—

ABB INDUSTRIAL DRIVES

ACS880-14 drive modules (132…400 kW,

200…400 hp)
Hardware manual
ACS880-14 drive modules
(132…400 kW, 200…400 hp)
Hardware manual

Table of contents

1. Safety instructions

5. Mechanical installation

7. Electrical installation

12. Start-up

3AXD50000035160 Rev E
EN
Original instructions
EFFECTIVE: 2023-04-03
 Table of contents 5

Table of contents

1 Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Safety in installation, start-up, maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2 Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Quick installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3 Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Block diagram of the main circuit of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Motor-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DC voltage boost function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Benefits of the DC voltage boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Impact of DC voltage boost on input current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Standard drive module configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
LCL filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drive module with full power cabling panels (option +H381) . . . . . . . . . . . . . . . . . . . . . . . . 38
Drive module without full-size output cable connection terminals (option +0H371)
and IP20 shrouds (option +0B051) and with common mode filter (+E208) . . . . . . 39
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Table of contents

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Guidelines for planning the mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Generic cabinet planning instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation positions of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Layout example, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Layout example, door open (standard drive module configuration) . . . . . . . . . . . . . . . . . . 49
Layout example, door open (option +0B051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Bookshelf mounting (standard drive module configuration) . . . . . . . . . . . . . . . . . . . . . . . 52
Bookshelf mounting (option +0B051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Bookshelf mounting (option +H381) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Required free space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Free space at the top of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Free space around the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ABB air inlet and outlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5 Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Moving and unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Package drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Drive module package without option +E202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Package with option +E202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
LCL filter module package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Examining the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Attaching the drive module and LCL filter module to a mounting plate or wall . . . . 64
Attaching the drive module to the LCL filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Attaching the drive module and the LCL filter module to the enclosure base . . . . . . 65
Grounding the drive module and the LCL filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Installing the drive in Rittal VX25 enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Optional input power cable connection terminals and ground busbar assembly
(+H370) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Drive module without full-size output cable connection terminals (option +0H371)
and IP20 shrouds (option +0B051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6 Guidelines for planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Selecting the main supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Selecting the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
 Table of contents 7

Requirements tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Requirements for ABB motors, Pn < 100 kW (134 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Requirements for ABB motors, Pn > 100 kW (134 hp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Requirements for non-ABB motors, Pn < 100 kW (134 hp) . . . . . . . . . . . . . . . . . . . . . . . . 71
Requirements for non-ABB motors, Pn > 100 kW (134 hp) . . . . . . . . . . . . . . . . . . . . . . . . 72
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Availability of du/dt filter and common mode filter by drive type . . . . . . . . . . . . . . 73
Additional requirements for explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . . . . . . . 73
Additional requirements for ABB motors of types other than M2_, M3_, M4_,
HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Additional requirements for the regenerative and low harmonics drives . . . . . 73
Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . . 73
Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . 73
Additional data for calculating the rise time and the peak line-to-line voltage . 74
Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Preferred power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Alternate power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Additional guidelines – North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Metal conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Power cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Grounding requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Additional grounding requirements – IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Additional grounding requirements – UL (NEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Signals that can be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Control panel to drive cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
General guidelines – IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
General guidelines – North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Continuous motor cable shield/conduit or enclosure for equipment on the
motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Implementing motor and motor cable short-circuit and thermal overload
protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Protecting the motor cables against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Protecting the motor against overload without thermal model or temperature
sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Protecting the drive and the input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . 85
Protecting the drive against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Protecting the input power cable against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8 Table of contents

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Connecting a motor temperature sensor to the drive through an option mod-
ule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Implementing the power loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Implementing the functions provided by the FSO safety functions module . . . . . . . . 88
Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Implementing an ATEX-certified motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Controlling a contactor between drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7 Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Measuring the insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Measuring the insulation resistance of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Measuring the insulation resistance of the input power cable . . . . . . . . . . . . . . . . . . . . . . 94
Measuring the insulation resistance of the motor and motor cable . . . . . . . . . . . . . . . 94
Grounding system compatibility check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
EMC filter options +E200 and +E202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installing the EMC filter (option +E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Preparing the cable ends and making 360° grounding at the cable entry . . . . . . . . 97
Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Removing the control panel holder from the external control unit . . . . . . . . . . . . . . . . . . . . 99
Attaching the control cable clamp plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Connecting the external control unit to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
External control unit connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Routing the external control unit cables into the drive module . . . . . . . . . . . . . . . . . . . . . 100
Connecting control cables to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Connecting control cables to the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Attaching the external control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Attaching the external control unit to a mounting plate or wall . . . . . . . . . . . . . . . . . . . . 103
Attaching the external control unit vertically on a DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Attaching the external control unit horizontally on a DIN rail . . . . . . . . . . . . . . . . . . . . . . . 104
Connecting the control cables to the terminals of the external control unit . . . . . . . . 104
Connecting a control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Panel bus (Control of several units from one control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Panel bus wiring with FDPI-02 – single drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Panel bus wiring with FDPI-02 and ZDPI-01 – several drives . . . . . . . . . . . . . . . . . . . . . . . . . 110
Panel bus wiring with FDPI-02 – several drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Installing the FSO-xx safety functions module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
 Table of contents 9

Installing I/O extension, fieldbus adapter and pulse encoder interface modules . 113
Wiring the option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

8 External control unit

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Unpacking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ZCU-14 layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Default I/O diagram of the drive control unit (ZCU-1x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Additional information on the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Connecting motor temperature sensors to the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
DIIL input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
The XD2D connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FSO safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
ZCU-1x ground isolation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

9 Installation into a Rittal VX25 enclosure

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Installation into a Rittal VX25 enclosure with ready-made ABB installation kits . . . . 126
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Necessary parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Overall flowchart of the installation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Installing the drive module and LCL filter module into an enclosure . . . . . . . . . . . . . . . . . . 128
Connecting the motor cables and installing the shrouds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Connecting the input cables and installing the shrouds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Installing the air baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Installing the roof and door (Rittal parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Removing the protective covering from the drive module and LCL filter module air
outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

10 Installation example with full cabling panels (option +H381)

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Necessary parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Overall flowchart of the installation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Installing the mechanical accessories into a enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Installing the drive module into the enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Assembly drawing of connecting the drive module to the cabling panels . . . . 144
Installing air baffles (non-ABB parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10 Table of contents

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Installing the rubber grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

11 Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

12 Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

13 Fault tracing
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

14 Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Descriptions of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Recommended functional safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Cleaning the interior of the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Cleaning the interior of the LCL filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Replacing the auxiliary cooling fans of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Replacing the drive module main cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Replacing the LCL filter module cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Replacing the standard drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Replacing the LCL filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Replacing the drive module with option +H381 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Replacing the LCL filter module with option +H381 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Replacing the ZCU-14 control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Replacing the memory unit of ZCU-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Replacing the memory unit of the line-side converter control unit (ZCU-12) . . . . 170
Functional safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

15 Ordering information
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
ACS-AP-W and ACS-AP-I control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Control panel mounting platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Output (du/dt) filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
 Table of contents 11

EMC filter ARFI-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Cabinet ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Air inlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Air outlet kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
FSO accessories kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Retrofit accessory kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

16 Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Electrical ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Deratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
When is derating necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Surrounding air temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Deratings for special settings in the drive control program . . . . . . . . . . . . . . . . . . . . . 182
Derating for output voltage boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Calculating the short-circuit current of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Circuit breakers (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Drive package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
LCL filter module package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Terminal and entry data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Units with optional cabling panels (+H381) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Units without full-size output cable connection terminals (+0H371) and with a
common mode filter (+E208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
DC connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Control panel type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Ecodesign data (EU ecodesign) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Protection classes for module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Package materials for module products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Package materials for options, accessories and spare parts . . . . . . . . . . . . . . . . . . . . . . . 199
Materials of manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
EMC compliance (IEC/EN 61800-3:2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
12 Table of contents

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Marine approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Declarations of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

17 Dimension drawings
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Location of power cable connection terminals with option +H370 . . . . . . . . . . . . . . . . . . . . 209
Configuration with options +0B051+0H371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Drive module with options +0B051+0H371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
LCL filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Configuration with option +H381 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Air baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Material of the air baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Air baffles for option +H381 in 800 mm wide Rittal VX25 enclosure . . . . . . . . . . . . . . . . . . 216
External control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

18 Example circuit diagrams

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

19 The Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Compliance with the European Machinery Directive and the UK Supply of Ma-
chinery (Safety) Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Dual-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Single-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Multiple drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Internal power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
External power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Start-up including validation test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Validation test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Validation test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
 Table of contents 13

Perfect proof test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Simplified proof test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
TÜV certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Declarations of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

20 Filters
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
When is a du/dt filter necessary? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Ordering codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . . . . 242
Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
When is a sine filter necessary? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
ABB ordering codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Description, installation and technical data of the sine filters . . . . . . . . . . . . . . . . . . . . . . 242

Step-by-step drawings for an installation example of standard drive configuration

in Rittal VX25 800 mm wide enclosure
Handling the drive module, power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Installing the drive module and LCL filter module into a Rittal VX25 enclosure . . . . . 244
Connecting the motor cables and installing the shrouds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Connecting the input power cables and installing the shrouds . . . . . . . . . . . . . . . . . . . . . . . . 252
Connecting the external control cables to the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Installing the air baffles and removing the cardboard covers . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Further information
14
 Safety instructions 15

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 draw attention to a
particular condition or fact, or give information on a subject.
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.
16 Safety instructions

General safety in installation, start-up and maintenance

These instructions are for all personnel 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.
• Lift a heavy drive with a lifting device. Use the designated lifting points. See the
dimension drawings.
• Obey the local laws and regulations applicable to lifting, such as requirements for
planning the lifting, for capacity and condition of lifting equipment, and for training
of personnel.
• 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 use the module extraction/installation ramp with plinth heights that exceed
the maximum allowed height.
• Attach the module extraction/installation ramp carefully.
• Make sure that the module does not fall over when you move it on the floor: To
open the support legs, press each leg a little down and turn it aside (1, 2). Whenever
possible attach the module also with chains. Do not tilt the drive module. It is
heavy and its center of gravity is high. The module overturns when tilted more
than 5 degrees. Do not leave the module unattended on a sloping floor.
 Safety instructions 17

1 3

3AUA0000086323

• To prevent the drive module from falling, attach its top lifting lugs with chains to
the cabinet (1) before you push the module into the cabinet and pull it from the
cabinet. 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 (2) to prevent the module from falling on its back.

1 1

2
2

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

and brake resistors, remain hot for a while after disconnection of the electrical
supply.
• Vacuum clean the area around the drive before the start-up to prevent the drive
cooling fan from drawing dust inside the drive.
18 Safety instructions

• 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. See the technical data.
• Keep the cabinet doors closed when the drive is powered. With the doors open,
a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists.
If you cannot avoid working on a powered drive, obey the local laws and regulations
on live working (including – but 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.
These functions reset the drive automatically and continue operation after a fault
or supply break. 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 you have connected safety circuits to the drive (for example, Safe torque off or
emergency stop), validate them at start-up. See separate instructions for the
safety circuits.
• Beware of hot air exiting from the air outlets.
• Do not cover the air inlet or outlet when the drive is running.
Note:
• If you select an external source for the start command and it is on, the drive will
start immediately after fault reset unless you configure the drive for pulse start.
See the firmware manual.
• If the drive is in remote control mode, you cannot stop or start the drive with the
control panel.
• Only authorized persons are allowed to repair a malfunctioning drive.
 Safety instructions 19

Electrical safety in installation, start-up and maintenance

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

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

1. Clearly identify the work location and equipment.

2. Disconnect all possible voltage sources. Make sure that re-connection is not
possible. Lock out and tag out.
• Open the main disconnecting device of the drive.
• Open the charging switch if 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.)
• Open the auxiliary voltage switch-disconnector (if present), and all other
possible disconnecting devices that isolate the drive from dangerous voltage
sources.
• If you have a permanent magnet motor connected to the drive, disconnect
the motor from the drive with a safety switch or by other means.
• Disconnect all dangerous external voltages from the control circuits.
• After you disconnect power from the drive, always wait 5 minutes to let the
intermediate circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a quality voltage tester. If the
measurement requires removal or disassembly of shrouding or other cabinet
structures, obey the local laws and regulations applicable to live working (including
– but 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 drive input power terminals (L1, L2,
L3) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive output terminals (T1/U, T2/V,
T3/W) and the grounding (PE) busbar is zero.
Important! Repeat the measurement also with the DC voltage setting of the
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 terminals (UDC+ and UDC-)
and the grounding (PE) terminal is zero.
20 Safety instructions

6. Install temporary grounding as required by the local regulations.

7. Ask for a permit to work from the person in control of the electrical installation
work.

￭ 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 is powered. With the doors open,
a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists.
• Make sure that the 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, keep away
from the area near motor, drive, and the drive power cabling when the drive is in
operation. There are electromagnetic fields present which can interfere with the
function of such devices. This can cause a health hazard.
• Remove the code labels attached to mechanical parts such as busbars, shrouds
and sheet metal parts before installation. They may cause bad electrical
connections, or, after peeling off and collecting dust in time, cause arcing or block
the cooling air flow.
Note:
• When the drive is connected to the input power, the motor cable terminals and
the DC bus are at a dangerous voltage.
After disconnecting the drive from the input power, these remain at a dangerous
voltage until the intermediate circuit capacitors have discharged.
• 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.

