AC and DC fuses in cabinet
This procedure instructs how to replace the drive AC and DC fuses inside the cabinet.
The location of the fuses vary depending on the drive type and options. Locate the
fuses to be replaced using the delivery-specific layout drawings and circuit diagrams.

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them,
injury or death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the door of the cubicle in which the fuses are.
3. Remove the shrouding from in front of the fuses.
4. Slacken the nuts of the headless screws of the fuses so that you can slide out the
fuse blocks. Make note of the order of the washers on the screws.
5. Remove the screws, nuts and washers from the old fuses and attach them to the
new fuses. Make sure to keep the washers in the original order.
6. Insert the new fuses into their slots in the cubicle. Pre-tighten the nuts first by
hand or by applying a torque of no more than 5 N·m (3.7 lbf·ft).
7. Tighten the nuts to torque as follows:
 Maintenance 209

• Bussmann fuses: 50 N·m (37 lbf·ft)

• Mersen (Ferraz-Shawmut): 46 N·m (34 lbf·ft)
• Other: Refer to the fuse manufacturer’s instructions.
8. Reinstall the shroud and close the door.

UCU control unit

￭ UCU control unit types
Different variants of the UCU control units are used in ACS880 drives: UCU-22…26.
These have a different number of converter module connections but are otherwise
identical. The UCU types are interchangeable as long as the number of connections
is sufficient. For example, the UCU-24 can be used as a direct replacement for both
UCU-22 and UCU-23.

￭ Replacing the memory unit (UCU)

If you replace the control unit, move the memory unit from the old control unit to the
new control unit to keep the existing parameter settings.

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.
210 Maintenance

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

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Make sure that the control unit is not powered.
3. Push and hold in the clips on the memory unit. Pull the memory unit out.
4. Push the new memory unit in.

￭ Replacing the UCU control unit battery

When the BAT LED is on, the real-time clock battery voltage is high enough. If the LED
is off, replace the battery.

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Open the battery cover.
3. Replace the battery with a new BR2032 battery. Make sure that the polarity is
correct.

Note: The real-time clock stays set for 2 minutes without battery.
4. Close the battery cover.
5. If necessary, set the real-time clock.
6. Dispose of the old battery according to local disposal rules or applicable laws.
 Maintenance 211

￭ Replacing the microSDHC memory card (UCU)

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

For the replacement card type, refer to the technical data.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Remove the UMU-01 memory unit from the control unit.
3. Take the memory unit out from the cabinet before you remove the microSDHC
card from it. The card is small and can fall into the cabinet.
4. Open the memory card cover in the memory unit.
5. Push the card to remove it.
6. Install a new card in reverse order.
212 Maintenance

BCU control unit

￭ BCU control unit types
There are three variants of the BCU control unit used in ACS880 drives: BCU-02, BCU-12
and BCU-22. These have a different number of converter module connections (2, 7 and
12 respectively) but are otherwise identical. The three BCU types are interchangeable
as long as the number of connections is sufficient. For example, the BCU-22 can be
used as a direct replacement for both BCU-02 and BCU-12.

￭ Replacing the memory unit (BCU)

If you replace the control unit, move the memory unit from the old control unit to the
new control unit to keep the existing parameter settings.

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

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

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Make sure that the control unit is not powered.
3. Remove the fastening screw and pull the memory unit out.
4. Install a memory unit in reverse order.

￭ Replacing the BCU control unit battery

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.

Replace the real-time clock battery if the BATT OK LED is off when the control unit is
powered.
„

Maintenance 213

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Remove the fastening screw.
3. Replace the battery with a new BR2032 battery.
4. If necessary, set the real-time clock.
5. Discard the old battery according to local disposal rules or applicable laws.

Functional safety components

The mission time of functional safety components is 20 years which equals the time
during which failure rates of electronic components remain constant. This applies to
the components of the standard Safe torque off circuit as well as any modules, relays
and, typically, any other components that are part of functional safety circuits.
The expiry of mission time terminates the certification and SIL/PL classification of
the safety function. The following options exist:
• Renewal of the whole drive and all optional functional safety module(s) and
components.
• Renewal of the components in the safety function circuit. In practice, this is
economical only with larger drives that have replaceable circuit boards and other
components such as relays.
Note that some of the components may already have been renewed earlier, restarting
their mission time. The remaining mission time of the whole circuit is however
determined by its oldest component. Also note that some components connected to
the functional safety system such as main and charging contactors or breakers may
have a shorter lifespan than 20 years, depending on their usage. These components
must be replaced before the end of their lifetime.
Contact your local ABB service representative for more information.
214
 Technical data 215

13
Technical data

Contents of this chapter

This chapter contains the technical specifications of the drive, for example, the ratings,
fuse data, sizes and technical requirements, provisions for fulfilling the requirements
for CE and other markings.

Ratings
The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The
symbols are described below the table.

Input Output ratings

rating No-overload use Light-overload use Heavy-duty use
ACS880-37-…
I1 I2 Imax Pn Sn ILd PLd IHd PHd
A A A kW hp kVA A kW hp A kW hp
Un = 400 V
0450A-3 418 450 590 250 – 312 432 200 – 337 160 –
0620A-3 575 620 810 355 – 430 595 315 – 464 250 –
0730A-3 677 730 950 400 – 506 701 355 – 546 250 –
0800A-3 742 800 1040 450 – 554 768 400 – 598 315 –
0870A-3 807 870 1050 500 – 603 835 450 – 651 355 –
1110A-3 1030 1110 1450 630 – 769 1066 560 – 830 450 –
1210A-3 1123 1210 1580 710 – 838 1162 630 – 905 500 –
1430A-3 1327 1430 1860 800 – 991 1373 710 – 1070 560 –
1700A-3 1577 1700 2040 1000 – 1178 1632 900 – 1272 710 –
2060A-3 1911 2060 2680 1200 – 1427 1978 1100 – 1541 800 –
2530A-3 2347 2530 3040 1400 – 1753 2429 1200 – 1892 1000 –
216 Technical data

Input Output ratings

rating No-overload use Light-overload use Heavy-duty use
ACS880-37-…
I1 I2 Imax Pn Sn ILd PLd IHd PHd
A A A kW hp kVA A kW hp A kW hp
Un = 500 V
0420A-5 390 420 550 250 350 364 403 250 300 314 200 250
0570A-5 529 570 750 400 500 494 547 355 450 426 250 350
0640A-5 594 640 840 450 500 554 614 400 500 479 315 400
0710A-5 659 710 930 500 600 615 682 450 500 531 355 450
0780A-5 724 780 1020 560 700 675.5 749 500 600 583 400 500
1010A-5 937 1010 1320 710 900 875 970 630 800 755 500 600
1110A-5 1030 1110 1450 800 1000 961 1066 710 900 830 560 700
1530A-5 1420 1530 1990 1100 1400 1325 1469 1000 1250 1144 800 1000
1980A-5 1837 1980 2580 1400 1750 1715 1901 1300 1500 1481 1000 1250
2270A-5 2106 2270 2960 1600 2000 1966 2179 1500 1900 1698 1200 1500
Un = 690 V
0320A-7 297 320 480 315 350 382 307 250 300 239 200 250
0390A-7 362 390 590 355 400 466 374 355 350 292 250 300
0460A-7 427 460 690 450 500 550 442 400 450 344 315 350
0510A-7 473 510 770 500 500 610 490 450 500 381 355 400
0580A-7 538 580 870 560 600 693 557 500 600 434 400 450
0660A-7 612 660 990 630 700 789 634 560 600 494 450 500
0770A-7 714 770 1160 710 800 920 739 710 700 576 560 600
0950A-7 881 950 1430 900 1000 1135 912 800 1000 711 710 700
1130A-7 1048 1130 1700 1100 1250 1350 1085 1000 1100 845 800 1000
1450A-7 1345 1450 2180 1400 1500 1733 1392 1300 1500 1085 1000 1100
1680A-7 1559 1680 2520 1600 1750 2008 1613 1500 1750 1257 1200 1250
1950A-7 1809 1950 2930 1900 2000 2330 1872 1800 2000 1459 1400 1500
2230A-7 2069 2230 3350 2200 2500 2665 2141 2000 2250 1668 1600 1750
2770A-7 2570 2770 4160 2700 3100 3310 2659 2600 2900 2072 2000 2250
3310A-7 3071 3310 4970 3200 – 3956 3178 3000 – 2476 2400 2700
 Technical data 217

￭ Definitions

Un Supply voltage range.

I1 Nominal rms input current
I2 Nominal output current (available continuously with no over-loading)
Imax Maximum output current. Available for 10 seconds at start, then as long as allowed by drive
temperature.
Pn Typical motor power in no-overload use. The horsepower ratings are typical NEMA motor
sizes at 460 V (ACS880-37-xxxxA-5) and 575 V (ACS880-37-xxxxA-7) respectively.
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
IHd Continuous rms output current allowing 50% overload for 1 minute every 5 minutes.
PHd Typical motor power in heavy-duty use
Note 1: The ratings apply at an ambient temperature of 40 °C (104 °F).
Note 2: 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.
218 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):

1.00

0.90

0.80
+40 °C +50 °C T
+104 °F +122 °F

Altitude derating
At altitudes more than 1000 m (3281 ft) above sea level, the output current derating
is 1 percentage point for every added 100 m (328 ft). For example, the derating factor
for 1500 m (4921 ft) is 0.95. The maximum permitted installation altitude is given in
the technical data.
If the surrounding air temperature is less than +40 °C (104 °F), the derating can be
reduced by 1.5 percentage points for every 1 °C (1.8 °F) reduction in temperature. A
few altitude derating curves are shown below.

4000 m
13123 ft
0.80

3500 m
11429 ft 0.85

3000 m 0.90
9842 ft

2500 m 0.95
8202 ft

1.00
2000 m
6562 ft

1500 m
4921 ft

1000 m
3300 ft
+20 °C +25 °C +30 °C +35 °C +40 °C
+68 °F +77 °F +86 °F +95 °F +104 °F

Derating factor 1.00

Derating factor 0.95
 Technical data 219

Derating factor 0.90

Derating factor 0.85
Derating factor 0.80

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.
220 Technical data

Derating for output voltage boosting

The drive can output a higher motor voltage than the supply voltage. This can require
derating of the drive output power depending on the difference between the supply
voltage and the output voltage to the motor for continuous operation.
„
This drawing shows the required derating. It is valid for all supply voltage ranges.

P
PN

1.2

1.0

0.8

0.6

0.4

0.2

0.0
0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 U
UN

Example: PN for ACS880-37-1010A-5 is 710 kW. The supply voltage (U) is 450 V. -> U /
UN = 450 V / 500 V = 0.9. -> P / PN = 0.9 -> The derated power P equals 0.9 × 710 kW =
639 kW.
To boost the output voltage to correspond to the nominal supply voltage 500 V,
increase the DC voltage to 500 V × √2 × 1.03 = 726 V.

Note: The drive voltage rating must always be selected according to the boosted
voltage value.

Note: Auxiliary voltage transformer must be set according to supply voltage levels. If
drive selection based on boosted voltage level causes an unsuitable tap setting of the
auxiliary voltage transformer, consult your local ABB representative.
 Technical data 221

Frame sizes and power module types

Supply module(s) used LCL filter(s) used Inverter modules used
ACS880-37-… Frame size Type Type
Qty Qty Type Qty
ACS880-104-… ACS880-104-…
Un = 400 V
0450A-3 1×R8i+1×R8i 1 0470A-3+E205 1 BLCL-13-5+V991 1 0470A-3+E205
0620A-3 1×R8i+1×R8i 1 0640A-3+E205 1 BLCL-13-5+V991 1 0640A-3+E205
0730A-3 1×R8i+1×R8i 1 0900A-3+E205 1 BLCL-15-5+V991 1 0760A-3+E205
0800A-3 1×R8i+1×R8i 1 0900A-3+E205 1 BLCL-15-5+V991 1 0830A-3+E205
0870A-3 1×R8i+1×R8i 1 0900A-3+E205 1 BLCL-15-5+V991 1 0900A-3+E205
1110A-3 2×R8i+2×R8i 2 0640A-3+E205 1 BLCL-24-5+V991 2 0640A-3+E205
1210A-3 2×R8i+2×R8i 2 0640A-3+E205 1 BLCL-24-5+V991 2 0640A-3+E205
1430A-3 2×R8i+2×R8i 2 0760A-3+E205 1 BLCL-24-5+V991 2 0760A-3+E205
1700A-3 2×R8i+2×R8i 2 0900A-3+E205 1 BLCL-25-5+V991 2 0900A-3+E205
2060A-3 3×R8i+3×R8i 3 0900A-3+E205 2 BLCL-24-5+V991 3 0760A-3+E205
2530A-3 3×R8i+3×R8i 3 0900A-3+E205 2 BLCL-24-5+V991 3 0900A-3+E205
Un = 500 V
0420A-5 1×R8i+1×R8i 1 0440A-5+E205 1 BLCL-13-5+V991 1 0440A-5+E205
0570A-5 1×R8i+1×R8i 1 0590A-5+E205 1 BLCL-13-5+V991 1 0590A-5+E205
0640A-5 1×R8i+1×R8i 1 0810A-5+E205 1 BLCL-15-5+V991 1 0670A-5+E205
0710A-5 1×R8i+1×R8i 1 0810A-5+E205 1 BLCL-15-5+V991 1 0740A-5+E205
0780A-5 1×R8i+1×R8i 1 0810A-5+E205 1 BLCL-15-5+V991 1 0810A-5+E205
1010A-5 2×R8i+2×R8i 2 0590A-5+E205 1 BLCL-24-5+V991 2 0590A-5+E205
1110A-5 2×R8i+2×R8i 2 0590A-5+E205 1 BLCL-24-5+V991 2 0590A-5+E205
1530A-5 2×R8i+2×R8i 2 0810A-5+E205 1 BLCL-25-5+V991 2 0810A-5+E205
1980A-5 3×R8i+3×R8i 3 0810A-5+E205 2 BLCL-24-5+V991 3 0740A-5+E205
2270A-5 3×R8i+3×R8i 3 0810A-5+E205 2 BLCL-24-5+V991 3 0810A-5+E205
Un = 690 V
0320A-7 1×R8i+1×R8i 1 0340A-7+E205 1 BLCL-13-7+V991 1 0340A-7+E205
0390A-7 1×R8i+1×R8i 1 0410A-7+E205 1 BLCL-13-7+V991 1 0410A-7+E205
0460A-7 1×R8i+1×R8i 1 0600A-7+E205 1 BLCL-15-7+V991 1 0480A-7+E205
0510A-7 1×R8i+1×R8i 1 0600A-7+E205 1 BLCL-15-7+V991 1 0530A-7+E205
0580A-7 1×R8i+1×R8i 1 0600A-7+E205 1 BLCL-15-7+V991 1 0600A-7+E205
0660A-7 2×R8i+2×R8i 2 0410A-7+E205 1 BLCL-24-7+V991 2 0410A-7+E205
0770A-7 2×R8i+2×R8i 2 0410A-7+E205 1 BLCL-24-7+V991 2 0410A-7+E205
0950A-7 2×R8i+2×R8i 2 0600A-7+E205 1 BLCL-25-7+V991 2 0530A-7+E205
1130A-7 2×R8i+2×R8i 2 0600A-7+E205 1 BLCL-25-7+V991 2 0600A-7+E205
1450A-7 3×R8i+3×R8i 3 0600A-7+E205 2 BLCL-24-7+V991 3 0530A-7+E205
1680A-7 3×R8i+3×R8i 3 0600A-7+E205 2 BLCL-24-7+V991 3 0600A-7+E205
1950A-7 4×R8i+4×R8i 4 0600A-7+E205 2 BLCL-25-7+V991 4 0600A-7+E205
2230A-7 4×R8i+4×R8i 4 0600A-7+E205 2 BLCL-25-7+V991 4 0600A-7+E205
2770A-7 6×R8i+5×R8i 6 0600A-7+E205 3 BLCL-25-7+V991 5 0600A-7+E205
222 Technical data

Supply module(s) used LCL filter(s) used Inverter modules used

ACS880-37-… Frame size Type Type
Qty Qty Type Qty
ACS880-104-… ACS880-104-…
3310A-7 6×R8i+6×R8i 6 0600A-7+E205 3 BLCL-25-7+V991 6 0600A-7+E205
 Technical data 223

Fuses
￭ AC fuses
Notes:
• Fuses with higher current rating than the recommended ones must not be used.
• Fuses from other manufacturers can be used if they meet the ratings and the
melting curve of the fuse does not exceed the melting curve of the fuse mentioned
in the table.

Ultrarapid (aR) AC fuses

Bussmann (IEC/UL) Mersen/Ferraz Shawmut (IEC only)
Input
ACS880- current Rated Clearing
Clearing
37-… Qty current Rated Rated I2t at
(A) I2t at
Type voltage Type voltage rated
(A) 660 V
(V) (V) voltage
(A2s)
(A2s)
Un = 400 V
0450A-3 450 3 700 170M6411 690 300000 SC32AR69V700TF 690 442000
0620A-3 620 3 900 170M6413 690 670000 SC33AR69V900TF 690 805000
0730A-3 730 3 1100 170M6415 690 1300000 SC33AR69V11CTF 690 1570000
0800A-3 800 3 1250 170M6416 690 1950000 SC33AR69V13CTF 690 2210000
0870A-3 870 3 1250 170M6416 690 1950000 SC33AR69V13CTF 690 2210000
1110A-3 1110 3 1600 170M6419 690 3900000 SC33AR60V16CTF 600 3000000
1210A-3 1210 3 2000 170M7062 690 3950000 – – –
1430A-3 1430 3 2500 170M7063 690 7800000 – – –
1700A-3 1700 3 2500 170M7063 690 7800000 – – –
2060A-3 2060 6 2000 170M7062 690 3950000 – – –
2530A-3 2530 6 2000 170M7062 690 3950000 – – –
Un = 500 V
0420A-5 420 3 700 170M6411 690 300000 SC32AR69V700TF 690 442000
0570A-5 570 3 900 170M6413 690 670000 SC33AR69V900TF 690 805000
0640A-5 640 3 1000 170M6414 690 945000 SC33AR69V10CTF 690 1070000
0710A-5 710 3 1100 170M6415 690 1300000 SC33AR69V11CTF 690 1570000
0780A-5 780 3 1250 170M6416 690 1950000 SC33AR69V13CTF 690 2210000
1010A-5 1010 3 1600 170M6419 690 3900000 SC33AR60V16CTF 600 3000000
1110A-5 1110 3 1600 170M6419 690 3900000 SC33AR60V16CTF 600 3000000
1530A-5 1530 3 2500 170M7063 690 7800000 – – –
1980A-5 1980 6 2000 170M7062 690 3950000 – – –
2270A-5 2270 6 2000 170M7062 690 3950000 – – –
Un = 690 V
0320A-7 320 3 500 170M6408 690 95000 SC32AR69V500TF 690 160000
0390A-7 390 3 630 170M6410 690 210000 SC32AR69V630TF 690 315000
0460A-7 460 3 700 170M6411 690 300000 SC32AR69V700TF 690 442000
0510A-7 510 3 800 170M6412 690 465000 SC32AR69V800TF 690 660000
0580A-7 580 3 900 170M6413 690 670000 SC33AR69V900TF 690 805000
224 Technical data

Ultrarapid (aR) AC fuses

Bussmann (IEC/UL) Mersen/Ferraz Shawmut (IEC only)
Input
ACS880- current Rated Clearing
Clearing
37-… Qty current Rated Rated I2t at
(A) I2t at
Type voltage Type voltage rated
(A) 660 V
(V) (V) voltage
(A2s)
(A2s)
0660A-7 660 3 1000 170M6414 690 945000 SC33AR69V10CTF 690 1070000
0770A-7 770 3 1250 170M6416 690 1950000 SC33AR69V13CTF 690 2210000
0950A-7 950 3 1400 170M6417 690 2450000 SC33AR69V14CTF 690 3030000
1130A-7 1130 3 1600 170M6419 690 3900000 SC33AR60V16CTF 600 3000000

3 1) 2500 170M7063 690 7800000 – – –

1450A-7 1450
6 2) 1250 170M7059 690 965000 – – –
3 1) 2500 170M7063 690 7800000 – – –
1680A-7 1680
6 2) 1250 170M7059 690 965000 – – –
1950A-7 1950 6 2000 170M7062 690 3950000 – – –
2230A-7 2230 6 2000 170M7062 690 3950000 – – –
2770A-7 2770 9 2000 170M7062 690 3950000 – – –
3310A-7 3310 9 2000 170M7062 690 3950000 – – –

1) Units with line contactor only.

2) All units.

￭ DC fuses
Drives with parallel-connected supply and inverter modules (ie. frames 2×R8i+2×R8i
and above) have DC fuses at the output of each supply module and at the input of
each inverter module.
Notes:
• Fuses with higher current rating than the recommended ones must not be used.
• Fuses from other manufacturers can be used if they meet the ratings and the
melting curve of the fuse does not exceed the melting curve of the fuse mentioned
in the table.

DC fuses
ACS880- Clearing I2t at
37-… Rated current Rated voltage
Qty Bussmann type 660 V
(A) (V)
(A2s)
Un = 400 V
1110A-3 8 1250 170M6416 690 1950000
1210A-3 8 1250 170M6416 690 1950000
1430A-3 8 1400 170M6417 690 2450000
1700A-3 8 1600 170M6419 690 3900000

6 1) 1400 170M6417 690 2450000

2060A-3
6 2) 1600 170M6419 690 3900000
2530A-3 12 1600 170M6419 690 3900000
Un = 500 V
 Technical data 225

DC fuses
ACS880- Clearing I2t at
37-… Rated current Rated voltage
Qty Bussmann type 660 V
(A) (V)
(A2s)
1010A-5
8 1100 170M6415 690 1300000
1110A-5
1530A-5 8 1400 170M6417 690 2450000
1980A-5
12 1400 170M6417 690 2450000
2270A-5
Un = 690 V
0660A-7
0770A-7
8 800 170M6546 1250 995000 3)

0950A-7 8 1000 170M6548 1100 2150000 3)

1130A-7 8 1100 170M6549 1000 2800000 3)
1450A-7 12 1000 170M6548 1100 2150000 3)
1680A-7 12 1100 170M6549 1000 2800000 3)
1950A-7
16 1100 170M6549 1000 2800000 3)
2230A-7
2770A-7 22 1100 170M6549 1000 2800000 3)
3310A-7 24 1100 170M6549 1000 2800000 3)

1) At outputs of supply modules.

2) At inputs of inverter modules.
3) Clearing at 1000 V.

￭ Brake chopper DC fuses

Optional (+D150) brake choppers have two DC fuses each. The fuse type is Bussmann
170M5146 (630 A 1250 V).

Dimensions and weights

See chapter Dimensions (page 247)

Free space requirements

The values are as required by cooling, maintenance and/or operation of the pressure
relief (if present). Also obey the general mechanical installation instructions.

Front Sides Above

mm in. mm in. mm in.

400
Measured from the base plate of the cabinet top.

1500 59 0 0 15.75
> 400 mm (15.75 in.)
226 Technical data

Cooling data, noise

The noise level depends on the size and structure of the cabinet, actual load, installation
method, and surrounding conditions.
Reported noise values are estimated values with a reference drive configuration
measured in a hemi-anechoic room in accordance with the ISO 9614-2 standard.

Air flow Heat dissipation Noise

ACS880-37-…
m3/h ft3/min kW dB(A)
Un = 400 V
0450A-3 3760 2210 11 75
0620A-3 3760 2210 15 75
0730A-3 3760 2210 18 75
0800A-3 3760 2210 20 75
0870A-3 3760 2210 23 75
1110A-3 7220 4250 27 77
1210A-3 7220 4250 29 77
1430A-3 7220 4250 34 77
1700A-3 7220 4250 45 77
2060A-3 11580 6820 56 78
2530A-3 11580 6820 68 78
Un = 500 V
0420A-5 3760 2210 11 75
0570A-5 3760 2210 15 75
0640A-5 3760 2210 15 75
0710A-5 3760 2210 18 75
0780A-5 3760 2210 21 75
1010A-5 7220 4250 27 77
1110A-5 7220 4250 28 77
1530A-5 7220 4250 41 77
1980A-5 11580 6820 51 78
2270A-5 11580 6820 60 78
Un = 690 V
0320A-7 3760 2210 13 75
0390A-7 3760 2210 15 75
0460A-7 3760 2210 17 75
0510A-7 3760 2210 19 75
0580A-7 3760 2210 23 75
0660A-7 7220 4250 26 77
0770A-7 7220 4250 29 77
0950A-7 7220 4250 38 77
1130A-7 7220 4250 44 77
1450A-7 11580 6820 54 78
1680A-7 11580 6820 63 78
 Technical data 227

Air flow Heat dissipation Noise

ACS880-37-…
m3/h ft3/min kW dB(A)
1950A-7 14440 8500 80 79
2230A-7 14440 8500 87 79
2770A-7 18800 11070 111 79
3310A-7 21660 12750 131 79

These losses are not calculated according to the ecodesign standard IEC 61800-9-2.
228 Technical data

Sine output filter data

Sine output filters are available as option +E206 for the drive types shown in the table
below. The table shows the types and technical data of the filters and filter cubicles
used. The standard filters listed require no current derating.
For availability of sine output filters for other drive types, contact your local ABB
representative.

Sine filter(s) used Nominal Cooling data Dimensions

current
Heat dis-
ACS880-37-… Air flow Width Weight
Qty Type sipation
A kW m3/h (ft3/min) mm kg (lbs)
Un = 400 V
0450A-3 1 NSIN-0485-6 447 2 700 (410) 400 350 (770)
0620A-3 1 NSIN-0900-6 783 5 2000 (1180) 1000 550 (1210)
0730A-3 1 NSIN-0900-6 783 5 2000 (1180) 1000 550 (1210)
0800A-3 1 NSIN-1380-6 1201 7 2000 (1180) 1000 750 (1650)
0870A-3 1 NSIN-1380-6 1201 7 2000 (1180) 1000 750 (1650)
1110A-3 1 NSIN-1380-6 1201 7 2000 (1180) 1000 750 (1650)
1210A-3 1 NSIN-1380-6 1201 7 2000 (1180) 1000 750 (1650)
Un = 500 V
0420A-5 1 NSIN-0485-6 447 2.5 700 (410) 400 350 (770)
0570A-5 1 NSIN-0900-6 783 6 2000 (1180) 1000 550 (1210)
0640A-5 1 NSIN-0900-6 783 6 2000 (1180) 1000 550 (1210)
0710A-5 1 NSIN-0900-6 783 6 2000 (1180) 1000 550 (1210)
0780A-5 1 NSIN-0900-6 783 6 2000 (1180) 1000 550 (1210)
1010A-5 1 NSIN-1380-6 1201 8 2000 (1180) 1000 750 (1650)
1110A-5 1 NSIN-1380-6 1201 8 2000 (1180) 1000 750 (1650)
Un = 690 V
0320A-7 1 NSIN-0485-6 447 3 700 (410) 400 350 (770)
0390A-7 1 NSIN-0485-6 447 3 700 (410) 400 350 (770)
0460A-7 1 NSIN-0900-6 783 6 2000 (1180) 1000 550 (1210)
0510A-7 1 NSIN-0900-6 783 6 2000 (1180) 1000 550 (1210)
0580A-7 1 NSIN-0900-6 783 7 2000 (1180) 1000 550 (1210)
0660A-7 1 NSIN-0900-6 783 7 2000 (1180) 1000 550 (1210)
0770A-7 1 NSIN-0900-6 783 7 2000 (1180) 1000 550 (1210)
0950A-7 1 NSIN-1380-6 1201 9 2000 (1180) 1000 750 (1650)
1130A-7 1 NSIN-1380-6 1201 9 2000 (1180) 1000 750 (1650)
 Technical data 229

Input cable sizes

The table below gives copper and aluminum cable types with concentric copper shield
for nominal current.