Printed circuit boards

WARNING!
Use a grounding wristband when you handle printed circuit boards. Do not
touch the boards unnecessarily. The boards contain components sensitive to
electrostatic discharge.
 Safety instructions 21

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

WARNING!
Obey these instructions. If you ignore them, injury or death, 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 the personnel safety.
• Make sure that the conductivity of the protective earth (PE) conductors is sufficient
and that other requirements are met. See the electrical planning instructions of
the drive. Obey the applicable national and local regulations.
• When using 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.
22 Safety instructions

General safety in operation

These instructions are for all personnel 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 is powered. With the doors open,
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, keep away
from the area near motor, drive, and the drive power cabling when the drive is in
operation. There are electromagnetic fields present which can interfere with the
function of such devices. This can cause a health hazard.
• 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 will start immediately
after the fault reset, unless you configure the drive for pulse start. See 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 supply break. 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.
• If the drive is in remote control mode, you cannot stop or start the drive with the
control panel.

Additional instructions for permanent magnet motor

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

WARNING!
Obey these instructions. If you ignore them, injury or death, 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.
 Safety instructions 23

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 like belt, nip, rope, etc.
• Do the steps in section Electrical safety precautions (Page 19).
• 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 overspeed, for example, driven by the load.
Motor overspeed causes overvoltage that can damage or destroy the capacitors
in the intermediate circuit of the drive.

￭ Safety in operation

WARNING!
Make sure that the motor cannot run overspeed, for example, driven by the
load. Motor overspeed causes overvoltage that can damage or destroy the
capacitors in the intermediate circuit of the drive.
24
 Introduction to the manual 25

2
Introduction to the manual

Contents of this chapter

This chapter describes the intended audience and contents of the manual. It contains
a flowchart of steps in examining the delivery, installing and commissioning the drive.
The flowchart refers to chapters/sections in this manual and other manuals.

Applicability
This manual applies to ACS880-14 drive modules intended for user-defined cabinet
installations.

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 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

The frame size identifies information which concerns only a certain frame size of the
drive. The frame size is shown on the type designation label. All frame sizes are listed
in the technical data.
The option code (A123) identifies information which concerns only a certain optional
selection. The options included in the drive are listed on the type designation label.
26 Introduction to the manual

Quick installation, commissioning and operating flowchart

Task See chapter/section
Plan the mechanical and electrical installation and Guidelines for planning the mechanical installa-
acquire the accessories needed (cables, fuses, etc.). tion (Page 47)
Examine the ambient conditions, ratings, required Guidelines for planning the electrical installa-
cooling air flow, input power connection, compatib- tion (Page 67)
ility of the motor, motor connection, and other Technical data (Page 177)
technical data.
Option manual (if optional equipment is included)

Unpack and examine the units. Moving and unpacking (Page 57)
Make sure that all necessary optional modules and Examining the delivery (Page 64)
equipment are present and correct. If the drive module has been non-operational for a
Only intact units can be started up. year or more, the converter DC link capacitors need
to be reformed. (Reforming the capacit-
ors (Page 167))

Examine the installation site. Attach the base of the Examining the installation site (Page 57)
cabinet to the floor. Ambient conditions (Page 197)

Route the cables. Routing the cables (Page 81)

Measure the insulation of the supply cable, the mo- Measuring the insulation (Page 94)
tor and the motor cable and the resistor cable (if
present).

Standard drive modules Installing the drive module and LCL filter module
• Install the additional components into the enclos- into an enclosure (Page 128)
ure: for example, main disconnector, main con- Connecting the motor cables and installing the
tactor, main AC fuses, etc.. shrouds (Page 129)
• Install the drive module into the enclosure. Connecting the input cables and installing the
• Connect the motor cables to the drive module shrouds (Page 130)
terminals.
Connecting the external control unit to the drive
• Connect the brake resistor and DC connection
module (Page 100)
cables (if any) to the drive module terminals.
• If the main disconnector is installed into the en- Attaching the external control unit (Page 102)
closure, connect it to the drive module terminals Manuals for any optional equipment
and the input power cabling to the disconnector.
• Connect the cables from the drive module to the
external control unit and install the control unit
into the enclosure
 Introduction to the manual 27

Task See chapter/section

Drive modules with optional cabling panels (+H381) Installing the mechanical accessories into a enclos-
• Install the cabling panels into the enclosure. ure (Page 137)
• Install the additional components into the enclos- Connecting the power cables (Page 139)
ure: for example, main disconnector, main con- Installing the drive module into the enclos-
tactor, main AC, fuses, etc. ure (Page 142)
• If the main disconnector is installed into the en-
Connecting the external control unit to the drive
closure, connect the input power cabling to it
module (Page 100)
• Connect the input power cables and motor cables
to the cabling panel terminals. Attaching the external control unit (Page 102)
• Connect the brake resistor and DC connection Manuals for any optional equipment
cables (if any) to the cabling panel terminals.
• Install the drive module into the enclosure
• Attach the cabling panel busbars to the drive
module busbars.
• Connect the cables from the drive module to the
control unit and install the control unit into the
enclosure

Drive modules without full-size output cable connec- Mechanical installation (Page 57)
tion terminals (option +0H371) and IP20 shrouds Electrical installation (Page 93)
(option +0B051)
Manuals for any optional equipment
• Install the additional components into the cabin-
et: for example, main PE busbar, main disconnect-
or, main contactor, main AC, fuses, etc.
• Install the drive module into the cabinet.
• Connect the power cabling between the drive
module and the rest of the main circuit compon-
ents in the cabinet (if any)
• Connect the input power cables and motor cables
to the drive cabinet.
• Connect the brake resistor and DC connection
cables (if any) to the drive cabinet.
• Connect the cables from the drive module to the
control unit and install the control unit into the
cabinet.

Connect the control cables to the drive control unit. Connecting the external control unit to the drive
module (Page 100)

Examine the installation. Installation checklist (Page 147)

Commission the drive. Start-up (Page 149)

Operate the drive: start, stop, speed control etc. Appropriate firmware manual

Terms and abbreviations

Term Description
BGDR Gate driver board
CMF Common mode filtering
DDCS Distributed drives communication system protocol
Drive Frequency converter for controlling AC motors
DTC Direct torque control, a motor control method
EMC Electromagnetic compatibility
FAIO-01 Analog I/O extension module
28 Introduction to the manual

Term Description
FCAN Optional CANopen® adapter module
FCNA-01 Optional ControlNet™ adapter module
FDCO-01 DDCS communication module with two pairs of 10 Mbit/s DDCS channels
FDCO-02 DDCS communication module with one pair of 10 Mbit/s and one pair of 5
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 TTL 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
atmospheres
Frame, frame size Physical size of the drive or power module
FSCA-01 Optional RS-485 (Modbus/RTU) adapter
FSE-31 Optional pulse encoder interface module for safety encoder
FSO-12, FSO-21 Optional functional safety modules
FSPS-21 Optional functional safety module
HTL High-threshold logic
IGBT Insulated gate bipolar transistor
IT system Type of supply network that has no (low-impedance) connection to ground.
See IEC 60364-5.
Line-side converter Converts alternating current and voltage to direct current and voltage for the
intermediate DC link of the drive. The line-side converter can transfer energy
from the electrical power system to the DC link and vice versa.
Motor-side converter Converts intermediate DC link current to AC current for the motor
PLC Programmable logic controller
QOIA Optical interface adapter board
RFI Radio-frequency interference
STO Safe torque off (IEC/EN 61800-5-2)
TN system Type of supply network that provides a direct connection to ground
TTL Transistor-transistor logic
ZBIB Adapter board connected to the control board in the control unit (ZCU)
ZCU Type of control unit
 Introduction to the manual 29

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

ACS880-14 manuals
30
 Operation principle and hardware description 31

3
Operation principle and hardware
description

Contents of this chapter

This chapter describes the operating principle and construction of the drive module.

Operation principle
The ACS880-14 is a regenerative drive module for controlling asynchronous AC
induction motors, permanent magnet motors, AC induction servomotors and ABB
synchronous reluctance motors (SynRM motors).
The drive includes a line-side converter and a motor-side converter. The parameters
and signals for both of them are combined into one primary user program.
32 Operation principle and hardware description

￭ Block diagram of the main circuit of the drive module

A
1

PE
L1/U1 T1/U2
L2/V1 T2/V2
L3/W1 T3/W2
3 4 5 6 7 8

UDC- UDC+

A ACS880-14 drive module

1 Charging circuit contactor
2 Charging circuit
3 Line contactor
4 LCL filter
5 Line-side converter
6 DC link. DC circuit between the line-side converter and motor-side converter.
7 Motor-side converter
8 Common mode filter (+E208)

￭ Line-side converter
The line-side converter rectifies three-phase AC current to direct current for the
intermediate DC link of the drive.
The line-side converter can transfer energy from the electrical power system to the
drive DC link and vice versa.Thus the drive can operate the motor in all four quadrants
(speed, torque). The figure below visualizes the operation of the four-quadrant drive.
In quadrants I and III, the drive operates in the motoring mode and takes energy from
the power system. In quadrants II and IV, the drive operates in generating mode, and
regenerates energy back to the power system.

II I

n
III IV
 Operation principle and hardware description 33

The following figure shows the simplified main circuit diagram of the line-side
converter.

1 2 3

4 5

1 LCL filter contactor

2 LCL filter
3 Line-side converter
4 DC capacitors
5 DC link

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.

￭ Motor-side converter
The motor-side converter 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. The
motor-side converter is controlled by a type ZCU control unit (external control unit).
This is called the drive control unit or control unit in this manual.

￭ DC voltage boost function

The drive can boost its DC link voltage. In other words, it can increase the operating
voltage of the DC link from its default value.
To take the DC voltage boost function in use:
34 Operation principle and hardware description

1. adjust the user DC voltage reference value (94.22) and

2. select the user-defined reference (94.22) as the source for the drive DC voltage
reference (94.21).

Benefits of the DC voltage boost

• possibility to supply nominal voltage to the motor even when the supply voltage
of the drive is below the motor nominal voltage level
• compensation of voltage drop due to output filter, motor cable or input supply
cables
• increased motor torque in the field weakening area (ie, when the drive operates
the motor in the speed range above the motor nominal speed)
• possibility to use a motor with higher nominal voltage than the actual supply
voltage of the drive. Example: A drive that is connected to 415 V can supply 460 V
to a 460 V motor.

Impact of DC voltage boost on input current

When the DC voltage is boosted, the drive can be drawing more input current than
what is rated in the type designation label. Derating is needed:
• when the motor is running at the field weakening area or close to it and the drive
is running at nominal load or close to it
• when the situation lasts long
• when the boost is more than 10%.
The rise of the input current can heat the fuses. If there are brief low line situations
when the drive boosts voltage significantly, there is a risk for nuisance fuse blowing
of smaller AC line fuses.
For more information, refer to ACS880-11, ACS880-31, ACS880-14, ACS880-34,
ACS880-17, ACS880-37 drives product note on DC voltage boost (3AXD50000691838
[English]).
 Operation principle and hardware description 35

Layout
￭ Standard drive module configuration

A B C

1 8 9
3

4
1
5
5

7
7

6 6

A Drive module. Contains line-side converter and 4 Lower front cover

motor side converter.
B LCL filter module 5 Cooling fan cassette
C LCL filter module connected to the drive 6 Support legs
module
1 Clear plastic shrouds attached 7 Pedestal
2 Circuit board compartment 8 Busbars for connecting the LCL filter module
to the drive module
3 Upper front cover 9 Cover on busbar connections
See the next page for descriptions and photos of the external control unit and drive module. For LCL
filter module, see section LCL filter module (Page 37).
36 Operation principle and hardware description

￭ Drive module

3 20
6
10
25
+H370 7
26
1a 4

23

16

1b
17

21
8

12
18

23
2 5 22
19
13 24

11
9

14
15

1 Clear plastic shroud to be attached onto the 14 Pedestal guide plate for the drive module
drive module input power cabling (1a). Entry
shroud for side cabling (1b).
2 Clear plastic shrouds to be attached onto the 15 Telescopic extraction/installation ramp
drive module output power cabling
3 Clear plastic shroud to be attached on top of 16 External control unit
the drive module (entry for top cabling)
4 Upper back clear plastic shroud 17 Control panel
5 Lower back clear plastic shroud 18 Control cable clamp plate
6 Front clear plastic shroud 19 Cables for connecting the control unit to the
drive module (ZBIB - INU STO and 24VDC
power)
7 Input power cable connection terminals (op- 20 Busbars for connecting the drive module to
tion +H370) the LCL filter electrically
 Operation principle and hardware description 37