ACS880-37-… IEC 1) US 2)
Al cable size Cu cable size Cu cable size
mm2 mm2 AWG/kcmil
Un = 400 V
0450A-3 2 × (3 × 240 + 72 Cu) 2 × (3 × 150 + 70) 2 × (3 × 300 kcmil)
0620A-3 3 × (3 × 185 + 57 Cu) 2 × (3 × 240 + 120) 3 × (3 × 250 kcmil)
0730A-3 4 × (3 × 240 + 72 Cu) 2 × (3 × 240 + 120) 3 × (3 × 500 kcmil)
0800A-3 4 × (3 × 240 + 72 Cu) 2 × (3 × 240 + 120) 3 × (3 × 500 kcmil)
0870A-3 4 × (3 × 240 + 72 Cu) 3 × (3 × 240 + 120) 3 × (3 × 500 kcmil)
1110A-3 4 × (3 × 300 + 88 Cu) 3 × (3 × 300 + 150) 4 × (3 × 400 kcmil)
1210A-3 5 × (3 × 240 + 72 Cu) 4 × (3 × 240 + 120) 4 × (3 × 500 kcmil)
1430A-3 6 × (3 × 240 + 72 Cu) 4 × (3 × 300 + 150) 5 × (3 × 400 kcmil)
1700A-3 7 × (3 × 240 + 72 Cu) 6 × (3 × 240 + 120) 6 × (3 × 400 kcmil)
2060A-3 9 × (3 × 240 + 72 Cu) 7 × (3 × 240 + 120) 7 × (3 × 500 kcmil)
2530A-3 9 × (3 × 300 + 88 Cu) 8 × (3 × 240 + 120) 8 × (3 × 500 kcmil)
Un = 500 V
0420A-5 2 × (3 × 185 +57 Cu) 2 × (3 × 150 + 70) 2 × (3 × 300 kcmil)
0570A-5 3 × (3 × 185 +57 Cu) 3 × (3 × 120 + 70) 3 × (3 × 300 kcmil)
0640A-5 4 × (3 × 185 +57 Cu) 3 × (3 × 185 + 95) 3 × (3 × 350 kcmil)
0710A-5 4 × (3 × 185 +57 Cu) 3 × (3 × 185 + 95) 3 × (3 × 350 kcmil)
0780A-5 4 × (3 × 185 +57 Cu) 3 × (3 × 185 + 95) 3 × (3 × 350 kcmil)
1010A-5 5 × (3 × 185 +57 Cu) 4 × (3 × 185 + 95) 4 × (3 × 400 kcmil)
1110A-5 4 × (3 × 300 + 88 Cu) 3 × (3 × 300 + 150) 4 × (3 × 400 kcmil)
1530A-5 7 × (3 × 240 + 72 Cu) 5 × (3 × 240 + 120) 6 × (3 × 400 kcmil)
1980A-5 8 × (3 × 240 + 72 Cu) 6 × (3 × 300 + 150) 6 × (3 × 500 kcmil)
2270A-5 8 × (3 × 300 + 88 Cu) 7 × (3 × 240 +120) 7 × (3 × 500 kcmil)
Un = 690 V
0320A-7 2 × (3 × 150 + 41 Cu) 2 × (3 × 95 + 50) 2 × (3 × 4/0 AWG)
0390A-7 2 × (3 × 185 + 57 Cu) 2 × (3 × 120 + 70) 2 × (3 × 250 kcmil)
0460A-7 3 × (3 × 185 + 57 Cu) 3 × (3 × 120 + 70) 3 × (3 × 300 kcmil)
0510A-7 3 × (3 × 185 + 57 Cu) 3 × (3 × 120 + 70) 3 × (3 × 300 kcmil)
0580A-7 3 × (3 × 185 + 57 Cu) 3 × (3 × 120 + 70) 3 × (3 × 300 kcmil)
0660A-7 3 × (3 × 240 + 72 Cu) 3 × (3 × 150 + 70) 3 × (3 × 300 kcmil)
0770A-7 4 × (3 × 185 + 57 Cu) 3 × (3 × 185 + 95) 3 × (3 × 350 kcmil)
0950A-7 4 × (3 × 240 + 72 Cu) 3 × (3 × 240 + 120) 3 × (3 × 500 kcmil)
1130A-7 4 × (3 × 300 + 88 Cu) 5 × (3 × 150 + 70) 4 × (3 × 400 kcmil)
1450A-7 6 × (3 × 240 + 72 Cu) 5 × (3 × 240 + 120) 5 × (3 × 400 kcmil)
1680A-7 7 × (3 × 240 + 72 Cu) 6 × (3 × 240 + 120) 6 × (3 × 500 kcmil)
1950A-7 8 × (3 × 240 + 72 Cu) 8 × (3 × 185 + 95) 6 × (3 × 500 kcmil)
230 Technical data

ACS880-37-… IEC 1) US 2)
Al cable size Cu cable size Cu cable size
mm2 mm2 AWG/kcmil
2230A-7 9 × (3 × 240 + 72 Cu) 7 × (3 × 240 + 120) 7 × (3 × 500 kcmil)
2770A-7 10 × (3 × 300 + 88 Cu) 9 × (3 × 240 + 120) 7 × (3 × 500 kcmil)
3310A-7 12 × (3 × 300 + 88 Cu) 9 × (3 × 300 + 150) 9 × (3 × 500 kcmil)

1) The cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one on top of
the other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (IEC/EN 60204-1 and IEC
60364-5-52/2001). For other conditions, size the cables according to local safety regulations, appropriate input
voltage and the load current of the drive.
2) The cable sizing is based on NEC Table 310-15(B)(16) for copper wires, 75 °C (167 °F) wire insulation at 40 °C (104
°F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or earth (directly
buried). For other conditions, size the cables according to local safety regulations, appropriate input voltage and
the load current of the drive.
 Technical data 231

Output cable sizes

The table below gives copper and aluminum cable types with concentric copper shield
for nominal current.

Note: If the drive is not equipped with a common motor terminal cubicle (option
+H359), common output terminals (option +H366) or sine filter (option +E206), each
inverter module of the drive is to be individually cabled to the motor.

ACS880-37-… IEC 1) US 2)
Al cable size Cu cable size Cu cable size
mm2 mm2 AWG/kcmil
Un = 400 V
0450A-3 2 × (3 × 240 + 72 Cu) 2 × (3 × 185 + 95) 2 × (3 × 300 kcmil)
0620A-3 4 × (3 × 150 + 41 Cu) 3 × (3 × 150 + 70) 3 × (3 × 300 kcmil)
0730A-3 4 × (3 × 240 + 72 Cu) 3 × (3 × 240 + 120) 3 × (3 × 500 kcmil)
0800A-3 4 × (3 × 240 + 72 Cu) 3 × (3 × 240 + 120) 3 × (3 × 500 kcmil)
0870A-3 4 × (3 × 240 + 72 Cu) 3 × (3 × 240 + 120) 3 × (3 × 500 kcmil)
1110A-3 6 × (3 × 185 + 57 Cu) 4 × (3 × 240 + 120) 4 × (3 × 500 kcmil)
1210A-3 6 × (3 × 240 + 72 Cu) 6 × (3 × 150 + 70) 6 × (3 × 300 kcmil)
1430A-3 8 × (3 × 185 + 57 Cu) 6 × (3 × 185 + 95) 6 × (3 × 350 kcmil)
1700A-3 8 × (3 × 240 + 72 Cu) 6 × (3 × 240 + 120) 6 × (3 × 500 kcmil)
2060A-3 9 × (3 × 240 + 72 Cu) 6 × (3 × 300 + 150) 9 × (3 × 350 kcmil)
2530A-3 12 × (3 × 240 + 72 Cu) 9 × (3 × 240 + 120) 9 × (3 × 500 kcmil)
Un = 500 V
0420A-5 2 × (3 × 240 + 72 Cu) 2 × (3 × 150 + 70) 2 × (3 × 300 kcmil)
0570A-5 3 × (3 × 185 + 57 Cu) 2 × (3 × 240 + 120) 2 × (3 × 500 kcmil)
0640A-5 4 × (3 × 185 + 57 Cu) 4 × (3 × 150 + 70) 4 × (3 × 350 kcmil)
0710A-5 4 × (3 × 185 + 57 Cu) 4 × (3 × 150 + 70) 4 × (3 × 350 kcmil)
0780A-5 4 × (3 × 185 + 57 Cu) 4 × (3 × 150 + 70) 4 × (3 × 350 kcmil)
1010A-5 6 × (3 × 150 + 41 Cu) 4 × (3 × 185 + 95) 4 × (3 × 400 kcmil)
1110A-5 6 × (3 × 185 + 57 Cu) 4 × (3 × 240 + 120) 4 × (3 × 500 kcmil)
1530A-5 8 × (3 × 185 + 57 Cu) 6 × (3 × 185 + 95) 6 × (3 × 400 kcmil)
1980A-5 9 × (3 × 240 + 72 Cu) 6 × (3 × 300 + 150) 9 × (3 × 350 kcmil)
2270A-5 12 × (3 × 185 + 57 Cu) 9 × (3 × 185 + 95) 9 × (3 × 400 kcmil)
Un = 690 V
0320A-7 2 × (3 × 150 + 41 Cu) 2 × (3 × 95 + 50) 2 × (3 × 4/0 AWG)
0390A-7 2 × (3 × 185 + 57 Cu) 2 × (3 × 150 + 70) 2 × (3 × 250 kcmil)
0460A-7 3 × (3 × 185 + 57 Cu) 2 × (3 × 240 + 120) 2 × (3 × 500 kcmil)
0510A-7 3 × (3 × 185 + 57 Cu) 2 × (3 × 240 + 120) 2 × (3 × 500 kcmil)
0580A-7 3 × (3 × 185 + 57 Cu) 2 × (3 × 240 + 120) 2 × (3 × 500 kcmil)
0660A-7 4 × (3 × 150 + 41 Cu) 4 × (3 × 120 + 70) 3 × (3 × 300 kcmil)
0770A-7 4 × (3 × 185 + 57 Cu) 4 × (3 × 120 + 70) 4 × (3 × 300 kcmil)
0950A-7 6 × (3 × 150 + 41 Cu) 4 × (3 × 185 + 95) 4 × (3 × 350 kcmil)
1130A-7 6 × (3 × 185 + 57 Cu) 4 × (3 × 240 + 120) 4 × (3 × 500 kcmil)
232 Technical data

ACS880-37-… IEC 1) US 2)
Al cable size Cu cable size Cu cable size
mm2 mm2 AWG/kcmil
1450A-7 9 × (3 × 150 + 41 Cu) 6 × (3 × 185 + 95) 6 × (3 × 350 kcmil)
1680A-7 9 × (3 × 185 + 57 Cu) 6 × (3 × 240 + 120) 6 × (3 × 500 kcmil)
1950A-7 9 × (3 × 240 + 72 Cu) 6 × (3 × 300 + 150) 8 × (3 × 350 kcmil)
2230A-7 12 × (3 × 185 + 57 Cu) 9 × (3 × 185 + 95) 8 × (3 × 500 kcmil)
2770A-7 12 × (3 × 240 + 72 Cu) 12 × (3 × 185 + 95) 10 × (3 × 500 kcmil)
3310A-7 12 × (3 × 300 + 88 Cu) 12 × (3 × 240 + 120) 12 × (3 × 500 kcmil)
XLPE-insulated only

1) The cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one on top of
the other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (IEC/EN 60204-1 and
IEC 60364-5-52/2001). For other conditions, size the cables according to local safety regulations, appropriate input
voltage and the load current of the drive.
2) The cable sizing is based on NEC Table 310-15(B)(16) for copper wires, 75 °C (167 °F) wire insulation at 40 °C (104 °F)
ambient temperature. Not more than three current-carrying conductors inraceway or cable or earth (directly buried).
For other conditions,size the cables according to local safety regulations, appropriateinput voltage and the load
current of the drive.

Terminal and cable entry data for the power cables

The locations and sizes of the cable entries are shown in the dimension drawings
delivered with the drive, and the dimension drawing examples in this manual.
Busbar terminal material: Tin-plated copper.

￭ Connection capability
The maximum number of motor cables depends on the cable size, cable material,
number of inverter modules and on the inverter unit cubicle width. Before you select
motor cable sizes, check the inverter unit construction from the project-specific
dimension drawings and use the tables below to determine the connection capability.

Maximum number of 3-phase motor cables (copper) for each inverter module, n×R8i with cable exit
from bottom
Cable cross section Copper compression cable
Connection method
(mm2) lugs (DIN 46235)

50 6*
70 6*
95 6*
120 6*
150 4
185 4

240 4

300 - -
* Requires additional engineering. Standard cable entry plate not suitable.
 Technical data 233

Maximum number of 3-phase motor cables (aluminum) for each inverter module, n×R8i with cable exit
from bottom
Cable cross section Aluminum compression
Connection method
(mm2) cable lugs (DIN 46329)

50 6*
70 6*
95 6*
120 6*
150 4
185 4

240 4

300 2

* Requires additional engineering. Standard cable entry plate not suitable.

Terminal data for the supply and inverter control units

See the Control unit chapter.

Terminal data for block X504

Cables accepted by the terminals:
• solid wire 0.08 … 4 mm2 (28…12 AWG)
• stranded wire with ferrule 0.14 … 2.5 mm2 (24…12 AWG)
• stranded wire without ferrule 0.08 … 2.5 mm2 (28…12 AWG).
Stripping length: 10 mm (0.4 in).