8 Output power cable connection terminals 21 Cover for the busbar connection
9 Grounding terminal for output power cable 22 Auxiliary cooling fan
shields
10 Metallic shroud. With option +H370, the shroud 23 Handle
includes a ground bar.
11 Fiber optic cables for connecting the control 24 Cover. When removed, you can attach the drive
unit to the drive module (INU ZBIB - QOIA) module to the LCL filter module.
12 PE (ground) terminal 25 Lifting lugs
13 Main cooling fans 26 Connector for charging circuit switch or con-
tactor

￭ LCL filter module

3
4

1 Busbars for connecting the LCL filter module 4 Pedestal guide plate for the LCL filter module
to the drive module electrically
2 Handle 5 Lifting lugs
3 Main cooling fans - -
38 Operation principle and hardware description

￭ Drive module with full power cabling panels (option +H381)

4 7
1

12

10 11
8
2

3 11
6

13
9
10

Accessories Assembled drive module

1 Input power cabling panel 8 Input power cabling panel to be attached to
the drive cabinet
2 Side guides 9 Output power cabling panel to be attached to
the drive cabinet
3 Output power cabling panel 10 Front cover
4 Top guide plate 11 Handle
5 Pedestal guide plate 12 Lifting lugs
6 Telescopic extraction and insertion ramp 13 Auxiliary cooling fan, another auxiliary cooling
fan is located below the circuit board compart-
ment
7 Rubber grommet - -
 Operation principle and hardware description 39

￭ Drive module without full-size output cable connection terminals

(option +0H371) and IP20 shrouds (option +0B051) and with common
mode filter (+E208)

15

9
10

4 8

5 9

16

13 14
11

12
7

1 Lifting lugs 9 Auxiliary cooling fan

2 Input cable connection busbars (L1/U1, L2/V1, 10 PE busbar
L3/W1) and DC+ and DC- busbars (UDC+, UDC-)
3 Circuit board compartment 11 Main cooling fans
4 Output cable connection busbars (T1/U2, 12 Base attaching screws
T2/V2, T3/W2)
5 Common mode filter (option +E208) 13 Pedestal guide plate
6 Pedestal 14 Telescopic extraction and insertion ramp
7 Retractable support legs 15 Connector for charging circuit switch or con-
tactor
8 Handle for pulling the drive module 16 Cover. When removed, you can attach the drive
module to the LCL filter module.

Note: The front covers are removed in this photo, see numbers 3 and 4 in Standard drive module config-
uration.
40 Operation principle and hardware description

￭ Control panel
In the standard drive module configuration, the control panel is located in the control
panel holder of the external control unit.
One control panel can also be used to control several drives through a panel link; see
section Panel bus (Control of several units from one control panel) (Page 106).
For the use of the control panel, see the firmware manual or ACS-AP-I, -S, -W and
ACH-AP-H, -W assistant control panels user’s manual (3AUA0000085685 [English]).

1 ACS-AP-I Assistant control panel (option +J425)

2 ACS-AP-W Assistant control panel with bluetooth
 Operation principle and hardware description 41

Overview of power and control connections

The diagram shows the power connections and control interfaces of the drive module.

A
Fxx ..........
..........
Fxxx 1 2 3

. . .
Slots 1, 2 and 3 6

........
....
X12
......
.. 4 X13 7

X205
.....
..... 8
V1, V2,
V20, V21

12
ACS880-14 V2, V7, V8, V13

L1 L1 10 U2

L2 L2 V2 M3~

L3 L3 9 11 W2

PE PE

UDC- UDC+

A External control unit (motor-side converter control unit)

B Line-side converter control unit
1
Analog and digital I/O extension modules, feedback interface modules and fieldbus communication
2
modules can be inserted into slots 1, 2 and 3. See Type designation key (Page 42).
3
4 Connector for the FSO-xx safety functions module (X12). The module can be installed on or above
the control unit, see Installing the FSO-xx safety functions module (Page 112).
5 Memory unit (see section Memory unit)
6 I/O terminal blocks. See chapter External control unit (Page 115).
7 Control panel (see section Control panel)
8 Fiber optic link to the motor-side converter. Similarly, the line-side converter is connected to the
line-side converter control unit with fiber optic cables.
9 Line-side converter
10 DC link
11 Motor-side converter
12 Socket for external line-side control unit control (not required for normal operation of the drive)
42 Operation principle and hardware description

Type designation label

The type designation label includes a rating, markings, a type designation and a serial
number, which allow individual recognition of each drive module. The type designation
label is located on the front cover. An example label is shown below.

2
6 8

4
7 10
5 9

1 Type designation, see section Type designation key.

2 Name and address of the manufacturer
3 Frame size
4 Cooling method
5 Degree of protection
6 Ratings, see section Electrical ratings (Page 177).
7 Prospective short-circuit current rating, see section Electrical power network specification (Page 194).
8 Valid markings
9 Serial number. The first digit of the serial number refers to the manufacturing plant. The next 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.
10 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. 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.

￭ Basic code

Code Description

ACS880 Product series

Type
 Operation principle and hardware description 43

Code Description

-14 The standard delivery includes: regenerative single drive module to be installed in an enclosure,
IP20 (UL Type Open), bookshelf mounting with pedestal, external control unit with ACS-AP-
W Assistant control panel with Bluetooth interface and panel holder, build-in LCL filter, full-
size output cable connection terminals, no EMC filter, DC connection busbars, clear plastic
shrouds for covering the input power and motor cable connections, ACS880 primary control
program, Safe torque off function, coated boards, printed multilingual quick installation and
start-up guide, extraction/installation ramp.
Refer to section Option codes (Page 43) for options.

Size

-xxxxA See the ratings table.

Voltage range

-3 380…415 V AC

-5 380…500 V AC

-7 525…690 V AC

￭ Option codes

Code Description
0B051 No IP20 shrouds for cabling area (Not to be used with option +H381)
C132 Marine type approval
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)
C208 Marine product certification issued by Registro Italiano Navale (RINA)
C209 Marine product certification issued by Bureau Veritas
E200 EMC filter for 2nd environment TN (grounded) system, category C3
E201 EMC filter for 2nd environment IT (ungrounded) system, category C3
EMC filter for 1st environment TN (grounded) system, category C2. Requires option +E208.
E202
Available for ACS880-14-xxxx-3 and -5 types only.
Common mode filter
ACS880-14-xxxx-3 and -5 drive modules: Option +E202 and option +E208 to be ordered to get
E208 common mode filter installed.
ACS880-14-xxxx-7 drive modules: Included as standard. +E208 not shown in the type designa-
tion label.
0H371 No full size cable connection terminals for output power cables
H370 Full-size input terminals
Full power cabling panels to be attached to a cabinet. The drive module can be pulled out
H381 from the cabinet without disconnecting the power cables. IP20 degree of protection. Not to
be used with options +0B051 and +H370.
0J400 No control panel
J410 DPMP-01 door mounting kit
J413 DPMP-02 door mounting kit (surface mounting) for the panel
J425 ACS-AP-I control panel
K451 FDNA-01 DeviceNet™ adapter module
K454 FPBA-01 PROFIBUS DP adapter module
44 Operation principle and hardware description

Code Description
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 EtherPOWERLINK adapter module
FENA-21 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols,
K475
2-port
K490 FEIP-21 EtherNet/IP adapter module
K491 FMBT-21 Modbus/TCP adapter module
K492 FPNO-21 PROFINET IO adapter module
L500 FIO-11 analog I/O extension module (1, 2 or 3 pcs)
L501 FIO-01 digital I/O extension module
L502 FEN-31 HTL incremental encoder interface module
L503 FDCO-01 optical DDCS communication adapter module
L508 FDCO-02 optical DDCS communication adapter module
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 CAIO-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
N5000 Winder control program
N5050 Crane control program
N5100 Winch control program
N5150 Centrifuge control program
N5200 PCP (Progressive Cavity Pump) control program
N5250 Rod pump control program
N5350 Cooling tower control program
N5450 Override control program
N5500 Spinning and traverse control program
N5600 ESP (Electrical Submersible Pump) control program
N5650 Tower crane control program
N8010 Drive application programming
0P919 No extraction/installation ramp
P904 Extended warranty (24 months from commissioning or 30 months from delivery)
P909 Extended warranty (36 months from commissioning or 42 months from delivery)
P911 Extended warranty (60 months from commissioning or 66 months from delivery)
Q971 ATEX-certified safe disconnection function
Q972 FSO-21 safety functions module
 Operation principle and hardware description 45

Code Description
Q973 FSO-12 safety functions module
Q982 PROFIsafe with FSO-xx safety functions module and FENA-21 Ethernet adapter module
Q986 PROFIsafe safety functions module, FSPS-21
R700 Printed manuals in English
R701 Printed manuals in German 1)
R702 Printed manuals in Italian1)
R703 Printed manuals in Dutch1)
R704 Printed manuals in Danish1)
R705 Printed manuals in Swedish1)
R706 Printed manuals in Finnish1)
R707 Printed manuals in French1)
R708 Printed manuals in Spanish1)
R709 Printed manuals in Portuguese1)
R711 Printed manuals in Russian1)
R712 Printed manuals in Chinese1)
R713 Printed manuals in Polish1)
R714 Printed manuals in Turkish1)

1) Manuals in English may be included if a translation in the specified language is not available.
46
 Guidelines for planning the mechanical installation 47

4
Guidelines for planning the mechanical
installation

Contents of this chapter

This chapter guides in planning drive cabinets and installing the drive module into a
user-defined cabinet. The chapter gives cabinet layout examples and free space
requirements around the module for cooling. These drive-specific guidelines are
essential for the safe and trouble-free use of the drive system.

Generic cabinet planning instructions

Refer to Drive modules cabinet design and construction instructions (3AUA0000107668
[English]).

Installation positions of the drive module

The drive module must be installed in an upright bookshelf position in a cabinet.
48 Guidelines for planning the mechanical installation

Layout example, door closed

This diagram shows a cabinet layout example with the input power cable entry from
top and the motor cable entry from bottom.

7 3

5
6

1 1
2

1 Air inlet for the drive module 6 Operating handle of the disconnector
2 An extra fan is not necessary if an extra air 7 Rubber grommets for degree of protection
baffle is used on the cabinet roof (see the fol-
lowing layout examples)
3 Air outlet for the drive module and LCL filter 8 Roof air flow viewed from top
module and other equipment on the cabinet
roof. An exhaust fan if needed.
4 Drive control panel with DPMP-01 mounting 9 Fan required for IP20, IP42 or IP54 air outlet
platform (option +J410). The control panel is kit, has to be ordered separately. See Cooling
connected to the drive module control unit in- fans (Page 175).
side the cabinet.
5 Contactor control switch and emergency stop -
switch (connected to the contactor control
circuit inside the cabinet)
Note: The sizes of the air inlet and outlet gratings are critical for proper cooling of the drive module.
For losses and cooling data requirements, see the technical data.
 Guidelines for planning the mechanical installation 49

Layout example, door open (standard drive module

configuration)

2c

2a
14 14

A B

4
2c

15 16
5 2a 1

2b
6
L1/U1
L2/V1
3 L3/W1

10
7 8

13 PE
T3/W2
3 T2/V2
T1/U2
3

12

11 A–A B– B
A B

1 Supporting frame of the cabinet 8 LCL filter module

2a Vertical (2a) and horizontal (2b) air baffles that 9 Motor cable including the protective ground
separate the cool and hot areas (leakproof conductor of the drive module
entries). See section Preventing the recircula-
2b 10 Drive module control unit
tion of hot air (Page 52).
2c Optional air baffle that is needed when there 11 External control cables
is no fan on the lower part of the cabinet door.
See section Preventing the recirculation of hot
air (Page 52).
3 Cabinet grounding busbar (PE) 12 Grounding screws
4 Input power cable including the protective 13 Alternative to grounding screws (12)
ground conductor (PE) of the drive
5 Disconnector and fuses 14 Air flow to the roof
6 Contactor 15 Air flow through the drive module
7 Drive module 16 Air flow through the LCL filter
50 Guidelines for planning the mechanical installation

Layout example, door open (option +0B051)

This diagram shows a layout example for drive modules with no IP20 shrouds (option
+0B051) or no cabling panels (option +H381 not included).

2e

2a
14 14

A B

4
2e

15 16
5 2a 1

2c
6 2b L1/U1
L2/V1
3 L3/W1
2d
10
7 8

13 PE
T3/W2
3 T2/V2
T1/U2

12

9 11 A–A B– B

A B

1 Supporting frame of the cabinet 9 Motor cable including the protective ground
conductor of the drive module
2 Vertical (2a, 2b) and horizontal (2c, 2d) air 10 Drive module control unit
baffles that separate the cool and hot areas
(leak-proof lead-throughs). See section Prevent-
ing the recirculation of hot air (Page 52).
2e Optional air baffle that is needed when there 11 External control cables
is no fan on the lower part of the cabinet door.
See section Preventing the recirculation of hot
air (Page 52).
3 Cabinet grounding busbar (PE) 12 Grounding screws
4 Input power cable including the protective 13 Alternative to grounding screws (12)
ground conductor (PE) of the drive
5 Disconnector and fuses 14 Air flow to the roof
6 Contactor 15 Air flow through the drive module
7 Drive module 16 Air flow through the LCL filter
8 LCL filter module - -
 Guidelines for planning the mechanical installation 51

Note: The power cable shields can also be grounded to the drive module grounding terminals.
Note: See also section Required free space (Page 54).