Electrical power network specification

Voltage (U1) 400 V units: 380…415 V AC 3-phase ± 10%. This is indicated in the type desig-
nation label as typical input voltage level (3~ 400 V AC).
500 V units: 380…500 V AC 3-phase ± 10%. This is indicated in the type desig-
nation label as typical input voltage levels (3~ 400/480/500 V AC).
690 V units:
IEC:
525…690 V AC 3-phase ± 10%
In corner-grounded TN systems: 525…600 V AC
UL/CSA:
525…600 V AC
The voltage range is indicated in the type designation label as typical input
voltage levels for example, 3~ 525/600/690 V AC.
234 Technical data

Network type TN (grounded) and IT (ungrounded) systems

Frequency 50/60 Hz, variation ± 5% of nominal frequency
Imbalance Max. ± 3% of nominal phase-to-phase input voltage
Short-circuit withstand IEC/EN 61439-1:2009
strength (IEC/EN 61439- Frame 1×R8i + 1×R8i:
1)
Maximum allowable prospective short-circuit current (Icc): 65 kA. The input
cable must be equipped with fuses as follows:
maximum 1250 A gG
Maximum allowed operating time is <0.1 s for fuses mentioned above.
Frame 2×R8i + 2×R8i and above:
Rated peak withstand current (Ipk): 105 kA (143 kA for units with air circuit
breaker and no grounding/earthing switch)
Rated short-time withstand current (Icw): 50 kA/1 s (65 kA/1 s for units with
air circuit breaker and no grounding/earthing switch)
Short-circuit current pro- The drive is suitable for use on a circuit capable of delivering not more than
tection (UL 508A, CSA 100,000 rms symmetrical amperes at 600 V maximum when the input cable
C22.2 No. 14-13) is protected with class T fuses.
Fundamental power 0.99
factor (cos phi1)
Harmonic distortion Harmonics are below the limits defined in IEEE519.
Rsc THD Voltage [%] THD Current [%]
20 3 2.5 1)
100 0.8 2.51)

1) Other loads may influence the THD value.

THD = Total Harmonic Distortion (THD). The voltage THD depends on the
short-circuit ratio (Rsc). The spectrum of the distortion also contains interhar-
monics.
Rsc = Isc/IN
Isc = short-circuit current at point of common coupling (PCC)
IN = supply unit nominal current
In = nth harmonic current component

Motor connection data

Motor types Asynchronous AC induction motors, permanent magnet synchronous motors
and AC induction servomotors, ABB synchronous reluctance (SynRM) motors
Voltage (U2) 0 … U1, 3-phase symmetrical, Umax at the field weakening point
Frequency (f2) 0…500 Hz (0…120 Hz with sine output filters (option +E206))
• For higher operational output frequencies, please contact your local ABB
representative.
• Operation above 150 Hz may require type-specific derating. For more in-
formation, contact your local ABB representative.
Current See the rating tables.
Switching frequency 3 kHz (typical). The switching frequency can vary per frame and voltage. For
exact values, contact your local ABB representative.
 Technical data 235

Maximum recommended 500 m (1640 ft).

motor cable length
Note: Longer cables cause a motor voltage decrease which limits the available
motor power. The decrease depends on the motor cable length and charac-
teristics. Contact ABB for more information. Also note that a sine filter (op-
tional) at the drive output also causes a voltage decrease.
Note: The maximum motor cable length for the EMC compliance is 100 m
(328 ft).

Efficiency
Approximately 97% at nominal power level
The efficiency is not calculated according to the ecodesign standard IEC 61800-9-2.

Energy efficiency data (ecodesign)

Energy efficiency data is not provided for the drive. The regenerative drives are exempt
from the EU ecodesign requirements (Regulation EU/2019/1781, §2.3.c) and the UK
ecodesign requirements (Regulation SI 2021 No. 745).

Protection classes
Degrees of protection IP22 (standard), IP42 (option +B054), IP54 (option +B055)
(IEC/EN 60529)
Enclosure types (UL50) UL Type 1 (standard), UL Type 1 (option +B054), UL Type 12 (Standard). For
indoor use only.
Arcing class B – ASSEMBLY providing personnel and ASSEMBLY protection under arcing
(IEC TR 61641) conditions.
Tested at the following voltage with an arcing current of 65 kA for 300 milli-
seconds:
• 400 V units (indicated by "-4" in drive type): 420 V
• 500 V units (indicated by "-5" in drive type): 550 V
• 690 V units (indicated by "-7" in drive type): 760 V
Overvoltage category III, except for auxiliary power connections (fan, control, heating, lighting etc)
(IEC/EN 60664-1) which are category II.
Protective class I
(IEC/EN 61800-5-1)
236 Technical data

Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.

Operation Storage Transportation

installed for stationary in the protective pack- in the protective pack-
use age age
Installation site altitude 0…2000 m (0…6562 ft) - -
above sea level. For alti-
tudes over 2000 m, con-
tact ABB.
Output derated above
1000 m (3281 ft).
Air temperature 0 … +40 °C -40 … +70 °C -40 … +70 °C
(+32 … +104 °F). No con- (-40 … +158 °F) (-40 … +158 °F)
densation allowed.
Output derated in the
range +40 … +50 °C
(+104 … +122 °F).
For UL and CSA compli-
ant installations, the
maximum surrounding
air temperature is 40 °C
(104 °F).
Relative humidity Max. 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the
presence of corrosive gases.
Contamination IEC/EN 60721-3-3:2002 IEC 60721-3-1:1997 IEC 60721-3-2:1997
Chemical gases: Class Chemical gases: Class Chemical gases: Class
3C2 1C2 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
(3S1 with IP20). No con- (packing must support
ductive dust allowed. this, otherwise 1S2)
Pollution degree 2
IEC/EN 60664-1
Vibration IEC/EN 60721-3-3:2002 IEC/EN 60721-3-1:1997 IEC/EN 60721-3-2:1997
IEC/EN 61800-5-1 10…57 Hz: max. 10…57 Hz: max. 2…9 Hz: max. 3.5 mm
IEC 60068-2-6:2007, 0.075 mm amplitude 0.075 mm amplitude amplitude
EN 60068-2-6:2008 57…150 Hz: 1 g 57…150 Hz: 1 g 9…200 Hz: 10 m/s2
Units with marine con- (32.8 ft/s2)
struction (option +C121):
Max. 1 mm (0.04 in)
(5 … 13.2 Hz), max. 0.7 g
(13.2 … 100 Hz) sinusoid-
al
Shock Not allowed With packing max. With packing max.
IEC 60068-2-27:2008, EN 100 m/s2 (328 ft/s2) 100 m/s2 (328 ft/s2)
60068-2-27:2009 11 ms 11 ms

Transportation
The table below specifies the transportation methods and conditions for the drive.
The transportation conditions must also comply with the environmental limits specified
 Technical data 237

in Ambient conditions (page 236). Seaworthy package (option +P912) is required for
non-weather protected transportation conditions.

Package type Method Weather-protected Non-weather protected

conditions conditions
(IEC 60721-3-2) (IEC 60721-3-2)
Standard package Road, air, sea (in 2K12: Transportation Not allowed.
Wooden crate container). without temperature and
Special vehicle humidity control allowed.
Vertical
requirements: High-cube
container. ABB
recommends the use of
container desiccant bags
in sea transportation.
Seaworthy package Road, air, sea (in 2K12: Transportation 2K14:
(option +P912) container). without temperature and Non-weather-protected
Special vehicle humidity control allowed. transportation
Wooden crate covered
requirements: High-cube worldwide.
with plywood sheets
Vertical container. ABB
recommends the use of
container desiccant bags
in sea transportation.

Storage conditions
The table below specifies the storage conditions for the drive. Store the drive in its
package. ABB recommends seaworthy package (option +P912) if the drive is in
long-term storage. The storage conditions must also comply with the environmental
limits specified in Ambient conditions (page 236).

Package type Storage conditions (IEC 60721-3-1)

Standard package 1K20: Up to 24 months in enclosed conditions (full temperature and humidity
Wooden crate control).
Vertical 1K22: Up to 6 months in enclosed conditions (no temperature or humidity
control).
1K23, 1K24: Up to 3 months in sheltered conditions (roof providing protection
from direct rain and sun).
1K25…1K27: Up to 48 hours between loading operations in open-air conditions
(no protection).
Seaworthy package 1K20: Up to 24 months in enclosed conditions (full temperature and humidity
(option +P912) control).
Wooden crate covered 1K22: Up to 12 months in enclosed conditions (no temperature or humidity
with plywood sheets control).
Vertical 1K23, 1K24: Up to 12 months in sheltered conditions (roof providing protection
from direct rain and sun).
1K25…1K27: Up to 1 month in open-air conditions (no protection). Not recom-
mended, but can be temporarily allowed.

Colors
RAL Classic 7035, RAL Classic 9017.
238 Technical data

Materials
￭ Drive
Refer to Recycling instructions and environmental information for ACS880
cabinet-installed drives and multidrive modules (3AXD50000153909 [English]).

￭ Packaging of drive
• Plywood 1)
• Wood
• PET (strapping)
• PE (VCI film)
• Metal (fixing clamps, screws)
• VCI emitter capsules
• Clay desiccant.
1) Seaworthy package only

￭ Packaging of options
• Cardboard
• Kraft paper
• PP (straps)
• PE (film, bubble wrap)
• Plywood, wood (only for heavy components).
Materials vary according to the item type, size and shape. Typical package consists
of a cardboard box with paper filling or bubble wrap. ESD-safe packing materials are
used for printed circuit boards and similar items.

￭ Manuals
Printed product manuals are made of recyclable paper. Product manuals are available
on the Internet.

Disposal
The main parts of the drive can be recycled to preserve natural resources and energy.
Product parts and materials should be dismantled and separated.
Generally all metals, such as steel, aluminum, copper and its alloys, and precious metals
can be recycled as material. Plastics, rubber, cardboard and other packaging material
can be used in energy recovery.
Printed circuit boards and DC capacitors need selective treatment according to IEC
62635 guidelines.
To aid recycling, most plastic parts are marked with an appropriate identification
code. In addition, components containing substances of very high concern (SVHCs)
are listed in European Chemicals Agency's SCIP database. SCIP is the database for
information on Substances of Concern In articles as such or in complex objects
(Products) established under the Waste Framework Directive (2008/98/EC). For further
information, contact your local ABB distributor or consult European Chemicals Agency's
 Technical data 239

SCIP database to find out which SVHCs are used in the drive, and to find out where
those components are located.
Contact your local ABB distributor for further information on environmental aspects.
End of life treatment must follow international and national regulations.
For more information on ABB end of life services, refer to
new.abb.com/service/end-of-life-services.

Applicable standards
Standard Information
European electrical safety
EN 61800-5-1:2007 + A1:2017 + Adjustable speed electrical power drive systems - Part 5-1: Safety
A11:2021 requirements – Electrical, thermal and energy
IEC 61800-5-1:2007 + AMD1:2016
EMC performance
EN 61800-3:2004 + A1:2012 Adjustable speed electrical power drive systems - Part 3: EMC re-
IEC 61800-3:2017 quirements and specific test methods

IEC 60533:2015 Electrical and electronic installations in ships - Electromagnetic

compatibility (EMC) - Ships with a metallic hull
IEC 62742:2021 Electrical and electronic installations in ships - Electromagnetic
compatibility (EMC) - Ships with a non-metallic hull 1)
Product requirements in North America
UL 508A: 3rd edition Industrial Control Panels 2)
CSA C22.2 No. 286-17, 1st edition Industrial Control Panels and Assemblies2)
Enclosure and environmental protection
EN 60529:1991 + A2:2013 + AC:2019 Degrees of protection provided by enclosures (IP code)
IEC 60529:1989 + AMD1:1999 +
AMD2:2013 + COR1:2019
UL 50: 12th edition Enclosures for Electrical Equipment, Non-Environmental Consider-
ations
UL 50E: 1st edition Enclosures for Electrical Equipment, Environmental Considerations
CSA C22.2 No. 94.1-15 Enclosures for Electrical Equipment, Non-Environmental Consider-
ations
CSA C22.2 No. 94.2-15 Enclosures for Electrical Equipment, Environmental Considerations

1) Compliance requires special arrangements for filtering, damping, and compartmentalization.

2) Applicable to drives with option +C129 or +C134.

Markings
These markings are attached to the drive:

CE mark
Product complies with the applicable European Union legislation. For fulfilling the EMC re-
quirements, see the additional information concerning the drive EMC compliance
(IEC/EN 61800-3).
240 Technical data

UKCA (UK Conformity Assessed) mark

Product complies with the applicable United Kingdom’s legislation (Statutory Instruments).
Marking is required for products being placed on the market in Great Britain (England, Wales
and Scotland).

UL Listed mark for USA and Canada

Product has been tested and evaluated against the relevant North American standards by
the Underwriters Laboratories. Valid with rated voltages up to 600 V.

TÜV Safety Approved mark (functional safety)

Product contains Safe torque off and possibly other (optional) safety functions which are
certified by TÜV according to the relevant functional safety standards. Applicable to drives
and inverters; not applicable to supply, brake or DC/DC converter units or modules.

CSA certification mark for USA and Canada

Product has been tested and evaluated against the relevant North American standards by
the CSA Group. Valid with rated voltages up to 600 V.

EAC (Eurasian Conformity) mark

Product complies with the technical regulations of the Eurasian Customs Union. EAC mark
is required in Russia, Belarus and Kazakhstan.

Electronic Information Products (EIP) symbol including an Environment Friendly Use Period
(EFUP).
Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T
11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of
Conformity is available from https://library.abb.com.

RCM mark
Product complies with Australian and New Zealand requirements specific to EMC, telecom-
munications and electrical safety. For fulfilling the EMC requirements, see the additional in-
formation concerning the drive EMC compliance (IEC/EN 61800-3).

KC mark
Product complies with Korean Registration of Broadcasting and Communications Equipment
Clause 3, Article 58-2 of Radio Waves Act.

WEEE mark
At the end of life the product should enter the recycling system at an appropriate collection
point and not placed in the normal waste stream.

EMC compliance (IEC/EN 61800-3)

￭ Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic
equipment to operate without problems within an electromagnetic environment.
 Technical data 241

Likewise, the equipment must not disturb or interfere with any other product or system
within its locality.
First environment includes establishments connected to a low-voltage network which
supplies buildings used for domestic purposes.
Second environment includes establishments connected to a network not supplying
domestic premises.
Drive of category C1: drive of rated voltage less than 1000 V and intended for use in
the first environment.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed
and started up only by a professional when used in the first environment.

Note: A professional is a person or organization having necessary skills in installing

and/or starting up power drive systems, including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in
the second environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current
equal to or above 400 A, or intended for use in complex systems in the second
environment.

￭ Category C2
The drive complies with the standard with the following provisions:
1. The drive is equipped with a diode supply unit or an IGBT supply unit.
2. The drive is equipped with the the EMC filter for category C2 (option +E202).
3. The input power, motor cables, and control cables are selected as specified in the
drive hardware manual.
4. The drive is installed according to the instructions given in the hardware manual.
5. Maximum motor cable length is 100 meters (328 ft).

WARNING!
The drive may cause radio interference if used in a residential or domestic
environment. The installer is required to take measures to prevent interference,
in addition to the requirements for CE compliance listed above, if necessary.

WARNING!
Do not install a drive equipped with the C2 EMC filter on IT (ungrounded)
systems. The supply network becomes connected to ground potential through
the EMC filter capacitors which may cause danger or damage the unit.

￭ Category C3
The drive complies with the standard with the following provisions:
1. The drive is installed according to the instructions given in the appropriate drive
hardware manual.
2. Maximum motor cable length is 100 meters (328 ft).
242 Technical data

WARNING!
A drive of category C3 is not intended to be used on a low-voltage public
network which supplies domestic premises. Radio frequency interference is
expected if the drive is used on such a network.

￭ Category C4
The drive complies with the C4 category with these provisions:
1. It is made sure that no excessive emission is propagated to neighboring
low-voltage networks. In some cases, the natural suppression in transformers
and cables is sufficient. If in doubt, a supply transformer with static screening
between the primary and secondary windings can be used.

1
7

2 8

4 4
5 9

6 6

1 Medium voltage network 6 Equipment

2 Neighboring network 7 Supply transformer
3 Point of measurement 8 Static screen
4 Low voltage 9 Drive
5 Equipment (victim) - -

2. An EMC plan for preventing disturbances is drawn up for the installation. A

template is available in Technical guide No. 3 EMC compliant installation and
configuration for a power drive system (3AFE61348280 [English]).
3. The motor and control cables are selected, and routed according to the electrical
planning guidelines of the drive. The EMC recommendations are obeyed.
4. The drive is installed according to its installation instructions. The EMC
recommendations are obeyed.

WARNING!
A drive of category C4 is not intended to be used on a low-voltage public
network which supplies domestic premises. Radio frequency interference is
expected if the drive is used on such a network.
 Technical data 243

UL and CSA checklist

WARNING!
Operation of this drive requires detailed installation and operation instructions
provided in the hardware and software manuals. The manuals are provided in
electronic format in the drive package or on the Internet. Keep the manuals
with the drive at all times. Hard copies of the manuals can be ordered through
the manufacturer.

• Make sure that the drive type designation label includes the applicable marking.
• DANGER - Risk of electric shock. After disconnecting the input power, always wait
for 5 minutes to let the intermediate circuit capacitors discharge before you start
working on the drive, motor or motor cable.
• The drive is to be used in a heated, indoor controlled environment. The drive must
be installed in clean air according to the enclosure classification. Cooling air must
be clean, free from corrosive materials and electrically conductive dust.
• For UL and CSA compliant installations, the maximum surrounding air temperature
is 40 °C (104 °F).
• The drive is suitable for use in a circuit capable of delivering not more than 100 kA
rms symmetrical amperes, 600 V maximum when protected by the UL fuses given
elsewhere in this chapter.
• The cables located within the motor circuit must be rated for at least 75 °C in
UL-compliant installations.
• The input cable must be protected with fuses or circuit breakers. These protective
devices provide branch circuit protection in accordance with the national
regulations (National Electrical Code (NEC) or Canadian Electrical Code). Obey
also any other applicable local or provincial codes.

WARNING!
The opening of the branch-circuit protective device may be an indication
that a fault current has been interrupted. To reduce the risk of fire or electric
shock, current-carrying parts and other components of the device should
be examined and replaced if damaged.

• The drive is equipped with UL listed fuses which provide branch circuit protection
in accordance with the National Electrical Code (NEC) and Canadian Electrical
Code.
The fuses are listed elsewhere in this chapter.
• The drive provides motor overload protection. The protection is not enabled when
the drive leaves the ABB factory. For enabling the protection, see the firmware
manual.
• The drive overvoltage category according to IEC 60664-1 is III, except for auxiliary
power connections (fan, control, heating, lighting, cooling unit pump etc) which
are of category II.
244 Technical data

Tightening torques
Unless a tightening torque is specified in the text, the following torques can be used.

￭ Electrical connections

Size Torque Strength class

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

￭ Mechanical connections

Size Max. torque Strength class

M5 6 N·m (53 lbf·in) 8.8
M6 10 N·m (7.4 lbf·ft) 8.8
M8 24 N·m (17.7 lbf·ft) 8.8

￭ Insulation supports

Size Max. torque Strength class

M6 5 N·m (44 lbf·in) 8.8
M8 9 N·m (6.6 lbf·ft) 8.8
M10 18 N·m (13.3 lbf·ft) 8.8
M12 31 N·m (23 lbf·ft) 8.8

￭ Cable lugs

Size Max. torque Strength class

M8 15 N·m (11 lbf·ft) 8.8 (A2-70 or A4-70)
M10 32 N·m (23.5 lbf·ft) 8.8
M12 50 N·m (37 lbf·ft) 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.
 Technical data 245

￭ Cyber security 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.

Declarations of conformity

Link to Declaration of conformity according to EU Machinery Directive

2006/42/EU (3AXD10000105027)

Link to Declaration of conformity according to UK Supply of Machinery (Safety)

Regulations 2008 (3AXD10001326695)
246
 Dimensions 247

14
Dimensions

Cabinet line-up dimensions

The drive consists of cubicles built into a cabinet line-up. The tables below show the
composition of cabinet line-ups for each frame size and the standard combinations
of options. The dimensions are in millimeters.
Notes:
• The side panels at the left and right ends of the line-up increase the total line-up
width by 30 millimeters (1.2”).
• The standard depth of the cabinet line-up is 644 mm (25.35”) excluding equipment
such as handles and air inlet gratings. This is increased by 200 mm (7.87”) with
top cable exit units, or by 130 mm with option +C128 (cooling air intake through
bottom of cabinet).
• UL Listed (+C129) units are top cable entry/exit by default.
• Not all possible configurations are presented. For information on unlisted
configurations, contact ABB.
• The data given is preliminary. ABB reserves the right to modify the design at any
time without notice. Consult ABB for up-to-date, drive-specific information.
The tables are followed by selected dimension drawing examples.
248 Dimensions

￭ Dimension tables

1×R8i+1×R8i
Supply and invert-

Brake chopper 22)

Brake resistor 22)

er module cubicle

Brake chopper 1 2)

Brake resistor 12)

Auxiliary control

terminal cubicle
Common motor

Section widths
Joining cubicle

Line-up width
cubicle (ACU)

Sine filter cu-

bicle 1)
400 800 1200 1200
400 800 300 1500 1500
400 800 400 1600 1600
400 800 1000 2200 2200
400 800 400 1600 1600
400 800 300 400 1900 1900
400 800 400 400 2000 2000
400 800 1000 400 2600 2600
400 800 400 800 2400 2400
400 800 300 400 800 2700 2700
400 800 400 400 800 2800 2800
400 800 1000 400 800 3400 3400
400 800 400 400 2000 2000
400 800 300 400 400 2300 2300
400 800 1000 400 400 3000 3000
400 800 400 800 400 800 3600 3600
400 800 300 400 800 400 800 3900 3900
2400 +
400 800 1000 200 400 800 400 800 4800
2400

1) 400 mm with ACS880-37-0450A-3, -0420-5, -0320A-7 and -0390A-7, 1000 mm with other types.
2) The number of brake choppers depends on required braking power. See chapter Resistor braking.

ACS880-37-1110A-3, -1010A-5, -1110A-5, -0660A-7, -0770A-7, -0950A-7, -1130A-7

Supply module cu-

Brake chopper 21)

Brake chopper 31)

Brake chopper 1 1)

Brake resistor 21)

Brake resistor 31)

Brake resistor 11)
Sine filter cubicle
Incoming cubicle
Auxiliary control

terminal cubicle
Inverter module

Common motor

Section widths
Joining cubicle

Joining cubicle

Line-up width
cubicle (ACU)

cubicle
(ICU)

bicle

400 400 800 600 2200 2200

400 400 800 600 300 2500 2500
400 400 800 600 1000 3200 3200
400 400 800 600 400 400 3000 3000
400 400 800 600 300 400 400 3300 3300
400 400 800 600 1000 400 400 4000 4000
2400
400 400 800 600 200 400 800 400 800 + 4800
2400
 Dimensions 249

ACS880-37-1110A-3, -1010A-5, -1110A-5, -0660A-7, -0770A-7, -0950A-7, -1130A-7

Supply module cu-

Brake chopper 21)

Brake chopper 31)

Brake chopper 1 1)

Brake resistor 21)

Brake resistor 31)

Brake resistor 11)
Sine filter cubicle
Incoming cubicle
Auxiliary control

terminal cubicle
Inverter module

Common motor

Section widths
Joining cubicle

Joining cubicle

Line-up width
cubicle (ACU)

cubicle
(ICU)

bicle
2500
400 400 800 600 300 400 800 400 800 + 4900
2400
3400
400 400 800 600 1000 200 400 800 400 800 + 5800
2400
400 400 800 600 400 400 400 3400 3400
400 400 800 600 300 400 400 400 3700 3700
3400
400 400 800 600 1000 200 400 400 400 + 4600
1200
2400
400 400 800 600 200 400 800 400 800 400 800 + 6000
3600
2500
400 400 800 600 300 400 800 400 800 400 800 + 6100
3600
3400
400 400 800 600 1000 200 400 800 400 800 400 800 + 7000
3600

1) The number of brake choppers depends on required braking power. See chapter Resistor braking.

ACS880-37-1210A-3, -1430A-3, -1700A-3, -1530A-5

Supply module cu-

Brake chopper 23)

Brake chopper 33)

Brake resistor 23)

Brake resistor 33)

Brake chopper 1 3)
terminal cubicle 1)

Brake resistor 13)

Incoming cubicle
Auxiliary control

Inverter module

Common motor
Adapter for top

Section widths
Joining cubicle

Joining cubicle

Line-up width
cubicle (ACU)

Sine filter cu-

cubicle

bicle 2)
entry
(ICU)

bicle

400 600 800 600 2400 2400

400 600 200 800 600 2600 2600
400 600 800 600 300 2700 2700
400 600 200 800 600 300 2900 2900
400 600 800 600 1000 3400 3400
400 600 200 800 600 1000 3600 3600
400 600 800 600 400 400 3200 3200
400 600 200 800 600 400 400 3400 3400
400 600 800 600 300 400 400 3500 3500
400 600 200 800 600 300 400 400 3700 3700
400 600 800 600 1000 400 400 4200 4200
3800
400 600 200 800 600 1000 200 400 400 + 4600
800
250 Dimensions

ACS880-37-1210A-3, -1430A-3, -1700A-3, -1530A-5

Supply module cu-

Brake chopper 23)

Brake chopper 33)

Brake resistor 23)

Brake resistor 33)

Brake chopper 1 3)
terminal cubicle 1)

Brake resistor 13)

Incoming cubicle
Auxiliary control

Inverter module

Common motor
Adapter for top

Section widths
Joining cubicle

Joining cubicle

Line-up width
cubicle (ACU)

Sine filter cu-

cubicle

bicle 2)
entry
(ICU)

bicle

2600
400 600 800 600 200 400 800 400 800 + 5000
2400
2800
400 600 200 800 600 200 400 800 400 800 + 5200
2400
2700
400 600 800 600 300 400 800 400 800 + 5100
2400
2900
400 600 200 800 600 300 400 800 400 800 + 5300
2400
3600
400 600 800 600 1000 200 400 800 400 800 + 6000
2400
3800
400 600 200 800 600 1000 200 400 800 400 800 + 6200
2400
400 600 800 600 400 400 400 3600 3600
400 600 200 800 600 400 400 400 3800 3800
400 600 800 600 300 400 400 400 3900 3900
400 600 200 800 600 300 400 400 400 4100 4100
2600
400 600 800 600 200 400 800 400 800 400 800 + 6200
3600
2800
400 600 200 800 600 200 400 800 400 800 400 800 + 6400
3600
2700
400 600 800 600 300 400 800 400 800 400 800 + 6300
3600
2900
400 600 200 800 600 300 400 800 400 800 400 800 + 6500
3600

1) Double-busbar version with ACS880-37-1430A-3, -1700A-3, -1530A-5

2) ACS880-37-1210A-3 only
3) The number of brake choppers depends on required braking power. See chapter Resistor braking.

3×R8i+3×R8i

Auxiliary Supply Common

Incoming Adapter Supply Inverter motor
control (LCL fil- Line-up
cubicle for top module module terminal Section widths
cubicle ter) cu- width
(ICU) entry cubicle cubicle cubicle
(ACU) bicle 1)

400 600 600 800 800 3200 3200

400 600 600 800 800 300 3500 3500
 Dimensions 251

3×R8i+3×R8i

Auxiliary Supply Common

Incoming Adapter Supply Inverter motor
control (LCL fil- Line-up
cubicle for top module module terminal Section widths
cubicle ter) cu- width
(ICU) entry cubicle cubicle cubicle
(ACU) bicle 1)

400 600 600 800 800 400 3600 3600

400 600 600 800 800 600 3800 3800
400 600 200 600 800 800 3400 3400
400 600 200 600 800 800 300 3700 3700
400 600 200 600 800 800 400 3800 3800
400 600 200 600 800 800 600 4000 4000

1) 300 mm double-busbar version with ACS880-37-1450A-7 and -1680A-7. 600 mm with ACS880-37-2530A-3+H353
(top exit). 400 mm with other types.