Cooling solutions
The drawing below shows typical cabinet cooling solutions. The air inlet is at the
bottom of the cabinet, while the outlet is on the roof or on the upper part of the door.
Use extra exhaust fans if the air outlet is on the cabinet door, see the technical data
for the required cooling air flow.

2
2

1 1 1 1

1 Air inlet
2 Air outlet
52 Guidelines for planning the mechanical installation

Preventing the recirculation of hot air

￭ Bookshelf mounting (standard drive module configuration)
This diagram shows the air baffle position inside an example cabinet. For dimensions
of the baffle, see the dimension drawings.

C B

8 2c
2c 2c

A A
5 2a 2a

2b 2b
6
L1/U1
L2/V1
L3/W1 3
2a
7
3 4

PE
9 T3/W2
3 T2/V2
T1/U2
3 1

C B B–B C–C

2b 2b

3 4
2a

A–A

1 Air flow to the drive modules, max. 40 °C 5 Disconnector and fuses

(104 °F)
2a Vertical air baffle that separates the cool and 6 Contactor
hot areas in the cabinet
2b Horizontal air baffle 7 Drive control unit
2c Optional air baffle that is needed when there 8 Air flow out
is no fan on the lower part of the cabinet door
3 Drive module 9 Cabinet grounding busbar (PE)
4 LCL filter module - -
 Guidelines for planning the mechanical installation 53

￭ Bookshelf mounting (option +0B051)

This diagram shows air baffle positions inside an example cabinet. For the descriptions,
see the next page.

D C

8 2e
2e

A A
2a 2a
5

2c 2c 2c
6 2b L1/U1
B B
L2/V1 2b 2b 2b 2b
L3/W1
3
2d 2d 2d
7
3 4

y
PE
T3/W2
3 T2/V2
9 T1/U2
1

D C x

C–C

2b
2e
2c

3 4
2a

2a
2b 2b 2c

A-A
y

2d

3 4
2a

B-B x
2d
D–D
54 Guidelines for planning the mechanical installation

1 Air flow to the drive modules, max. 40 °C 4 LCL filter module

(104 °F)
2a Vertical air baffle that separates the cool and 5 Disconnector and fuses
hot areas in the cabinet
2b Vertical air baffle 6 Contactor
2c Upper horizontal air baffle 7 Drive control unit
2d Lower horizontal air baffle 8 Air flow out
2e Optional air baffle that is needed when there 9 Cabinet grounding busbar (PE)
is no fan on the lower part of the cabinet door
3 Drive module - -

￭ Bookshelf mounting (option +H381)

See Installation example with full cabling panels (option +H381) (Page 135).

Required free space

Free space around the drive module is needed for ensuring that sufficient cooling air
flows through the module and the module cools correctly.

￭ Free space at the top of the drive module

The required free space at the top of the drive module is shown below.

2
350 mm (13.78 in)

1 Air inlet
2 Air outlet
 Guidelines for planning the mechanical installation 55

￭ Free space around the drive module

A free space of 10 mm (0.39 in) around the drive module is required from the cabinet
back panel and front door. No free space for cooling is required on the left- and
right-hand sides of the module.
The module can be installed in a cabinet with the following dimensions:
• width 800 mm (31.50 in)
• depth 600 mm (23.62 in)
• height 2000 mm (78.74 in).

ABB air inlet and outlet kits

See chapter Ordering information (Page 171).
56
 Mechanical installation 57

5
Mechanical installation

Contents of this chapter

This chapter describes alternatives of the mechanical installation of the drive module.
10
It refers to the installation example chapters which contain instructions that depend
on the selected drive configuration.

Examining the installation site

The material below the drive must be non-flammable and strong enough to carry the
weight of the drive.
See section Ambient conditions (Page 197) for the allowed ambient conditions and
section Losses, cooling data and noise (Page 192) for the required cooling air.

Moving and unpacking

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

Move the transport package by pallet truck to the installation site.

To unpack the package:
• Cut the straps.
• Lift the lid.
• Lift the sleeve.
• Unpack the top boxes (drive module package).
• Insert lifting hooks to the drive and LCL filter module lifting lugs and lift the
modules to the installation place.
58 Mechanical installation

￭ Package drawings
Drive module package without option +E202

5 12

22
13
7

3
2
15
9

18

6
4
11

16
1

19 14

21
20
10

17
3AXD50000174287_20210204

Transport package contents

1 Finger guard
2 Pedestal guide plate for the LCL filter module
3 Pedestal guide plate for the drive module
4 Accessories box
See the box contents on the following pages.
5 Center of gravity symbol
6 Package for LCL filter fan
7 Package for LCL filter pedestal
8 Telescopic extraction/installation ramp
9 Package for option +H370: Full-size input power cable connection terminals and PE busbar.
10 Plywood support
11 With standard drive module configuration: Clear plastic shrouds box and output cable con-
nection terminals box.
With option +H370: Also input cable connection terminals box.
12 Lid for sleeve
13 Cardboard sleeve
14–16 Cardboard support
 Mechanical installation 59

17 Pallet
18 Strap
19 VCI film or bag
20 Drive module with factory installed options and multilingual residual voltage warning sticker,
fastening screws in a plastic bag, control panel and cable or control panel with door mounting
kit (option +J410), delivery documents, printed multilingual quick installation and start-up
guide.
21 External control unit
22 Edgeboard supports

Package with option +E202

5
13

14
23

6 2

3 10
10

16 7

19 12

10 4

17

22

15
1

11

21 20
18
3AXD50000174287_091117

Transport package contents

1 With standard drive module configuration: Clear plastic shrouds.
With option +H381: Input cabling panel parts.
See below for the box contents.
2 Pedestal guide plate for the LCL filter module
3 Pedestal guide plate for the drive module
4 Accessories box
See below for the box contents
5 Center of gravity symbol
6 Package for EMC filter ARFI-10 (option +E202)
7 Package for LCL filter fan
8 Package for LCL filter pedestal
60 Mechanical installation

9 Telescopic extraction and insertion ramp

10 Package for option H370: Full-size input power cable connection terminals and PE busbar.
11 Plywood support
12 With standard drive module configuration: Clear plastic shrouds box and output cable con-
nection terminals box.
With option +H370: Also Input cable connection terminals box.
13 Lid for sleeve
14 Cardboard sleeve
15–17 Cardboard support
18 Pallet
19 Strap
20 VCI film or bag
21 Drive module with factory installed options and multilingual residual voltage warning sticker,
fastening screws in a plastic bag, control panel and cable or control panel with door mounting
kit (option +J410), delivery documents, printed multilingual installation and start-up quick
guides. Other printed manuals with option +R700.
22 External control unit
23 Edgeboard supports

Boxes

Shroud box with standard drive module

3 configuration
1 Paper fill
2 Clear plastic shroud for output
cabling
3 Cardboard box cover
1
4 Cardboard box bottom
12 13 5 Support

7 6 Bands
9
7 Back clear plastic shroud (lower)
8
11 8 Back clear plastic shroud (upper)
10 9 Front clear plastic shroud
2
6 10 Clear plastic shroud for input
cabling
11 Top clear plastic shroud
12 Clear plastic shroud for input cable
entry from side
14 13 Screws in a plastic bag
14 Metallic shroud without ground bar
5
4 3AXD50000009484
 Mechanical installation 61

Option +H381 box: Input power cabling

panel parts
8
1 Screw package
2 Paper fill
3
2 3 Code label
4 Output power cabling panel
5 Input power cabling panel
5 6 Grounding busbar to be connected
to the input power cabling panel
and the drive module
7 Cardboard box bottom
9
8 Cardboard box cover
9 Rubber grommet
11
10 Strap
1
11 Support bracket

6
4

10

10
7 3AXD5000023536

Output connection terminals box with

3 1 standard drive module configuration
1 Paper fill
7 2 Output cable connection terminal
4 T3/W2
3 Output cable connection terminal
2 T2/V2
5
4 Output cable connection terminal
T1/U2
5 Grounding terminal
6 Cardboard box
7 Screws and insulators in a plastic
6 bag

3AXD5000009515
62 Mechanical installation

Option +H370: input cable connection

2 terminals box
1 Metallic shroud with ground bar
7 2 Paper fill

4 3 Input cable connection terminal

5
L3/W1
3 1
4 Input cable connection terminal
L2/V1
5 Input cable connection terminal
L1/U1
6 Cardboard box
6 7 Screws and insulators in a plastic
bag

3AXD5000009522

Ramp box
1 Cardboard box
2 1 2 Combi screws (4 pcs)
3 Ramp extension (50 to 150 mm)
4 Ramp up to 50 mm

3AXD50000476145
 Mechanical installation 63

Accessories box
1 Screw package

1
2 Busbar for main contactor - LCL
6
connection (3 pcs)
3 Busbar for IGBT - LCL connection (3
3
2 pcs)
4 Cardboard box
5 5 Installation bracket (2 pcs)
6 Feed-through (4 pcs)

3AXD50000477104

LCL filter module package

10

7
9

8
6

5 1
3AXD50000113651

1 VCI bag
2 Plywood support
3 Lid for cardboard sleeve
4 Cardboard sleeve
5 Cardboard support
6 Pallet
7 Strap
8 LCL filter module
9 Edgeboard supports
64 Mechanical installation

Examining the delivery

Make sure that all items listed in Moving and unpacking (Page 57) are present.
Make sure that there are no signs of damage. Before attempting installation and
operation, examine the information on the type designation label of the drive to verify
that the unit is of the correct type.

Lifting
Lift the drive module only by the lifting lugs.

Attaching the drive module and LCL filter module to a

mounting plate or wall
Attach the LCL filter module and the drive module to wall or a mounting plate at the
points shown below.

You can attach the modules to Rittal VX25 enclosure with the mounting brackets
delivered with the drive, see Step-by-step drawings for an installation example of
standard drive configuration in Rittal VX25 800 mm wide enclosure (Page 243).
 Mechanical installation 65

Attaching the drive module to the LCL filter module

See Step-by-step drawings for an installation example of standard drive configuration
in Rittal VX25 800 mm wide enclosure (Page 243).

Attaching the drive module and the LCL filter module to

the enclosure base
See Step-by-step drawings for an installation example of standard drive configuration
in Rittal VX25 800 mm wide enclosure (Page 243).

Grounding the drive module and the LCL filter module

Ground the drive module and the LCL filter module from the fastening points:

10

Installing the drive in Rittal VX25 enclosure

For an installation example on how to install the drive module into a Rittal VX25
enclosure, see Installation into a Rittal VX25 enclosure (Page 125) and Step-by-step
drawings for an installation example of standard drive configuration in Rittal VX25
800 mm wide enclosure (Page 243).
66 Mechanical installation

Optional input power cable connection terminals and

ground busbar assembly (+H370)
Install the metallic shroud with ground bar as shown below.

Combi screw M4×8

Torx T20 2 N·m

Connect the input power cable connection terminals as shown in Step-by-step drawings
for an installation example of standard drive configuration in Rittal VX25 800 mm wide
enclosure (Page 243).

Drive module without full-size output cable connection

terminals (option +0H371) and IP20 shrouds (option
+0B051)
The power cables can be connected directly to the drive module input and output
terminals with cable lugs or by busbars. The drive module can also be installed self
standing on the floor in an electrical equipment room when the power cable terminals
and electrical parts are protected against contact and the drive module is grounded
correctly.
 Guidelines for planning the electrical installation 67

6
Guidelines for planning the electrical
installation

Contents of this chapter

This chapter contains guidelines for planning the electrical installation of the drive.

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).

Selecting the main supply disconnecting device

You must equip the drive with a main supply disconnecting device which meets the
local safety regulations. You must be able to lock the disconnecting device to the open
position for installation and maintenance work.
68 Guidelines for planning the electrical installation

To comply with European Union directives and United Kingdom regulations related
to standard EN 60204-1, the disconnecting device must be one of these types:
• switch-disconnector of utilization category AC-23B (IEC 60947-3)
• disconnector that has an auxiliary contact that in all cases causes switching devices
to break the load circuit before the opening of the main contacts of the
disconnector (EN 60947-3)
• circuit-breaker suitable for isolation in accordance with IEC 60947-2.

Selecting the main contactor

You can equip the drive with a main contactor.
Follow these guidelines when you select a customer-defined main contactor:
• Dimension the contactor according to the nominal voltage and current of the
drive. Also consider the environmental conditions such as surrounding air
temperature.
• IEC installations: Select contactor with utilization category AC-1 (number of
operations under load) according to IEC 60947-4.
• Consider the application life time requirements.

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 69). For basics of protecting the motor insulation and bearings in drive
systems, see Protecting the motor insulation and bearings (Page 68).
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.
 Guidelines for planning the electrical installation 69

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.

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

See also Abbreviations (Page 72).

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.
70 Guidelines for planning the electrical installation

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

See also Abbreviations (Page 72).

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 71

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

See also Abbreviations (Page 72).

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.
72 Guidelines for planning the electrical installation

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

See also Abbreviations (Page 72).