4×R8i+4×R8i
Auxili- Com-
Incom- Supply Inverter
ary con- Adapter Supply Inverter monmo-
ing cu- module module Line-up
trol cu- for top module module tor ter- Section widths
bicle cubicle cubicle width
bicle entry cubicle 1 cubicle 1 minal
(ICU) 2 2
(ACU) cubicle
400 600 800 800 600 600 3800 3800
400 600 800 800 600 400 600 4200 4200
400 600 200 800 800 600 600 4000 4000
400 600 200 800 800 600 400 600 3800 + 600 4400

6×R8i+5×R8i
Supply module cu-

Supply module cu-

Supply module cu-

Incoming cubicle
Auxiliary control

terminal cubicle
Inverter module

Inverter module
Common motor
Adapter for top

Section widths
Joining cubicle

Line-up width
cubicle (ACU)

cubicle 2
cubicle 1
(ICU) 1)

bicle 2

bicle 3
bicle 1
entry

2)

400 600 800 800 800 200 800 600 3600 + 1400 5000
400 600 800 800 800 200 800 400 600 3600 + 1800 5400
400 600 200 800 800 800 200 800 600 3800 + 1400 5200
400 600 200 800 800 800 200 800 600 600 3800 + 2000 5800
400 1000 800 800 800 200 800 600 4000 + 1400 5400
400 1000 800 800 800 200 800 400 600 4000 + 1800 5800
400 1000 200 800 800 800 200 800 600 4200 + 1400 5600
400 1000 200 800 800 800 200 800 600 600 4200 + 2000 6200

1) 1000 mm with UL Listed (+C129) and CSA Approved (+C134) units, otherwise 600 mm.
2) 400 mm with bottom exit, 600 mm with top exit.
252 Dimensions

6×R8i+6×R8i

Supply module cu-

Supply module cu-

Supply module cu-

Incoming cubicle
Auxiliary control

terminal cubicle
Inverter module

Inverter module
Common motor
Adapter for top

Section widths
Joining cubicle

Line-up width
cubicle (ACU)

cubicle 2
cubicle 1
(ICU) 1)

bicle 2

bicle 3
bicle 1
entry

400 600 800 800 800 200 800 800 3600 + 1600 5200
400 600 800 800 800 200 800 600 800 3600 + 2200 5800
400 600 200 800 800 800 200 800 800 3800 + 1600 5400
400 600 200 800 800 800 200 800 600 800 3800 + 2200 6000
400 1000 800 800 800 200 800 800 4000 + 1600 5600
400 1000 800 800 800 200 800 600 800 4000 + 2200 6200
400 1000 200 800 800 800 200 800 800 4200 + 1600 5800
400 1000 200 800 800 800 200 800 600 800 4200 + 2200 6400

1) 1000 mm with UL Listed (+C129) and CSA Approved (+C134) units, otherwise 600 mm.

￭ Weights
The table below lists the approximate basic weights.

Weight
ACS880-37...
kg lbs
0450A-3 0420A-5 0320A-7
0620A-3 0570A-5 0390A-7
0730A-3 0640A-5 0460A-7 1180 2600
0800A-3 0710A-5 0510A-7
0870A-3 0780A-5 0580A-7
0660A-7
1010A-5 0770A-7
1110A-3 1970 4340
1110A-5 0950A-7
1130A-7
1210A-3
1430A-3 1530A-5 2090 4610
1700A-3
2060A-3
2290 5050
2530A-3
1450A-7
2730 6020
2230A-7
1980A-5
2930 6460
2270A-5
1950A-7
3700 8160
2230A-7
2770A-7 4830 10650
3310A-7 4980 10980
 Dimensions 253
204 Dimensions

￭ Dimension drawing examples

 Dimension drawing examples
Frame 1×R8i+1×R8i
Frame 1×R8i + 1×R8i
 254 Dimensions
Dimensions 205

Frame 1×R8i1×R8i+1×R8i,
Frame + 1×R8i, top top
cable entry/exit
cable (+H351+H353)
entry/exit (+H351+H353)
206 Dimensions

Frame 1×R8i + 1×R8i with brake choppers and resistors (+D150+D151)

Dimensions 255

Frame 1×R8i+1×R8i with brake choppers and resistors (+D150+D151)

 Dimensions 207

Frame 1×R8i + 1×R8i with sine output filter (+E206)

256 Dimensions

Frame 1×R8i+1×R8i with sine output filter (+E206)

208 Dimensions

Frame 2×R8i + 2×R8i (eg. ACS880-1737-1110A-3), IP22

Dimensions 257

Frame 2×R8i+2×R8i (eg. ACS880-37-1110A-3), IP22

 Dimensions 209

258 Dimensions
Frame 2×R8i + 2×R8i (eg. ACS880-1737-1210A-3), IP54

Frame 2×R8i+2×R8i (eg. ACS880-37-1210A-3), IP54

210 Dimensions

Dimensions 259
Frame 2×R8i + 2×R8i with main breaker (+F255) and common motor terminal cubicle
(+H359), 1/2
Frame 2×R8i+2×R8i with main breaker (+F255) and common motor terminal cubicle
(+H359), 1/2
260 Dimensions

Frame 2×R8i+2×R8i with main breaker (+F255) and common motor terminal cubicle
(+H359), 2/2
 Dimensions 261
212 Dimensions

Frame 2×R8i+2×R8i with main breaker (+F255) and top entry/top exit (+H351+H353),
Frame
1/22×R8i + 2×R8i with main breaker (+F255) and top entry/top exit (+H351+H353),
1/2
262 Dimensions

Frame 2×R8i+2×R8i with main breaker (+F255) and top entry/top exit (+H351+H353),
2/2
 Dimensions 263
214 Dimensions
Frame 3×R8i+3×R8i, 1/2
Frame 3×R8i + 3×R8i, 1/2
 Dimensions 215
264 Dimensions
Frame 3×R8i + 3×R8i, 2/2
Frame 3×R8i+3×R8i, 2/2
 Dimensions 265
216 Dimensions

Frame
Frame 3×R8i 3×R8i+3×R8i
+ 3×R8i with common
with common motorcubicle
motor terminal terminal cubicle1/2
(+H359), (+H359), 1/2
 Dimensions 217
266 Dimensions
Frame 3×R8i + 3×R8i with common motor terminal cubicle (+H359), 2/2
Frame 3×R8i+3×R8i with common motor terminal cubicle (+H359), 2/2
 Dimensions 267

Dimensions of empty cubicles (options +C199, +C200, +C201)

IP22/IP42
268 Dimensions

IP54
 Dimensions 269

Location and size of input terminals

218 Dimensions
218 Dimensions

Location
Note: See and size oftables
the dimension input as terminals
to which incoming cubicles are used with which
Location
drive typeand size of input terminals
and options.
 Frame 1×R8i + 1×R8i, bottom cable entry
 Frame
￭ Frame 1×R8i+1×R8i,
1×R8i bottom
+ 1×R8i, bottom cable
cable entry
entry

 ￭Frame 1×R8i
Frame + 1×R8i, top
1×R8i+1×R8i, cable
top entry
cable entry (+H351)
 Frame 1×R8i + 1×R8i, top cable entry
270 Dimensions
Dimensions 219

￭Frame
Frame2×R8i+2×R8i with
2×R8i + 2×R8i main
with switch/disconnector
main switch/disconnector(400
(400mm),
mm),bottom
cable entrycable
bottom (+H353)
entry

220 Dimensions

￭ Frame
Frame2×R8i+2×R8i with
2×R8i + 2×R8i main
with switch/disconnector
main switch/disconnector(600
(600 mm),
mm), bottom
 Frame 2×R8i + 2×R8i with main switch/disconnector (400 mm), top
cable entry
bottom cable entry
cable entry

 Frame 2×R8i + 2×R8i with main switch/disconnector (600 mm), top

cable entry
 Dimensions
Dimensions 221271
Dimensions 221

 Units with main breaker (600

(600 mm),
mm, bottom
bottom cable entry
￭ Units
Unitswith
withmain
mainbreaker
breaker (600 mm), +F255), bottom
cable cable entry
entry

￭ Unitswith
Units withmain
main breaker
breaker (600
(600 mm),
mm, top cabletop
+F255), entry
cable entry (+H351)
 Units with main breaker (600 mm), top cable entry
272 Dimensions

￭ Units with main breaker (1000 mm), top cable entry

 Dimensions 273

￭ Units with main breaker (1000 mm), bottom cable entry (+H350)

Location and size of output terminals

￭ Units without common motor terminal cubicle
Frame 1×R8i+1×R8i (without sine output filter)
See sections Frame 1×R8i+1×R8i, bottom cable entry (page 269) and Frame 1×R8i+1×R8i,
top cable entry (+H351) (page 269)
274 Dimensions

Inverter module cubicle with two R8i modules, bottom cable exit

„
 Dimensions 275

Inverter module cubicle with two R8i modules, top cable exit
„

„
276 Dimensions

Inverter module cubicle with three R8i modules, bottom cable exit

„
 Dimensions 277

Inverter module cubicle with three R8i modules, top cable exit
„

„
278 Dimensions

Brake chopper cubicle

 „
Dimensions 279

Sine filter cubicle, 1000 mm, bottom cable exit

 „
280 Dimensions

Sine filter cubicle, 1000 mm, top cable exit

 Dimensions 281

￭ Units with common motor terminal cubicle (+H359)

Cubicle width 300 mm, bottom cable exit
282 Dimensions

Cubicle width 300 mm, top cable exit

 Dimensions 283

Cubicle width 400 mm, bottom cable exit

284 Dimensions

Cubicle width 400 mm, top cable exit

 Dimensions 285

Cubicle width 600 mm, bottom cable exit

286 Dimensions

Cubicle width 600 mm, top cable exit

 The Safe torque off function 287

15
The Safe torque off function

Contents of this chapter

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

Description

WARNING!
In case of parallel-connected drives or dual-winding motors, the STO must be
activated on each drive to remove the torque from the motor.

The Safe torque off function can be used, for example, as the final actuator device of
safety circuits (such as an emergency stop circuit) that stop the drive in case of danger.
Another typical application is a prevention of unexpected start-up function 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 drive.
When activated, the Safe torque off function disables the control voltage for the power
semiconductors of the drive output stage, thus preventing the drive 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.
288 The Safe torque off function

The Safe torque off function complies with these standards:

Standard Name

IEC 60204-1:2021 Safety of machinery – Electrical equipment of machines – Part 1:

EN 60204-1:2018 General requirements

IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards –

Immunity requirements for equipment intended to perform functions
in a safety-related system (functional safety) in industrial locations

IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use –
EMC requirements – Part 3-1: Immunity requirements for safety-re-
lated systems and for equipment intended to perform safety-related
functions (functional safety) – General industrial applications

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/electron-
ic/programmable electronic safety-related systems

IEC 61511-1:2017 Functional safety – Safety instrumented systems for the process in-
dustry sector

IEC 61800-5-2:2016 Adjustable speed electrical power drive systems – Part 5-2: Safety
EN 61800-5-2:2007 requirements – Functional

EN IEC 62061:2021 Safety of machinery – Functional safety of safety-related control

systems

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 ISO 14118:2018 (ISO 14118:2017), and Uncontrolled stop (stop category 0) as
specified in EN/IEC 60204-1.

￭ Compliance with the European Machinery Directive and the UK Supply

of Machinery (Safety) Regulations
Refer to the technical data.
 The Safe torque off function 289

Wiring
For the electrical specifications of the STO connection, see the technical data of the
control unit.

￭ Activation switch
In the wiring diagrams, 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, FSPS, FSCS, or FPTC module can also be used. For more information, see
the module documentation.

￭ Cable types and lengths

• ABB recommends double-shielded twisted-pair cable.
• Maximum cable lengths:
• 300 m (1000 ft) between activation switch [K] and drive control unit
• 60 m (200 ft) between multiple drives
• 60 m (200 ft) between external power supply and first control unit
• 30 m (100 ft) between control unit and last inverter module in the chain.

Note: A short-circuit in the wiring between the switch and an STO terminal causes a
dangerous fault. Therefore, it is recommended to use a safety relay (including wiring
diagnostics) or a wiring method (shield grounding, channel separation) which reduces
or eliminates the risk caused by the short-circuit.

Note: The voltage at the STO input terminals of the control unit (or frame R8i inverter
module) must be at least 17 V DC to be interpreted as “1”.
The pulse tolerance of the input channels is 1 ms.

￭ Grounding of protective shields

• Ground the shield in the cabling between the activation switch and the control
unit at the control unit only.
• Ground the shield in the cabling between two control units at one control unit
only.
• Do not ground the shield in the cabling between control unit and inverter module,
or between inverter modules.
290 The Safe torque off function

￭ Dual-channel connection with internal power supply (UCU)

1
XSTO
+24 V OUT
SGND K

STO1
STO2

XSTO OUT STO IN (X52) 2

OUT1 24VDC CH1

SGND GND CH1
OUT2 24VDC CH2
SGND GND CH2
FE

2 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
24VDC CH2 3
GND CH2
FE

1 Inverter control unit

2 Inverter module(s)
3 To remaining inverter modules
K Activation switch
 The Safe torque off function 291

￭ Dual-channel connection with internal power supply (BCU)

1
XSTO
+24 V OUT
SGND K

IN1
IN2

XSTO OUT STO IN (X52) 2

IN1 24VDC CH1

SGND GND CH1
IN2 24VDC CH2
SGND GND CH2
FE

2 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
24VDC CH2 3
GND CH2
FE

1 Inverter control unit

2 Inverter module(s)
3 To remaining inverter modules
K Activation switch
292 The Safe torque off function

￭ Single-channel connection of activation switch (UCU)

1
XSTO K
2

+24 V OUT
SGND

STO1
STO2

Note:
• Both STO inputs (STO1, STO2) 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.
1 Drive
2 Control unit
K Activation switch

Note: A single-channel activation switch can limit the SIL/PL capability of the safety function
to a lower level than the SIL/PL capability of the STO function of the drive.