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 73

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

Product type Availability of du/dt filter Availability of common mode fil-

ter (CMF)
ACS880-14 Ordered separately, see chapter Option +E208
Filters (Page 241)

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 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).
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.
74 Guidelines for planning the electrical installation

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 75

A B
3.0 5.5
ÛLL/Un 5.0
2.5 du/dt
-------------(1/ µs)
4.5 Un
2.0 4.0
3.5
1.5
3.0
ÛLL/Un
1.0 2.5
du/dt
-------------(1/ µs)
Un 2.0
0.5
1.5
0.0 1.0
100 200 300 100 200 300
l (m) l (m)

A Drive with du/dt filter

B Drive without du/dt filter
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 with resistor braking.

Additional note for sine filters

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

￭ 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 76).
Symmetrical shielded cable reduces electromagnetic emission of the whole drive
system as well as the stress on motor insulation, bearing currents and wear.
76 Guidelines for planning the electrical installation

Metal conduit reduces electromagnetic emission of the whole drive system.

￭ Typical power cable sizes

See the technical data.

￭ Power
„ cable types
Preferred power cable types
„
This section presents 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)

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 with phase conductor smaller Yes with phase conductor smaller
than 10 mm2 (8 AWG) Cu. than 10 mm2 (8 AWG) Cu, or mo-
PVC
tors up to 30 kW (40 hp).
Note: Shielded or armored cable,
Four-conductor cabling in PVC or cabling in metal conduit is al-
conduit or jacket (three phase ways recommended to minimize
conductors and PE) radio frequency interference.

„
 Guidelines for planning the electrical installation 77

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-
EMT tors up to 30 kW (40 hp)

Four-conductor cabling in metal

conduit (three phase conductors
and PE). For example, EMT, or
four-conductor armored cable
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-
L1 L2 L3
conductive outer sheath
L2 L3 L3 L1 L1 L2 (jacket) of the cables have
Preferable cable arrangement to good contact with a prop-
avoid voltage or current unbal- erly grounded conductive
ance between the phases surface. For example, install
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.

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
78 Guidelines for planning the electrical installation

￭ Additional guidelines – North America

ABB recommends the use of metallic conduit for power wiring. ABB also recommends
the use of symmetrical shielded VFD cable between drive and motor(s).
This table shows examples of methods for wiring the drive. Refer to NFPA 70 (NEC)
along with state and local codes for the appropriate methods for your application.

Wiring method Notes

Conduit - Metallic 1) 2)
Electrical metallic tubing: Type EMT Prefer symmetrical shielded VFD cable.
Rigid metal conduit: Type RMC Use separate conduit run for each motor.
Liquid-tight flexible metal electrical conduit: Type Do not run input power wiring and motor wiring in
LFMC the same conduit.

Conduit - Non-metallic 2) 3)
Prefer symmetrical shielded VFD cable.
Use separate conduit run for each motor.
Liquid-tight flexible non-metallic conduit: Type LFNC
Do not run input power wiring and motor wiring in
the same conduit.
Wireways 2)
Prefer symmetrical shielded VFD cable.
Separate motor wiring from input power wiring and
other low voltage wiring.
Metallic
Do not run outputs of multiple drives parallel. Bundle
each cable (wiring) together and use separators
where possible.
Free air 2)
Prefer symmetrical shielded VFD cable.
Enclosures, air handlers, etc. Allowed internally in enclosures when in accordance
with UL.

1) Metallic conduit may be used as an additional ground path, provided this path is a solid path capable of handling
ground currents.
2) See NFPA NFPA 70 (NEC), UL, and local codes for your application.
3) Non-metallic conduit use underground is allowed; however, these installations inherently have an increased chance
for nuisance problems due to the potential for water/moisture in the conduit. Water/moisture in the conduit
increases the likelihood of VFD faults or warnings. Proper installation is required to make sure there is no intrusion
of water/moisture.

Metal conduit
Couple separate parts of a metal conduit together: bridge the joints with a ground
conductor bonded to the conduit on each side of the joint. Also bond the conduits to
the drive enclosure and motor frame. Use separate conduits for input power, motor,
brake resistor, and control wiring. Do not run motor wiring from more than one drive
in the same conduit.

￭ 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
 „

Guidelines for planning the electrical installation 79

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.
This 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
conductor(s) and the protective earth conductor are made of the same metal. If this
is not so, 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.

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,
80 Guidelines for planning the electrical installation

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 grounding conductors only when their
conductivity is sufficient.

￭ 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.
 Guidelines for planning the electrical installation 81

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 RJ-45 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).

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.
82 Guidelines for planning the electrical installation

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)

￭ General guidelines – North America

Make sure that the installation is in accordance with national and local codes. Obey
these general guidelines:
• Use separate conduits for the input power, motor, brake resistor (optional), and
control cabling.
• Use separate conduit for each motor cabling.
The following figure illustrates the cable routing guidelines with an example drive.
 Guidelines for planning the electrical installation 83

1 1 1

3 3 3
1

2
2 3
2
2

3
3

1 Input power cabling

2 Motor cabling
3 Conduit

￭ Continuous motor cable shield/conduit or 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.

￭ 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)
84 Guidelines for planning the electrical installation

Implementing motor and motor cable short-circuit and

thermal overload protection
￭ 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.

￭ Protecting the motor cables against thermal overload

The drive protects the motor cables against thermal overload when the cables are
sized according to the nominal output current of the drive. No additional thermal
protection devices are needed.

WARNING!
If the drive is connected to multiple motors, use a separate overload protection
for each motor cable and motor. The drive overload protection is tuned for the
total motor load. It may not detect an overload in one motor circuit only.
North America: The local code (NEC) requires an overload protection and a
short-circuit protection for each motor circuit. Use, for example:
• manual motor protector
• circuit breaker, contactor and overload relay or
• fuses, contactor and overload relay.

￭ 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.
 Guidelines for planning the electrical installation 85

￭ 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 and the input power cable in

short-circuits
Protect the drive (1) with fuses (a) and the input cable with fuses (b) or a circuit breaker.

~
b a
M
3~
~

Select the fuses or the circuit breaker according to local regulations for the input cable
protection. Select the fuses for the drive according to the instructions given in the
technical data. The fuses for the drive protection will restrict drive damage and prevent
damage to adjoining equipment in case of a short-circuit inside the drive.

Note: Circuit breakers must not be used without fuses.

WARNING!
Due to the inherent operating principle and construction of circuit breakers,
independent of the manufacturer, hot ionized gases can escape from the
breaker enclosure in case of a short-circuit. To ensure safe use, pay special
attention to the installation and placement of the breakers. Obey the
manufacturer’s instructions.

Protecting the drive against thermal overload

The drive has overload protection as standard.
86 Guidelines for planning the electrical installation

Protecting the input power cable against thermal overload

The drive has overload protection as standard. If the sizing of the input power cable
is correct, the drive overload protection protects also the cable against overload. In
case of parallel input power cables, it may be necessary to protect each cable
separately. Obey the local regulations.

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. See Connecting
a motor temperature sensor to the drive through an option module (Page 86).
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
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.
 Guidelines for planning the electrical installation 87

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.

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 rated).

For more information, refer to the applicable option module user's 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.

￭ Residual current device compatibility

The drive is suitable for use with residual current devices of Type B.
88 Guidelines for planning the electrical installation

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

For safety reasons, install the emergency stop devices at each operator control station
and at other operating stations where the emergency stop may be needed. Implement
the emergency stop according to relevant standards.

Note: You can use the Safe torque off function of the drive to implement the Emergency
stop function.

Implementing the Safe torque off function

See The Safe torque off function (Page 221).

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 you equip the drive with a main contactor or breaker, make sure that it restores the
drive input power after a short break. The contactor must either re-connect after the
break automatically, or remain closed over the break. Depending on the contactor
control circuit design, this can require an additional hold circuit, uninterruptible auxiliary
power supply or auxiliary power supply buffering.

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. If the installation is equipped with a main contactor, prevent its tripping at the
input power break. For example, use a time delay relay (hold) in the contactor
control circuit.
3. 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 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
 Guidelines for planning the electrical installation 89

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
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

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.
90 Guidelines for planning the electrical installation

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 more information, see:

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

Controlling a contactor between drive and motor

The control of the output contactor depends on how you use the drive, that is, which
motor control mode and which motor stop mode you select.
If you have the DTC motor control mode and the motor ramp stop mode selected, 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.
If you have the DTC motor control mode and the motor coast stop, or scalar control
mode selected, open the contactor as follows:
1. Give a stop command to the drive.
2. Open the contactor.

WARNING!
When the DTC motor control mode is in use, never open the output contactor
while the drive controls the motor. The DTC motor control operates extremely
fast, much faster than it takes for the contactor to open its contacts. When
the contactor starts opening while the drive controls the motor, the DTC control
will try to maintain the load current by immediately increasing the drive output
voltage to the maximum. This will damage, or even burn, the contactor
completely.

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
 Guidelines for planning the electrical installation 91

installation must be clearly marked as defined in IEC/EN/UL 61800-5-1, subclause

6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”.

WARNING!
Never connect the drive output to the electrical power network. The connection
may damage the drive.

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.

230 V AC

1
2

230 V AC

+ 24 V DC

1 Relay output
2 Varistor
3 RC filter
4 Diode
92
 Electrical installation 93

7
Electrical installation

Contents of this chapter

This chapter gives instructions on the wiring of the drive.

Safety
WARNING! 11
If you are not a qualified electrical professional, do not do installation or
maintenance work. Obey the safety instructions of the drive. If you ignore them,
injury or death, or damage to the equipment can occur.

Grounding the motor cable shield at the motor end

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

Measuring the insulation

￭ Measuring the insulation resistance of the drive

WARNING!
Do not do any voltage withstand or insulation resistance tests on any part of
the drive as testing can damage the drive. Every drive has been 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 input power cable

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

￭ 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 19) 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
[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

Grounding system compatibility check

The standard drive with ground-to-phase varistors connected can be installed to a
symmetrically grounded TN-S system. If you install the drive to another system, you
may need to disconnect the EMC filter and ground-to-phase varistors. See ACS880
frames R1 to R11 EMC filter and ground-to-phase varistor disconnecting instructions
(3AUA0000125152 [English]).
 Electrical installation 95

￭ EMC filter options +E200 and +E202

WARNING!
Do not install the drive with EMC filter +E200 or option +E202 connected to a
system that the filter is not suitable for. This can cause danger, or damage the
drive.

Note: When EMC filter +E200 or +E202 is disconnected, the drive EMC compatibility
is considerably reduced.

￭ Ground-to-phase varistor
A drive with the ground-to-phase varistor connected can be installed to a symmetrically
grounded TN-S system. If you install the drive to another system, you may need to
disconnect the varistor. See ACS880 frames R1 to R11 EMC filter and ground-to-phase
varistor disconnecting instructions (3AUA0000125152 [English]).

WARNING!
Do not install the drive with the ground-to-phase varistor connected to a system
that the varistor is not suitable for. If you do, the varistor circuit can be
damaged.

Installing the EMC filter (option +E202)

See ARFI-10 EMC filter installation guide (3AFE 68317941 [English).

Connecting the power cables

WARNING!
11
Obey the safety instructions of the drive. If you ignore them, injury or
death, or damage to the equipment can occur.
96 Electrical installation

￭ Power cable connection diagram

(PE) PE (PE) L1 L2 L3

2a 2b

L1 L2 L3
PE
1

ACS880-14
L1/ L2/ L3/
UDC- UDC+
U1 V1 W1
INPUT
PE
OUTPUT
T1/ T2/ T3/
U2 V2 W2
9
6

V1
U1 W1
5
3 ~
M

1 For alternatives, see Guidelines for planning the electrical installation (Page 67). In the installing
example of this chapter, the disconnecting device is not in the same cubicle with the drive
module.
2 If a shielded cable is used (not required but recommended) and the conductivity of the shield
is < 50% of the conductivity of the phase conductor, use a separate PE cable (2a) or a cable
with a grounding conductor (2b)
3 ABB recommends 360° grounding at the cabinet entry if a shielded cable is used. Ground the
other end of the input cable shield or PE conductor at the distribution board.
4 ABB recommends 360° grounding at the cabinet entry
 Electrical installation 97

5 Use a separate grounding cable if the conductivity of the cable shield is < 50% of the conduct-
ivity of the phase conductor and there is no symmetrically constructed grounding conductor
in the cable (see Guidelines for planning the electrical installation (Page 67))
6 Common mode filter (option)
7 du/dt filter (option)
8 EMC filter (option +E202)
9 The drive module frame must be connected to the cabinet frame. See Drive modules cabinet
design and construction instructions (3AUA0000107668 [English]) and section Grounding
the drive module and the LCL filter module (Page 65).

Note: If there is a symmetrically constructed grounding conductor in the motor cable in addition to the
conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor
ends.
Do not use an asymmetrically constructed motor cable. Connecting its fourth conductor at the motor
end increases bearing currents and causes extra wear.

￭ Preparing the cable ends and making 360° grounding at the cable
entry
1. Peel off 3…5 cm (1 1/4 … 2 in) of the outer insulation of the cables at the cable
entries with the conductive sleeves for the 360° high-frequency grounding.

11

2. Prepare the ends of the cables.

PE PE
98 Electrical installation

3. Put the cables through the entry plate. If the entry holes have rubber grommets,
use one grommet for each cable. Cut adequate hole into the grommet and put
the cable through the grommet inside the cabinet.
4. Attach the conductive sleeves to the cable shields with cable ties. Tie up the unused
conductive sleeves with cable ties. An example of bottom entry is shown below.
For top entry, put the grommet upwards.

￭ Power 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. Run the motor cables from the motor to the cabinet. Ground the cable shields
360° at the entry plate.
2. Twist the cable shields of the motor cables into bundles and connect them and
any separate ground conductors or cables to the ground terminal of the drive
module or to the cabinet ground bar.
3. Connect the phase conductors of the motor cables to terminals T1/U2, T2/V2 and
T3/W2 of the drive module. For the tightening torques, see the technical data.
4. Make sure that all power is disconnected and reconnection is not possible. Use
correct safe disconnect procedures according to local codes.
5. Run the input cables from the supply source to the cabinet. Ground the cable
shields 360° at the entry plate.
6. Twist the cable shields of the input cables into bundles and connect them and
any separate ground conductors or cables to the drive module ground terminal
or to the cabinet PE busbar.
7. Connect the phase conductors of the input cables to terminals L1/U1, L2/V1 and
L3/W1 of the drive module. For the tightening torques, see the technical data.
 Electrical installation 99

Removing the control panel holder from the external

control unit
1. Disconnect the control panel cable from connector X13 on the control unit.
2. Loosen the mounting screws of the control panel holder and take the holder off.

2
2

2 X13

1
2 X13

Attaching the control cable clamp plate

Attach the control cable clamp plate either to the top or base of the control unit with
four screws as shown below. 11

Note: If you install the FSO-xx safety functions module above the control unit, attach
the control cable clamp plate on the base of the control unit.

0.7 N·m
(6.2 lbf·in)
100 Electrical installation

Connecting the external control unit to the drive module

￭ External control unit connection cables
The cables that are delivered with the drive module for connecting the drive module
and control panel to the external control unit are shown below.

1 2

ZBIB
INU STO
STO1 X7
BGDR
STO2 X8

2600 mm (102.4 in)

QOIA
V2 V2
BINT
V1 V7
V21 V8
V20 V13
2600 mm (102.4 in)

X3 X2 BPOW
24VDC
2600 mm (102.4 in)

1 ZCU control unit

2 Drive module

WARNING!
Handle the fiber optic cables with care. When you unplug the cables, always
grab the connector, not the cable itself. Do not touch the ends of the fibers
with bare hands as the ends are extremely sensitive to dirt.

￭ Routing the external control unit cables into the drive module
Route the control unit connection cables to the drive module through the slot in the
middle front cover at the front or left side. First, remove the plate which covers the
slot. Then, install the rubber grommet (item 2) from the accessories box.

￭ Connecting control cables to the drive module

1. Connect power supply cable to terminal X2.
2. Connect the STO cable to the INU STO connector.
3. Connect the fiber optic cables to the QOIA V8, V13, V2 and V7 connectors.
 Electrical installation 101

QOIA ZBIB
X7 (STO1)
INU STO
X8 (STO2)
X2 X3
V2 V2
V7 V1
V8 V21
I
SUpanel
Cat
5cabl
e V13 V22

Note: ISU ext. 24VDC connector is for supplying external 24 V DC to the line-side converter control unit
if needed. ISU panel connector is for connecting the control panel to the line-side converter control unit
if needed.

￭ Connecting control cables to the control unit 11

1. Pull the fiber optic, power supply and STO cables through the hollow back frame
of the control unit.
2. Connect the cables to the ZBIB terminals.
102 Electrical installation

QOIA ZBIB
X7 (STO1)
1 INU STO
X8 (STO2)
X2 X3
2
V2 V2
V7 V1
V8 V21
V13 V22

ISU ZBIB INU ZBIB

V20 V21 V1 V2

Attaching the external control unit

The drive control unit can be attached on a mounting plate or onto a DIN rail.
 Electrical installation 103

￭ Attaching the external control unit to a mounting plate or wall

The external control unit and its mounting template are delivered in a cardboard box
inside the drive module package. The mounting template contains a mounting pattern
for two different control units, one on each side. Make sure to use the ZCU-14 control
unit mounting pattern.
1. Mark the positions of the fastening screws to the wall through the mounting
template.
2. Attach the screws.
3. Lift the control unit onto the screws and tighten the screws.

1
2

11

3AUA0000130997

￭ Attaching the external control unit vertically on a DIN rail

1. Attach the latch (A) to the back of the control unit with three screws.
2. Click the control unit to the rail as shown below (B).
104 Electrical installation

B
A

3AUA0000130997

￭ Attaching the external control unit horizontally on a DIN rail

1. Attach the latches (A) to the back of the control unit with three screws.
2. Click the control unit to the rail as shown below (B).

A
B
A

3AUA0000130997

Connecting the control cables to the terminals of the

external control unit
1. Route the cables to the control unit as shown below.
 Electrical installation 105

2. Ground the shields of the control cables at the clamp plate. Use torque 1.5 N·m
(13 lbf·in). The shields should be continuous as close to the terminals of the control
unit as possible. Only remove the outer jacket of the cable at the cable clamp so
11
that the clamp presses on the bare shield. The shield (especially in case of multiple
shields) can also be terminated with a lug and fastened with a screw at the clamp
plate. Leave the other end of the shield unconnected or ground it indirectly via a
few nanofarads high-frequency capacitor 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. Tighten the screws to secure
the connection.
3. Connect the conductors to the appropriate detachable terminals of the control
unit. See the Default I/O diagram of the drive control unit (ZCU-1x) (Page 117). Use
shrink tubing or insulating tape to contain any strain strands.

Note: 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. Keep the shields continuous as close to the terminals of the control unit
as possible.

Connecting a control panel

With control panel door mounting platform, connect the control panel as follows:
1. Connect an Ethernet cable to the RJ-45 connector of the control panel.
2. Connect the other end of the cable to the X13 connector of the control unit.
106 Electrical installation

Note: When a PC is connected to the control panel, the control panel keypad is disabled.
In this case, the control panel acts as a USB-RS485 adapter.

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).
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.
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 an FDPI-02 module, move termination switch S2 into the TERMINATED
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.
 Electrical installation 107

With twin connectors in the control panel holder:

1 2 3

11
108 Electrical installation

With FDPI-02 modules:

1 ED
AT
IN
RM
TE N
E
OP

2 2

ED
AT
IN
RM
TE EN
OP
 Electrical installation 109

With FDPI-02 module ACS880-14 and ACS880-34:

3
ED
AT
IN
RM
TE EN
OP

2
ISU
panel

￭ Panel bus wiring with FDPI-02 – single drive

11
FDPI-02
X1 X2 X3

1 2

X202 X204 X203

ZDPI-01

X1-1 FDPI-02 diagnostics and panel interface installed onto the motor-side converter control unit

X2-X204 X2: Daisy chain bus terminal 1, RJ-45 shielded female connector for connecting a control
panel
110 Electrical installation

X3-2 X3: Daisy chain bus terminal 2, RJ-45 shielded female connector for connecting to the line-
side converter control unit RJ-45 connector (X13, CONTROL PANEL)

￭ Panel bus wiring with FDPI-02 and ZDPI-01 – several drives

FDPI-02
X1 X2 X3

4 3 1 2

X202 X204 X203 X202 X204 X203 X202 X204 X203 X202 X204 X203
ZDPI-01 ZDPI-01 ZDPI-01 ZDPI-01

X1-1 FDPI-02 diagnostics and panel interface installed onto the motor-side converter control unit

X2-X204 X2: Daisy chain bus terminal 1, RJ-45 shielded female connector for connecting a control
panel

X3-2 X3: Daisy chain bus terminal 2, RJ-45 shielded female connector for connecting to the line-
side converter control unit RJ-45 connector (X13, CONTROL PANEL)

3 Drive 2

4 Drive 3
 Electrical installation 111

￭ Panel bus wiring with FDPI-02 – several drives

FDPI-02 FDPI-02 FDPI-02

X1 X2 X3 X1 X2 X3 X1 X2 X3

4 3 1 2

X202 X204 X203

ZDPI-01

X1-1 FDPI-02 diagnostics and panel interface installed onto the motor-side converter control unit

X2-X204 X2: Daisy chain bus terminal 1, RJ-45 shielded female connector for connecting a control
panel

X3-2 X3: Daisy chain bus terminal 2, RJ-45 shielded female connector for connecting to the line-
side converter control unit RJ-45 connector (X13, CONTROL PANEL)

3 Drive 2 11
4 Drive 3

Connecting a PC
WARNING!
Do not connect the PC directly to the control panel connector of the control
unit as this 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. See the documentation of the PC tool for setup instructions.
112 Electrical installation

USB connected 4
2
?

Stop Loc/Rem Start

Stop Loc/Rem Start

2 3a 3b

Installing option modules

￭ Installing the FSO-xx safety functions module
Install the FSO safety functions module in Slot 2 of the control unit as described below.

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 19)
before you start the work.
2. If the bottom plate of the FSO-xx module looks different from that in the drawing
below, remove the bottom plate and attach the alternative bottom plate from the
FSO package to module.
3. Connect the FSO-xx data cable to connector X12 on the control unit.
4. Attach the FSO-xx module to Slot 2 with four screws.
5. Tighten the FSO module electronics grounding screw to 0.8 N·m. Note: The screw
tightens the connections and grounds the module. It is essential for fulfilling the
EMC requirements and for proper operation of the module.
6. Connect the FSO-xx data cable to FSO-xx connector X110.
7. Connect the Safe torque off four-wire cable to connector X111 on the module and
to connector XSTO on the drive module control unit.
 Electrical installation 113

8. Connect the external +24 V power supply cable to connector X112.

9. Connect the other wires as shown in FSO-12 safety functions module user’s manual
(3AXD50000015612 [English]) or FSO-21 safety functions module user’s manual
(3AXD50000015614 [English]).

3 6

11
￭ Installing I/O extension, fieldbus adapter and pulse encoder interface
modules
See Overview of power and control connections for the available slots for each module.

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 19)
before you start the work.
2. Insert the module carefully into its position on the control unit.
3. Tighten the grounding screw torque of 0.8 N·m.
Note: The screw tightens the connections and grounds the module. It is essential
for fulfilling the EMC requirements and for correct operation of the module.
114 Electrical installation

￭ Wiring the option modules

See the appropriate option module manual for specific installation and wiring
instructions.
 External control unit 115

8
External control unit

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).

Unpacking the delivery

The external control unit is delivered in a cardboard box inside the main drive module
package.
Unpack the external control unit package. Make sure that it contains these items:
• ZCU-14 control unit
• mounting template.
The mounting template contains a mounting pattern for a ZCU-14 control unit on one
side and a mounting pattern for a CCU-24 control unit on the other side.
116 External control unit

ZCU-14 layout
Description
XPOW External power input
XAI Analog inputs
XRO1 XAO Analog outputs
XD2D Drive-to-drive link

XRO2 XRO1 Relay output RO1

XRO2 Relay output RO2
XRO3 Relay output RO3
XRO3
XD24 Digital input interlock (DIIL) and +24 V
output
XPOW XDIO Digital input/outputs
AI1, AI2 XDI Digital inputs
XSTO Safe torque off connection (inverter unit
only).
XAI
Note: This connection only acts as a true
Safe torque off input when the ZCU is
controlling an inverter unit. When the ZCU
is controlling a supply unit, de-energizing
XAO the inputs will stop the unit but will not
X12 constitute a true safety function.
J3 X12 Connection for FSO-xx safety functions
module (inverter unit only).
XD2D
X13 Control panel connection
X202 Option slot 1
X203 Option slot 2
XSTO
X204 Option slot 3
X205 Memory unit connection (memory unit
inserted in the drawing)
XDI
AI1, AI2 Voltage/Current selection jumpers (AI1,
AI2) for analog inputs

XDIO J3 Drive-to-drive link termination switch (J3)

J6 J6 Common digital input ground selection
jumper (J6).
XD24

X13 X205
 External control unit 117

Default I/O diagram of the drive control unit (ZCU-1x)

Connection Term Description
XPOW External power input
+24VI

1 +24VI GND 24 V DC, 2 A min. (without optional modules)

2 GND

XAI Reference voltage and analog inputs

+VREF 10 V DC, RL 1…10 kohm
1 +VREF
2 -VREF -VREF -10 V DC, RL 1…10 kohm
3 AGND AGND Ground
4 AI1+
AI1+ Speed reference
5 AI1-
6 AI2+ AI1- 0(2)…10 V, Rin > 200 kohm 1)
7 AI2- AI2+ By default not in use.
AI2:I AI1:I
AI2- 0(4)…20 mA, Rin = 100 ohm1)
AI2:U AI1:U
J1 Current (I) / voltage (U) selection jumper for AI1
J2 Current (I) / voltage (U) selection jumper for AI2
XAO Analog outputs
AO1 Motor speed rpm
1 AO1
AGND 0…20 mA, RL < 500 ohm
2 AGND
3 AO2 AO2 Motor current
4 AGND 0…20 mA, RL < 500 ohm
AGND

XD2D Drive-to-drive link

B Master/follower, drive-to-drive or embedded
1 B
A fieldbus connection 2)
2 A
3 BGND BGND
4 Shield
Shield
2)
J3 Drive-to-drive link termination
XRO1, XRO2, XRO3 Relay outputs
NC Ready run
1 NC
COM 250 V AC / 30 V DC
2 COM
3 NO
2A
NO
1 NC
NC Running
2 COM
COM 250 V AC / 30 V DC
3 NO
Fault 2A
1 NC NO
2 COM
NC Fault (-1)
3 NO
COM 250 V AC / 30 V DC
2 +24VD
XD24

2A
5 DIOGND NO
118 External control unit

Connection Term Description

XD24 Auxiliary voltage output, digital interlock 3)

3)
DIIL Run enable
1 DIIL
2 +24VD +24VD +24 V DC 200 mA 4)
3 DICOM
DICOM Digital input ground
4 +24VD
4)
5 DIOGND +24VD +24 V DC 200 mA
DIOGND Digital input/output ground
XDIO Digital input/outputs
DIO1 Output: Ready run
1 DIO1
2 DIO2 DIO2 Output: Running
J6 Ground selection 5)
XDI Digital inputs
DI1 Stop (0) / Start (1)
2 +24VD
XD24

DI2 Forward (0) / Reverse (1)

5 DIOGND
DI3 Reset
1 DI1 DI4 Acc/Dec time select 6)
2 DI2
DI5 Constant speed 1 (1 = On) 7)
3 DI3
4 DI4 DI6 By default, not in use.