￭ Single-channel connection of activation switch (BCU)

1
XSTO K
2

+24 V OUT
SGND

IN1
IN2

Note:
• Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL classi-
fication 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.
1 Drive
2 Control unit
K Activation switch

Note: A single-channel activation switch can limit the SIL/PL capability of the safety function
to a lower level than the SIL/PL capability of the STO function of the drive.
 The Safe torque off function 293

￭ Multiple drives
Internal power supply (example, drives with UCU)

XSTO
+24 V OUT
SGND K

STO1
STO2
2

XSTO
OUT
SGND

STO1
STO2
2

XSTO
OUT
SGND

STO1
STO2
2

1 Drive
2 Control unit
K Activation switch
294 The Safe torque off function

Internal power supply (example, drives with BCU)

XSTO

+24 V OUT

SGND K

IN1
2 IN2

XSTO
OUT
SGND

IN1
2 IN2

XSTO
OUT
SGND

IN1
2 IN2

1 Drive
2 Control unit
K Activation switch
 The Safe torque off function 295

External power supply (example, drives with UCU)

24 V DC
XSTO
+24 V OUT
SGND

STO1
STO2
2

XSTO
OUT
SGND

STO1
STO2
2

XSTO
OUT
SGND

STO1
STO2
2

1 Drive
2 Control unit
K Activation switch
296 The Safe torque off function

External power supply (example, drives with BCU)

24 V DC
– +
XSTO
+24 V OUT
SGND

IN1
2 IN2

XSTO
OUT
SGND

IN1
2 IN2

XSTO
OUT
SGND

IN1
2 IN2

1 Drive
2 Control unit
K Activation switch
 The Safe torque off function 297

Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay
contacts open).
2. The STO inputs of the drive control unit de-energize.
3. The control unit cuts off the control voltage from the output IGBTs.
4. The control program generates an indication as defined by parameter 31.22 (refer
the firmware manual of the drive).
The parameter selects which indications are given when one or both STO signals
are switched off or lost. The indications also depend on whether the drive is
running or stopped when this occurs.

Note: This parameter does not affect the operation of the STO function itself. The
STO function will operate regardless of the setting of this parameter: a running
drive will stop upon removal of one or both STO signals, and will not start until
both STO signals are restored and all faults reset.

Note: The loss of only one STO signal always generates a fault as it is interpreted
as a malfunction of STO hardware or wiring.
5. The motor coasts to a stop (if running). The drive cannot restart while the
activation switch or safety relay contacts are open. After the contacts close, a
reset may be needed (depending on the setting of parameter 31.22). A new start
command is required to start the drive.
298 The Safe torque off function

Start-up including validation 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 a validation test.
The test must be performed
1. at initial start-up of the safety function
2. after any changes related to the safety function (circuit boards, wiring,
components, settings, replacement of inverter module, etc.)
3. after any maintenance work related to the safety function
4. after a drive firmware update
5. at the proof test of the safety function.

￭ Competence
The validation 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.

￭ Validation test reports

Signed validation 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 validation tests performed due
to changes or maintenance shall be logged into the logbook.

￭ Validation test procedure

After wiring the Safe torque off function, validate its operation as follows.

Note: If the drive is equipped with safety option +L513, +L514, +L536, +L537, +Q950,
+Q951, +Q952, +Q957, +Q963, +Q964, +Q965, +Q978 or +Q979, also do the procedure
shown in the documentation of the option.
If an FSO, FSCS, FSPS, or FPTC module is installed, refer to its documentation.

Note: All inverter modules of the drive must be powered and connected to the STO
circuit during the validation test.

Action

WARNING!
Obey the safety instructions. If you ignore them, injury or death, or damage to the equip-
ment can occur.

Make sure that the motor can be run and stopped freely during start-up.

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

Check the STO circuit connections against the wiring diagram.

Close the disconnector and switch the power on.

In case the drive consists of parallel-connected modules, check that the number of modules
detected (parameter 95.14) matches the actual number of modules, and that the drive type is
correctly set in parameter 95.31.
 The Safe torque off function 299

Action

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

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

Test the operation of the failure detection of the drive. The motor can be stopped or running.
• Open the 1st input channel of the STO circuit. If the motor was running, it should coast to a
stop. The drive generates an FA81 fault indication (refer the firmware manual).
• Give a start command to verify that the STO function blocks the drive's operation. The motor
should not start.
• Open the STO circuit (both channels).
• Give a reset command.
• Close the STO circuit (both channels).
• Reset any active faults. Restart the drive and check that the motor runs normally.
• Open the 2nd input channel of the STO circuit. If the motor was running, it should coast to
a stop. The drive generates an FA82 fault indication (refer the firmware manual).
• Give a start command to verify that the STO function blocks the drive's operation. The motor
should not start.
• Open the STO circuit (both channels).
• Give a reset command.
• Close the STO circuit (both channels).
• Reset any active faults. Restart the drive and check that the motor runs normally.

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

Use
1. Open the activation switch, or activate the safety functionality that is wired to
the STO connection.
2. The STO inputs on the drive control unit de-energize, and the control unit cuts off
the control voltage from the output IGBTs.
3. The control program generates an indication as defined by parameter 31.22 (refer
the firmware manual of the drive).
4. The motor coasts to a stop (if running). The drive will not restart while the
activation switch or safety relay contacts are open.
5. Deactivate the STO by closing the activation switch, or resetting 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 drive. Therefore maintenance work on electrical parts
of the drive or the motor can only be carried out after isolating the drive from
the supply and all other voltage sources.

WARNING!
The Safe torque off functionality is only achieved through the XSTO connector
of the inverter control unit (A41). 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
control program. It is not supported by supply, DC/DC converter or brake
firmware.

WARNING!
The drive cannot detect or memorize any changes in the STO circuitry when
the drive control unit is not powered or when the main power to the drive is
off. If both STO circuits are closed and a level-type start signal is active when
the power is restored, it is possible that the drive starts without a fresh start
command. Take this into account in the risk assessment of the system.

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

Notes:
• If a running drive is stopped by using the Safe torque off function, the drive will
cut off the motor supply voltage and the motor will coast to a stop. If this causes
 The Safe torque off function 301

danger or is not otherwise acceptable, stop the drive 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 drive.
• 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.
302 The Safe torque off function

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 10 years; refer section Safety data (page 305).
There are two alternative procedures for proof testing:
1. Perfect proof testing. It is assumed that all dangerous failures of the STO circuit
are detected during the test. PFDavg values for STO with the perfect proof testing
procedure are given in the safety data section.
2. Simplified proof testing. This procedure is faster and simpler than perfect proof
testing. Not all dangerous failures of the STO circuit are detected during the test.
The PFDavg value for STO with the simplified proof testing procedure is given in
the safety data section.

Note: The proof testing procedures are only valid for proof testing (periodic test, item
5 under section Start-up including validation test) but not for re-validation after
changes made in the circuit. Re-validation (items 1…4 under Start-up including
validation test) must be done according to the initial validation procedure.

Note: Refer 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 drive runs.
If any wiring or component change is needed after start-up, or the parameters are
restored, do the test given in section Validation test procedure (page 298).
Use only spare parts approved by ABB.
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.
 The Safe torque off function 303

￭ Perfect proof test procedure

Action

WARNING!
Obey the safety instructions. If you ignore them, injury or death, or damage to the equip-
ment can occur.

Test the operation of the STO function. If the motor is running, it will stop during the test.
• Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill.
Make sure that the drive operates as follows:
• Open the STO circuit. The drive generates an indication if one is defined for the 'stopped'
state in parameter 31.22 (see the firmware manual).
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.

Test the operation of the failure detection of the drive. The motor can be stopped or running.
• Open the 1st input channel of the STO circuit. If the motor was running, it should coast to a
stop. The drive generates an FA81 fault indication (see the firmware manual).
• Open the STO circuit (both channels).
• Give a reset command.
• Close the STO circuit (both channels).
• Reset any active faults.
• Open the 2nd input channel of the STO circuit. If the motor was running, it should coast to
a stop. The drive generates an FA82 fault indication (see the firmware manual).
• Open the STO circuit (both channels).
• Give a reset command.
• Close the STO circuit (both channels).
• Reset any active faults. Restart the drive and check that the motor runs normally.

Document and sign the test report to verify that the safety function has been tested according
to the procedure.

￭ Simplified proof test procedure

Action

WARNING!
Obey the safety instructions. If you ignore them, injury or death, or damage to the equip-
ment can occur.

Test the operation of the STO function. If the motor is running, it will stop during the test.
• Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill.
Make sure that the drive operates as follows:
• Open the STO circuit. The drive generates an indication if one is defined for the 'stopped'
state in parameter 31.22 (see the firmware manual).
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.

Document and sign the test report to verify that the safety function has been tested according
to the procedure.
304 The Safe torque off function

Fault tracing
The indications given during the normal operation of the Safe torque off function are
selected by drive control program 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 drive trips on an FA81 or FA82 fault. An attempt to use the STO
in a non-redundant manner, for example activating only one channel, will trigger the
same reaction.
Refer the firmware manual of the drive control program for the indications generated
by the drive, 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.
 The Safe torque off function 305

Safety data
The safety data for the Safe torque off function is given below.

Note: The safety data is calculated for redundant use, and applies only if both STO
channels are used.
 PFH PFDavg
MTTFD DC SFF TM PFHdiag λDiag_s λDiag_d
Frame size SIL SC PL (T1 = 20 a) Perfect proof test Simplified proof test Cat. HFT CCF
(a) (%) (%) (a) (1/h) (1/h) (1/h)
(1/h) T1 = 5 a T1 = 10 a T1 = 5 or 10 a
R8i 3 3 e 5.82E-10 1.25E-05 2.51E-05 5.06E-05 4824 ≥90 >99 3 1 80 20 5.35E-09 3.32E-07 2.86E-07
2×R8i 3 3 e 5.92E-10 1.27E-05 2.55E-05 5.15E-05 4483 ≥90 >99 3 1 80 20 6.13E-09 4.50E-07 3.65E-07
3×R8i 3 3 e 6.02E-10 1.29E-05 2.59E-05 5.23E-05 4187 ≥90 >99 3 1 80 20 6.92E-09 5.67E-07 4.43E-07
4×R8i 3 3 e 6.11E-10 1.31E-05 2.63E-05 5.31E-05 3928 ≥90 >99 3 1 80 20 7.71E-09 6.85E-07 5.22E-07
5×R8i 3 3 e 6.21E-10 1.33E-05 2.68E-05 5.39E-05 3699 ≥90 >99 3 1 80 20 8.50E-09 8.02E-07 6.01E-07
6×R8i 3 3 e 6.30E-10 1.35E-05 2.72E-05 5.48E-05 3495 ≥90 >99 3 1 80 20 9.29E-09 9.19E-07 6.80E-07
306 The Safe torque off function

3AXD10000078136 K, 3AXD10001716945 D
 The Safe torque off function 307

• The STO is a type B safety component as defined in IEC 61508-2.

• 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 response times:
• STO reaction time (shortest detectable break): 1 ms
• STO response time: 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.
• Indication delays:
• STO fault indication (parameter 31.22) delay: < 500 ms
• STO warning indication (parameter 31.22) delay: < 1000 ms.

￭ Terms and abbreviations

Term or Reference Description

abbreviation
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 (%)
HFT IEC 61508 Hardware fault tolerance
MTTFD EN ISO 13849-1 Mean time to dangerous failure: (Total number of life units) /
(Number of dangerous, undetected failures) during a particular
measurement interval under stated conditions
PFDavg IEC 61508 Average probability of dangerous failure on demand, that is, mean
unavailability of a safety-related system to perform the specified
safety function when a demand occurs
PFH IEC 61508 Average frequency of dangerous failures per hour, that is, average
frequency of a dangerous failure of a safety related system to
perform the specified safety function over a given period of time
PFHdiag IEC/EN 62061 Average frequency of dangerous failures per hour for the
diagnostic function of STO
PL EN ISO 13849-1 Performance level. Levels a…e correspond to SIL
Proof test IEC 61508, IEC 62061 Periodic test performed to detect failures in a safety-related
system so that, if necessary, a repair can restore the system to
an "as new" condition or as close as practical to this condition
SC IEC 61508 Systematic capability (1…3)
SFF IEC 61508 Safe failure fraction (%)
SIL IEC 61508 Safety integrity level (1…3)
STO IEC/EN 61800-5-2 Safe torque off
308 The Safe torque off function

Term or Reference Description

abbreviation
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.
See also section Maintenance.
TM EN ISO 13849-1 Mission time: the period of time covering the intended use of the
safety function/device. After the mission time elapses, the safety
device must be replaced. Note that any TM values given cannot
be regarded as a guarantee or warranty.
λDiag_d IEC 61508-6 Dangerous failure rate (per hour) of the diagnostics function of
STO
λDiag_s IEC 61508-6 Safe failure rate (per hour) of the diagnostics function of STO

￭ TÜV certificate
The TÜV certificate is available on the Internet.
 Resistor braking 309

16
Resistor braking

Contents of this chapter

This chapter describes how to select, protect and wire brake choppers and resistors.
The chapter also contains the related technical data.

Operation principle
The brake chopper handles the extra energy generated by motor during a quick
deceleration. The extra energy increases the drive DC link voltage. The chopper connects
the brake resistor to the DC link whenever the voltage is higher than the operation
limit of the chopper. Energy consumption by the resistor losses lowers the voltage
until it is below the limit at which the chopper stops.
310 Resistor braking

Factory-installed brake choppers and resistors

The following brake choppers (option +D150) and resistors (+D151) are available for
the drive as factory-installed. It is also possible to use option +D150 with a custom
resistor assembly.