5 DI5
6 DI6

OUT Safe torque off circuits must be closed for the

1 OUT drive to start. 8)
SGND
SGND
2
3 IN1 IN1
4 IN2
IN2
X12 Safety options connection
X13 Control panel connection
X205 Memory unit connection

1) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected by jumper. Change of
setting requires reboot of control unit.
2) See section The XD2D connector (Page 119)
3) See section DIIL input (Page 119).
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) Determines whether DICOM is separated from DIOGND (ie. common reference for digital inputs floats; in practice,
selects whether the digital inputs are used in current sinking or sourcing mode). See also ZCU-1x ground isolation
diagram (Page 123). DICOM=DIOGND ON: DICOM connected to DIOGND. OFF: DICOM and DIOGND separate.
6) 0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use. 1 = Acceleration/deceleration ramps
defined by parameters 23.14/23.15 in use.
7) Constant speed 1 is defined by parameter 22.26.
8) See chapter The Safe torque off function (Page 221).

The wire size accepted by all screw connectors (for both stranded and solid wire) is
0.5 … 2.5 mm2 (24…12 AWG). The torque is 0.5 N·m (5 lbf·in).
 External control unit 119

Additional information on the connections

￭ Connecting motor temperature sensors to the drive
IEC/EN 60664 requires double or reinforced insulation between the control unit and
the live parts of the motor. To achieve this, use an FPTC-01 or FPTC-02 protection
module or an FAIO-01 extension module. See Implementing a motor temperature
sensor connection (Page 86) and the module manuals.

￭ External power supply for the control unit (XPOW)

The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW.
Using an external supply is recommended, if:
• the control unit needs to be kept operational during input power breaks, for
example, because of continuous fieldbus communication
• immediate restart is needed after a power break (that is, no control unit power-up
delay is allowed).

￭ DIIL input
The DIIL input is used for the connection of safety circuits. The input is parametrized
to stop the unit when the input signal is lost.

Note: This input is not SIL or PL certified.

￭ 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 of the drive for the related parameter settings.
Enable bus termination on the units at the ends of the drive-to-drive link. Disable bus
termination on the intermediate units.
Use a high-quality shielded twisted-pair cable for the wiring, fro exmple, Belden 9842.
The nominal impedance of the cable should be 100…165 ohm. You can use one pair
for the data wiring and another pair or a wire for the grounding. Avoid unnecessary
loops and parallel runs near power cables.
The following diagram shows the wiring between control units.
120 External control unit

ZCU-14
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)

See chapter The Safe torque off function (Page 221).

Note: The XSTO input only acts as a true Safe torque off input on the inverter control
unit. De-energizing the IN1 and/or IN2 terminals of other units (supply, DC/DC
converter, or brake unit) will stop the unit but not constitute a true safety function.

￭ FSO safety functions module connection (X12)

Refer to the applicable FSO module user's manual.

Connector data
Power supply (XPOW) Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
24 V (±10%) DC, 2 A
External power input.
Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
(XRO1…XRO3) 250 V AC / 30 V DC, 2 A
Protected by varistors
+24 V output (XD24:2 and XD24:4) Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
Total load capacity of these outputs is 4.8 W (200 mA / 24 V)
minus the power taken by DIO1 and DIO2.
Digital inputs DI1…DI6 Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
(XDI:1…XDI:6) 24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP (DI1…DI5), PNP (DI6)
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
DI6 (XDI:6) can alternatively be used as an input for a PTC sensor.
"0" > 4 kohm, "1" < 1.5 kohm.
Imax: 15 mA (DI1…DI5), 5 mA (DI6)
Start interlock input DIIL (XD24:1) Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
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
 External control unit 121

Digital inputs/outputs DIO1 and DIO2 Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
(XDIO:1 and XDIO:2) As inputs: 24 V logic levels: "0" < 5 V, "1" > 15 V. Rin: 2.0 kohm.
Input/output mode selection by Filtering: 1 ms.
parameters. As outputs: Total output current from +24VD is limited to 200
DIO1 can be configured as a frequency mA
input (0…16 kHz with hardware
+24VD
filtering of 4 microseconds) for 24 V
level square wave signal (sinusoidal or
other wave form cannot be used). DIO2
can be configured as a 24 V level square
wave frequency output. See the DIOx
firmware manual, parameter group
111/11. RL

DIOGND

Reference voltage for analog inputs Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
+VREF and -VREF (XAI:1 and XAI:2) 10 V ±1% and -10 V ±1%, Rload 1…10 kohm
Maximum output current: 10 mA
Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
(XAI:4 … XAI:7). Current input: -20…20 mA, Rin = 100 ohm
Current/voltage input mode selection Voltage input: -10…10 V, R > 200 kohm
in
by jumpers
Differential inputs, common mode range ±30 V
Sampling interval per channel: 0.25 ms
Hardware filtering: 0.25 ms, adjustable digital filtering up to 8
ms
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
Analog outputs AO1 and AO2 (XAO) Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
0…20 mA, Rload < 500 ohm
Frequency range: 0…300 Hz
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
XD2D connector Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
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 jumper
RS-485 connection (X485) Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
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)
122 External control unit

Safe torque off connection (XSTO) Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
Input voltage range: -3…30 V DC
Logic levels: "0" < 5 V, "1" > 17 V.

Note: For the unit to start, both connections must be “1”. This
applies to all control units (including drive, inverter, supply, brake,
DC/DC converter etc. control units), but true 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
EMC (immunity) according to IEC 61326-3-1 and IEC 61800-5-2
Safe torque off output (XSTO OUT ) Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
To STO connector of inverter module.
Control panel connection (X13) Connector: RJ-45
Cable length < 100 m (328 ft)
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.
 External control unit 123

￭ ZCU-1x ground isolation diagram

XPOW
+24VI 1
GND 2
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5 Common mode voltage between
AI2+ 6 channels ±30 V
AI2- 7
XAO
AO1 1
AGND 2
AO2 3
AGND 4
XD2D
B 1
A 2
BGND 3
XRO1, XRO2, XRO3
NC 11
COM 12
NO 13
NC 21
COM 22
NO 23
NC 31
COM 32
NO 33
XD24
DIIL 1
+24VD 2
DICOM 3
+24VD 4
DIOGND 5
XDIO
DIO1 1
DIO2 2
XDI
DI1 1 *
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
XSTO
OUT1 1
GND 2
IN1 3
IN2 4

* Ground selector (J6) settings

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

Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from DIO signal ground (DIOGND).
Isolation voltage 50 V.
124
 Installation into a Rittal VX25 enclosure 125

9
Installation into a Rittal VX25 enclosure

Contents of this chapter

This chapter gives an installation example of the standard drive module configuration
in a 800 mm wide Rittal VX25 enclosure with Rittal parts, alternative ABB parts and
needed customer-made parts. For control cable installation, see chapter Electrical
installation (Page 93).
For instructions on how to install the drive module in a 800 mm wide Rittal TS 8
enclosure, see revision B of this manual.
This chapter also includes references on how to install the drive module with
ready-made ABB installation kits into a Rittal VX25 enclosure.

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).
126 Installation into a Rittal VX25 enclosure

Installation into a Rittal VX25 enclosure with ready-made

ABB installation kits
A supplement to this manual, ACH580-34, ACQ580-34, ACS880-14 and ACS880-34
drive modules installation in Rittal VX25 enclosure supplement (3AXD50000815838
[English]), gives instructions on how to install the drive module and additional
equipment into a Rittal VX25 400 mm + 800 mm wide enclosure. The installation uses
ready-made ABB installation kits. The supplement contains dimension drawings,
ordering codes and an example set of circuit diagrams. The kits include their installation
drawings.
ACH580-34, ACQ580-34, ACS880-14 and ACS880-34 drive modules installation in Rittal
VX25 enclosure animation (3AXD50000883707 [English]) shows an example installation
in detail.

Safety
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.
 Installation into a Rittal VX25 enclosure 127

Necessary parts
Drive module standard parts

• Drive module and LCL filter module

• Fastening brackets (2 pcs)
• Pedestal guide plates (2 pcs)
• Telescopic extraction/installation ramp
• Fastening screws and insulators in a plastic bag
• External control unit
Rittal parts / Alternative ABB parts
Rittal part code Qty (pcs) Description
8806.000 1 Enclosure without bottom plates and side panels. Includes
supports for installing air baffles.
7967.000 1 Spacers for roof plates / ABB roof
(one set = four pieces)
8100.743 1 Punched section with mounting flange, inner mounting level
for 800 mm horizontal
Contact ABB for the suitable 4 Air filter. Remove the filter mats.
filter
Alternative ABB parts for Rittal parts
ABB air inlet kit 800 mm 2 See section Air inlet kits (Page 172)
3AUA0000117005 (IP20)
3AUA0000117009 (IP42)
ABB air outlet kit 800 mm 2 See section Air outlet kits (Page 174)
3AUA0000125203 (IP20 )
3AUA0000114968 (IP42)
Customer-made parts (not ABB or Rittal products)
Air baffles 4 See section Air baffles (Page 215)
Bottom plate 1 See section Bottom plate (Page 214)

Necessary tools
• Set of screw drivers (Torx and Pozidriv)
• Set of metric magnetic-end hexagon sockets
• Torque wrench
• Step drill bit for drilling the holes in the clear plastic shroud for input power cables

Overall flowchart of the installation process

Step Task For instructions, see

1 Install the Rittal parts, drive bottom guide Installing the drive module and LCL filter
plate and loose drive options in the drive module into an enclosure (Page 128)
module cubicle

2 Install the auxiliary components (such as The component manufacturer’s instructions

mounting plates, switches, busbars etc.) Preventing the recirculation of hot
air (Page 52)
128 Installation into a Rittal VX25 enclosure

Step Task For instructions, see

3 Attach the drive module and LCL filter module Installing the drive module and LCL filter
into the enclosure module into an enclosure (Page 128)

4 Connect the power cables and clear plastic Connecting the motor cables and installing
shrouds to the drive module. the shrouds (Page 129)
Connect the power supply cable to the LCL Connecting the input cables and installing the
filter cooling fan. shrouds (Page 130)
Connecting the power cables (Page 95)

5 Install the air baffles Installing the air baffles (Page 132)

6 Install the external control unit Attaching the external control unit (Page 102)

7 Connect the control cables Connecting the control cables to the terminals
of the external control unit (Page 104)

8 Install the remaining parts, for example, air The component manufacturer’s instructions
baffles, cabinet doors, side plates, etc.

Installing the drive module and LCL filter module into an

enclosure
See Installing the drive module and LCL filter module into a Rittal VX25
enclosure (Page 244).

Step Tasks
Mechanical accessories
1 Attach the plinth to the floor.
2 Attach the enclosure frame to the plinth.
3 Make the bottom plate with 360-degree grounding entries for power cables. Attach the bottom
plate to the enclosure frame.
4 Attach the punched section to the back of enclosure frame.
5 Attach the mounting brackets to the punched section.
LCL filter module
6 Install the pedestal to the LCL filter module.
7 Install the cooling fan to the LCL filter module.
8 Attach the LCL filter module pedestal guide plate to the enclosure bottom plate.
9 Attach the drive module pedestal guide plate to the enclosure bottom plate.
10 Attach the extraction/installation ramp to the LCL filter module pedestal guide plate.
11 To prevent the LCL filter module from falling, attach its lifting lugs with chains to the enclosure
frame.
 Installation into a Rittal VX25 enclosure 129

12 Push the LCL filter module carefully into the enclosure along the extraction/installation ramp.
Work preferably with help from another person as shown below. Keep a constant pressure
with one foot on the base of the module to prevent the module from falling on its back.