UN ACS880-37 type Brake chopper type (+D150) Brake resistor type (+D151)

ACS880-37-0450A-3
NBRA-659 2 × SAFUR180F460
ACS880-37-0620A-3

ACS880-37-0870A-3

400 V ACS880-37-1110A-3 2 × NBRA-659 2 × (2 × SAFUR180F460)

ACS880-37-1210A-3

ACS880-37-1430A-3
3 × NBRA-659 3 × (2 × SAFUR180F460)
ACS880-37-1700A-3

ACS880-37-0420A-5
NBRA-659 2 × SAFUR200F500)
ACS880-37-0570A-5

ACS880-37-0780A-5
500 V
ACS880-37-1010A-5 2 × NBRA-659 2 × (2 × SAFUR200F500)

ACS880-37-1110A-5

ACS880-37-1530A-5 3 × NBRA-659 3 × (2 × SAFUR200F500)

ACS880-37-0320A-7
NBRA-669 2 × SAFUR200F500)
ACS880-37-0390A-7

ACS880-37-0580A-7
2 × NBRA-669 2 × (2 × SAFUR200F500)
690 V ACS880-37-0660A-7

ACS880-37-0770A-7

ACS880-37-0770A-7 3 × NBRA-669 3 × (2 × SAFUR200F500)

ACS880-37-1130A-7
 Resistor braking 311

Technical data
￭ Ratings of chopper/resistor combinations

Duty Cycle Duty Cycle

R Pbrmax Pbrcont Imax (10/60 s) (1/5 min)
UN Chopper(s) Resistors
(ohm) (kW) (kW) (A) Pbr Irms Pbr Irms
(kW) (A) (kW) (A)
2×
400 V NBRA-659 1.2 353 54 545 287 444 167 444
SAFUR180F460
2 × (2 ×
400 V 2 × NBRA-659 1.2 706 108 1090 575 888 333 514
SAFUR180F460)
3 × (2 ×
400 V 3 × NBRA-659 1.2 1058 162 1635 862 1332 500 771
SAFUR180F460)
2×
500 V NBRA-659 1.35 403 54 605 287 355 167 206
SAFUR200F500
2 × (2 ×
500 V 2 × NBRA-659 1.35 806 108 1210 575 710 333 412
SAFUR200F500)
3 × (2 ×
500 V 3 × NBRA-659 1.35 1208 162 1815 862 1065 500 618
SAFUR200F500)
2×
690 V NBRA-669 1.35 404 54 835 287 257 167 149
SAFUR200F500
2 × (2 ×
690 V 2 × NBRA-669 1.35 807 108 1670 575 514 333 298
SAFUR200F500)
3 × (2 ×
690 V 3 × NBRA-669 1.35 1211 162 2505 862 771 500 447
SAFUR200F500)

￭ Definitions
UN Nominal voltage
Rn Nominal (recommended) resistance of the resistor assembly of one chopper module
Resistance of specified resistors (per chopper module). This is also the minimum allowed
Rmin
resistance for the resistor assembly.
Pbrmax Maximum short-term (1 min in every 10 min) braking power
Pbrcont Maximum continuous power rating
Imax Maximum peak current
Pbr Maximum braking power for the specified duty cycle
Irms Rms current for the specified duty cycle
312 Resistor braking

￭ SAFUR resistor data

The following SAFUR resistors are available separately.

UN R ER PRcont
Type IPxx
V ohm kJ kW

SAFUR125F500 500 4.0 3600 9.0 IP00

SAFUR210F575 575 3.4 4200 10.5 IP00

SAFUR200F500 500 2.7 5400 13.5 IP00

SAFUR180F460 460 2.4 6000 15.0 IP00

UN Nominal voltage
R Resistance
ER Short energy pulse that the resistor assembly will withstand each 400 seconds
PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER dissipates
in 400 seconds.
IPxx Degree of protection

￭ Terminals and cable lead-through data of factory-installed

chopper/resistor cubicles
See the dimension drawings delivered with the unit.
 Resistor braking 313

Planning the braking system

￭ Verifying the load capacity of the braking equipment
1. Calculate the maximum power generated by the motor during braking (Pmax).
2. Ensure that the maximum power rating of the braking equipment is equal to or
greater than Pmax.
The Pbrmax values specified in the ratings table are for the reference braking cycle
(1 minute of braking, 9 minutes of rest). If the actual duty cycle does not correspond
to the reference cycle, either use the power rating given for the other two reference
cycles (Pbr), or calculate the maximum braking power for a custom braking cycle.
See below for instructions on calculating Pbr for other braking cycles.
3. Check the resistor selection. The energy generated by the motor during a
400-second period must not exceed the heat dissipation capacity of the resistor
(ER). If you use custom resistor(s), see also the separate instructions below.
If the ER value of the resistor is not sufficient, it is possible to use a four-resistor
assembly in which two resistors are connected in parallel, two in series. The ER
value of the four-resistor assembly is four times that of a single resistor.

Custom resistor
Resistors other than those available as option +D151 can be used provided that
• the resistance is not lower than the value given in the ratings table

WARNING!
Never use a brake resistor with a resistance below the value specified for
the particular drive / brake chopper / resistor combination. The drive and
the chopper would not able to handle the overcurrent caused by the low
resistance.

• the resistance of the custom resistor does not restrict the braking capacity needed,
ie.
Pmax < UDC2/R
where

Pmax Maximum power generated by the motor during braking

UDC Voltage over the resistor during braking. UDC equals
1.35 · 1.25 · 415 V DC (when supply voltage is 380 to 415 V AC)
1.35 · 1.25 · 500 V DC (when supply voltage is 440 to 500 V AC) or
1.35 · 1.25 · 690 V DC (when supply voltage is 525 to 690 V AC)
R Resistor resistance (ohm)

• the heat dissipation capacity ER of the resistor is sufficient for the application
(see step 3 above).

Calculating the maximum braking power for a custom duty cycle

These rules must be met during any braking cycle:
314 Resistor braking

1. Braking energy transferred during any ten minute period must be less than or
equal to the energy transferred during the reference braking cycle (1/9 min).
2. The maximum braking power for a custom braking cycle (Pbr) must not exceed
the rated maximum value Pbrmax.
The rules as equations:
1. n × Pbr × tbr ≤ Pbrmax × 60 s => Pbr ≤ (Pbrmax × 60 s)/(n × tbr)
2. Pbr ≤ Pbrmax

n Number of braking pulses during a 10-minute period

Pbr Maximum braking power (kW) for a custom braking cycle
tbr Braking time (s)
Pbrmax Maximum braking power for a reference braking cycle (1 minute of braking, 9 minutes of rest)

Example 1
The duration of a braking cycle is 30 minutes. The braking time is 15 minutes.
Result: If the braking time exceeds 10 minutes, the braking is considered continuous.
The allowed continuous braking power is 10% of maximum braking power (Pbrmax).
Example 2
The duration of a braking cycle (T) is three minutes. The braking time (tbr) is 40 seconds.
1. n × Pbr × tbr ≤ Pbrmax × 60 s => Pbr ≤ (Pbrmax × 60 s) / (4 × 40 s) = 0.375 × Pbrmax
2. Pbr ≤ Pbrmax <=> 0.375 × Pbrmax ≤ Pbrmax OK
Result: The maximum braking power for the custom braking cycle is 37% of the rated
value given for the reference cycle.

￭ Selecting and routing the cables of a custom resistor

Use the same cable type for the resistor cabling as for the drive input cabling to ensure
that the input fuses also protect the resistor cable. Alternatively, a two conductor
shielded cable with the same cross-sectional area can be used.

Minimizing electromagnetic interference

Make sure that the installation is compliant with the EMC requirements. Obey these
rules in order to minimize electromagnetic interference caused by the rapid voltage
and current changes in the resistor cables:
• Shield the brake resistor cable. Use shielded cable or a metallic enclosure. If you
use unshielded single-core cables, route them 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 the other cables at 90° angles.
• Keep the cable as short as possible in order to minimize the radiated emissions
and stress on the brake chopper. The longer the cable the greater the radiated
emissions, inductive load and voltage peaks over the IGBT semiconductors of the
brake chopper.
 Resistor braking 315

Maximum cable length

The maximum length of the resistor cable(s) is 50 m (164 ft).

￭ Selecting the installation location for the brake resistors

Protect the open (IP00) brake resistors against contact. Install the brake resistor in a
place where it cools effectively. Arrange the cooling of the resistor so that:
• no danger of overheating is caused to the resistor or nearby materials, and
• the temperature of the space that the resistor is in does not go above the allowed
maximum value.

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,
make sure that the material withstands high temperatures. Protect the resistor
against contact.

￭ Protecting the brake system against thermal overload

The brake chopper protects itself and the resistor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. By
default, a brake chopper fault is wired to stop the supply unit of the drive.

Thermal protection of the resistors

The standard resistors available as option +D151 are equipped with a thermal switch.
The switches of the resistors are wired in series and connected to the Enable input of
the brake chopper. The relay output of the chopper is wired to the supply control unit
so that a chopper fault condition stops the supply unit.
With custom resistors, user must implement a similar protection. Use cable rated as
follows:
• twisted pair, shielding recommended
• rated operating voltage between a conductor and ground (U0) > 750 V
• insulation test voltage > 2.5 kV.
Keep the cable as short as possible.

￭ Protecting the resistor cable against short-circuits

The input fuses of the drive will also protect the resistor cable provided that the
resistor cable is of the same type as the input cable.

Mechanical installation of custom brake resistors

Obey the resistor manufacturer’s instructions.
316 Resistor braking

Electrical installation of custom brake resistors

￭ Connection diagram

Brake chopper cubicle

X1
R+ R- 1 2

1 2 3

R+ R-

t°

Brake resistor cubicle

￭ Connection procedure

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them,
injury or death, or damage to the equipment can occur.

• Do the steps in section Electrical safety precautions in chapter Safety instructions

before you start the work.
• Connect the resistor cable at the resistor end only. If a shielded three-conductor
cable is used, cut off the third conductor. Ground the twisted shield of the cable
as well as any separate PE conductor (if present).
• At the chopper end of the cable, connect the R+ and R- conductors of the resistor
cable together. Measure the insulation resistance between the combined
conductors and the PE conductor by using a measuring voltage of 1 kV DC. The
insulation resistance must be higher than 1 Mohm.
 any separate PE conductor (if present).
• At the chopper end of the cable, connect the R+ and R- conductors of the resistor
cable together. Measure the insulation resistance between the combined conductors
and the PE conductor by using a measuring voltage of 1 kV DC. The insulation
Resistor braking 317
resistance must be higher than 1 Mohm.

R+

R-
ohm
PE

• Connect the resistor cable to the R+ and R- terminals of the chopper. If a shielded
• Connect the resistorcable
three-conductor cable to thecut
is used, R+offand R-third
the terminals of theGround
conductor. chopper.
theIftwisted
a shielded
three-conductor cableasiswell
shield of the cable used, cut separate
as any off the third conductor.(if
PE conductor Ground the twisted shield of
present).
the cable as well as any separate PE conductor (if present).
• Connect the thermal switch of the brake resistor to the enable input (X1) on the
• Connect the thermal
brake chopper switch
control of the
board. Usebrake
cableresistor
specifiedtounder
the enable input
Thermal (X1) onof
protection the brake
chopper control (page
the resistors board.315).
UseIfcable
there specified under
are multiple Thermal
thermal protection
switches, ofthem
connect the resistors
in
series.
(page 267). If there are multiple thermal switches, connect them in series.
WARNING!
WARNING! The ENABLE
The ENABLE input block
input terminal terminal block
of the brakeof the brakeischopper
chopper is at
at intermediate
intermediate circuit potential
circuit potential when the when
supplytheunit
supply
of theunit of the
drive drive isThis
is running. running.
voltageThis
voltage is extremely
is extremely dangerous
dangerous and and can cause
can cause seriousserious
damage damage or ifinjury
or injury the if the
isolation level isolation
and protection conditions
level and protectionforconditions
the thermal forswitches
the thermalareswitches
not sufficient.
are notThe
thermal switchessufficient. The thermal
must always switches
be properly must always
insulated (overbe 2.5properly
kV) andinsulated
shrouded (over
against
contact. 2.5 kV) and shrouded against contact.

Brake system start-up

Start-up
Check the settings of the following inverter control program parameters (ACS880
Check the settings
primary of the following inverter control program parameters (ACS880 primary
control program):
control
• program):
30.30 Overvoltage control: Overvoltage control disabled.
• For
30.30 Overvoltage
settings control:
of other control Overvoltage
programs, control
see the disabled.
appropriate firmware manual.
ForNote:
settings of other control programs, see the appropriate firmware manual.
New brake resistors may be coated with storage grease. As the brake chopper
operates
Note: for theresistors
New brake first time,
maythebe
grease burns
coated offstorage
with and may produce
grease. Assome smoke.
the brake Make
chopper
sure there is proper ventilation.
operates for the first time, the grease burns off and may produce some smoke. Make sure
there is proper ventilation.
318 Resistor braking

Maintenance
￭ Replacing the brake resistor cabinet fan

WARNING!
Wear protective gloves and long sleeves. Some parts have sharp edges.

1. Stop the drive and do the steps in section Electrical safety precautions (page 22)
before you start the work.
2. Remove any shrouding in front of the cooling fans.
3. Disconnect the fan wiring.
4. Undo the two fastening screws (a).
5. Pull the fan housing outwards.
6. Install a new fan in reverse order.

a
—
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/contact-centers.

Product training
For information on ABB product training, navigate to new.abb.com/service/training.

Providing feedback on ABB manuals

Your comments on our manuals are welcome. Navigate to forms.abb.com/form-26567.

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet at
www.abb.com/drives/documents.

a5 (frozen)
PDF-A4
Created 2025-01-10, 10:25:43
www.abb.com/drives

3AXD50000020437F

3AXD50000020437 Rev F (EN) 2025-01-10

© Copyright 2025 ABB. All rights reserved.

Specifications subject to change without notice.