13 Unfasten the extraction/installation ramp and attach the LCL filter module to bottom plate.
Drive module
14 Attach the extraction/installation ramp to the drive module pedestal guide plate.
15 Remove the sheeting from the clear plastic shrouds of the drive module from both sides.
16 Install the top metallic shroud to the drive module.
17 Install the back shrouds to the drive module.
18 To prevent the drive module from falling, attach its lifting lugs with chains to the enclosure
frame.
19 Push the drive module carefully into the enclosure along the extraction/installation ramp.
Work preferably with help from another person as shown above. Keep a constant pressure
with one foot on the base of the module to prevent the module from falling on its back.
20 Unfasten the extraction/installation ramp and attach the drive module to the bottom plate.
LCL filter module and drive module attachments and intermediate electrical connections
21 Attach the LCL filter module and drive module to the punched section.
22 Attach the LCL filter module to the side of drive module from top. Reinstall the cover.
23 Attach the drive module and LCL filter module to the bottom plate.
24 Connect the LCL filter busbars to the drive module busbars with the connecting busbars.
25 Attach the LCL filter module to the drive module side from bottom.
26 Connect the LCL filter fan power supply cable to connector FAN3:LCL.
Air baffles
- After the electrical installation has been done, install the air baffles. For instructions, see
section Installing the air baffles (Page 132).

Connecting the motor cables and installing the shrouds

See Connecting the motor cables and installing the shrouds (Page 249).

Step Tasks (motor cables)

1 Install the grounding terminal to the drive module base.
2 Run the motor cables to the enclosure. Ground the cable shields 360° at the enclosure entry.
130 Installation into a Rittal VX25 enclosure

3 Connect the twisted shields of the motor cables to the grounding terminal.
4 Screw in and tighten the insulators to the drive module by hand. Install the T3/W2 connection
terminal to the insulators.

WARNING!
Do not use longer screws or bigger tightening torque than given in the installation
drawing. They can damage the insulator and cause dangerous voltage to be
present at the module frame.

5 Connect the phase T3/W2 conductors to the T3/W2 terminal.

6 Install the T2/V2 connection terminal to the insulators. See the warning in step 4.
7 Connect the phase T2/V2 conductors to the T2/V2 connection terminal.
8 Install the T1/U2 connection terminal to the insulators. See the warning in step 4.
9 Connect the phase T1/U2 conductors to the T1/U2 terminal.
10 Remove the plastic sheeting from the motor cable clear plastic shroud from both sides.
11 Install the shroud on the motor cable connections.
12 Install the lower front cover to the drive module.
13 Drill holes for the power cables to the bottom clear plastic shrouds.
14 Remove the plastic sheeting from the bottom clear plastic shrouds.
15 Install the bottom first shroud on the motor cable entry.
16 Install the second shroud on the motor cable entry.

Connecting the input cables and installing the shrouds

See Connecting the input power cables and installing the shrouds (Page 252).

Step Tasks (input cables)

1 Ground the input cable shields (if present) 360° at the enclosure entry.
2 Connect the twisted shields of the input cables and separate ground cable (if present) to the
enclosure grounding busbar.
3 Step drill carefully sufficiently big holes to the entry clear plastic shroud for the cables to be
connected. Align the holes in the vertical direction according to the alignment holes in the
shroud. Smooth the hole edges.
Remove the plastic sheeting from both sides of the shroud.
Attach the cables firmly to the enclosure frame to prevent chafing against the hole edges.
4 Put the conductors of the input cables through the drilled holes in the clear plastic shroud.
5 For drive modules without option +H370: Connect the input cable conductors to the drive
module L1/U1, L2/V1 and L3/W1 connection busbars. Go to step 12.
6 Tasks with option +H370: Do steps 6 to 11.
7 Screw in and tighten the insulators to the drive module by hand. Install the L1/U1 connection
terminal to the insulators.

WARNING!
Do not use longer screws or bigger tightening torque than given in the installation
drawing. They can damage the insulator and cause dangerous voltage to be
present at the module frame.

8 Connect the L1/U1 conductors to the L1/U1 connection terminal.

9 Install the L2/V1 connection terminal to the insulators. See the warning in step 5.
10 Connect the L2/V1 conductors to the L2/V1 connection terminal.
11 Install the L3/W1 connection terminal to the insulators. See the warning in step 5.
 Installation into a Rittal VX25 enclosure 131

12 Connect the L3/W1 conductors to the L3/W1 connection terminal.

13 Install the side clear plastic shroud and the upper front cover of the drive module.
14 Install the entry clear plastic shroud and motor cable shroud.
15 Install the top clear plastic shroud to the drive module.
132 Installation into a Rittal VX25 enclosure

Installing the air baffles

See:
• Step-by-step drawings for an installation example of standard drive configuration
in Rittal VX25 800 mm wide enclosure (Page 243)
• Air baffles (Page 215)
• Air baffles for option +H381 in 800 mm wide Rittal VX25 enclosure (Page 216).

Installing the roof and door (Rittal parts)

This drawing shows a layout tested by ABB.

1 Door
2 Install these gratings as close to each other as possible. Remove the filter mats.
 Installation into a Rittal VX25 enclosure 133

Removing the protective covering from the drive module

and LCL filter module air outlet
WARNING!
Remove the protective covering from the top of the drive module after the
installation. If the covering is not removed, the cooling air cannot flow freely
through the module and the drive will overheat.

WARNING!
Remove the protective covering from the top of the LCL filter module after the
installation. If the covering is not removed, the cooling air cannot flow freely
through the module and the module will overheat.
134
 Installation example with full cabling panels (option +H381) 135

10
Installation example with full cabling
panels (option +H381)

Contents of this chapter

In this chapter, the drive module and LCL filter module are installed in a 800 mm wide
Rittal VX25 enclosure in a bookshelf way. The modules are placed in an upright position
on the enclosure bottom with the front facing the enclosure door. Space for the
additional components can be made by connecting two or more VX25 enclosures
together. Available alternative ABB parts are also given.

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).
136 Installation example with full cabling panels (option +H381)

Safety
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.

Necessary parts
Drive module standard parts

• Drive module and LCL filter module

• Top guide plate
• Fastening brackets (2 pcs)
• Grounding busbar
• Pedestal guide plates (2 pcs)
• Telescopic extraction and insertion ramp
• Fastening screws in a plastic bag
• External control unit
Drive module options
Option code Qty (pcs) Description
+H381 1 Full power cabling panels
Rittal parts and alternative ABB parts
Rittal part code Qty (pcs) Description
VX 8806.000 1 Enclosure frame: Frame, rear door, roof plate, plinth.
VX 8106.245 1 Side panels for the enclosure
SZ/DK 7967.000 1 Spacers for roof plate. Alternative ABB roof (3AUA0000125203
(one set = four pieces) + [IP20], AUA0000114968 [IP42]), see Air outlet kits (Page 174).
additional spacers
VX 8617.140 1 Punched section without mounting flange, for 800 mm hori-
(one set = four pieces) zontal

SK 3243.200 / 4/ Air filter 323 mm × 323 mm. Remove the filter mat according
ABB 3AUA0000117002 (IP20) 2 to the manufacturer’s instructions.
ABB 3AUA0000117007 (IP42) Alternative ABB air filters (3AUA0000117002 [IP20],
3AUA0000117007 [IP42]), see Air inlet kits (Page 172).
Customer-made parts (not ABB or Rittal products)
Air baffles 4 See Air baffles for option +H381 in 800 mm wide Rittal VX25
enclosure (Page 216)
Enclosure bottom plate 1 See Bottom plate (Page 214)

Necessary tools
• Set of screw drivers (Torx and Pozidriv)
• Set of metric magnetic-end hexagon sockets
• Torque wrench with a 500 mm (20 in) or 2 × 250 mm (2 × 10 in) long extension bar
 Installation example with full cabling panels (option +H381) 137

Overall flowchart of the installation process

Step Task For instructions, see

1 Install the Rittal parts and drive module Installing the mechanical accessories into a
mechanical accessories into the enclosure enclosure (Page 137)

2 Connect the power cables to the cabling pan- Connecting the power cables (Page 139)
els

3 Install the drive module into the enclosure Installing the drive module into the enclos-
ure (Page 142)

4 Install the external control unit Attaching the external control unit (Page 102)

5 Connect the control cables Connecting the external control unit to the
drive module (Page 100)

6 Install the remaining parts, for example, en- The component manufacturer’s instructions
closure doors, side plates, etc.

Installing the mechanical accessories into a enclosure

See Step-by-step drawings for an installation example of standard drive configuration
in Rittal VX25 800 mm wide enclosure (Page 243) for these steps:
1. Attach the plinth to the floor.
2. Attach the enclosure frame to the plinth.
3. Make the bottom plate with 360-degree grounding entries for power cables. Attach
the bottom plate to the enclosure frame.
4. Attach the punched section to the back of enclosure frame.
5. Attach the mounting brackets to the punched section.
To install the full cabling panels to the enclosure frame (see the drawings on the next
page):
1. Install the Rittal punched sections VX 8100.742 to which the output cabling panel
and the input cabling panel will be attached.
2. Attach the output cabling panel to the punched sections.
3. Install the side guides to the output cabling panel (2 screws for each guide).
4. Attach the grounding busbar to the input cabling panel.
5. Attach the input cabling panel to the punched sections.
6. Attach the input cabling panel to the side guides (2 screws for each side guide).
7. Install the telescopic extraction and insertion ramp as shown in chapter
Step-by-step drawings for an installation example of standard drive configuration
in Rittal VX25 800 mm wide enclosure (Page 243).
138 Installation example with full cabling panels (option +H381)

1
4
3 3
1

2
1

6
 Installation example with full cabling panels (option +H381) 139

Connecting the power cables

￭ Connection diagram

L1 L2 L3 (PE) PE (PE)

L1 L2 L3

2b 2a

ACS880-14 4 L1/U1 L2/V1 L3/W1 UDC-

UDC- UDC+

L1/U1 L2/V1 L3/W1 UDC- UDC+

INPUT

OUTPUT
T1/U2 T2/V2 T3/W2 PE

7
9
4 T1/U2 T2/V2 T3/W2

V1 W1
U1
6
3 ~
M

1 For alternatives, see section Selecting the main supply disconnecting device (Page 67). In the in-
stalling example of this chapter, the disconnecting device is not in the same cubicle with the drive
module.
2 If a shielded cable is used (not required but recommended) and the conductivity of the shield is <
50% of the conductivity of the phase conductor, use a separate PE cable (2a) or a cable with a
grounding conductor (2b).
3 ABB recommends 360° grounding at the enclosure entry if a shielded cable is used. Ground the
other end of the input cable shield or PE conductor at the distribution board.
140 Installation example with full cabling panels (option +H381)

4 Input and output power cabling panels (option +H381)

5 ABB recommends 360° grounding at the enclosure entry
6 Use a separate grounding cable if the conductivity of the cable shield is < 50% of the conductivity
of the phase conductor and there is no symmetrically constructed grounding conductor in the
cable (see section Recommended power cable types)
7 Common mode filter (option)
8 du/dt filter (option)
9 The drive module frame must be connected to the enclosure frame. See Drive modules cabinet
design and construction instructions (3AUA0000107668 [English]) and section Grounding the drive
module and the LCL filter module (Page 65).

Note: If there is a symmetrically constructed grounding conductor in the motor cable in addition to the
conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor
ends.
Do not use an asymmetrically constructed motor cable. Connecting its fourth conductor at the motor
end increases bearing currents and causes extra wear.

￭ Power 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.

Refer to Units with optional cabling panels (+H381) (Page 194) for the tightening torques
of the power cables.
1. Run the motor cables from the motor to the enclosure. Ground the cable shields
360° at the entry plate.
2. Twist the cable shields of the motor cables into bundles and connect them and
any separate ground conductors or cables to the ground busbar of the output
power cabling panel.
3. Connect the phase conductors of the motor cables to terminals T1/U2, T2/V2 and
T3/W2 of the output cabling panel.
4. Make sure that all power is disconnected and reconnection is not possible. Use
proper safe disconnect procedures according to local codes.
5. Run the input cables to the enclosure. If IP20 degree of protection for the drive
module is needed, install the input power cables through the rubber grommet.
For instructions, refer to Installing the rubber grommet (Page 145).
6. Twist the cable shields of the input cables into bundles and connect them and
any separate ground conductors or cables to grounding busbar of the input cabling
panel.
7. Connect the phase conductors of the input cables to terminals L1/U1, L2/V1 and
L3/W1 of the input cabling panel.
 Installation example with full cabling panels (option +H381) 141

An example installation is shown below.

A
B

E
L1/U1, L2/V1, L3/W1

102 mm (4 in)

T1/U2, T2/V2, T3/W2

C
E
C

View without enclosure side plate in place.

A 360-degree grounding at the entry plate for the input power cables
B Grounding busbar of the input power cabling panel
C 360-degree grounding at the entry plate for the output power cables
D Grounding busbar of the output power cabling panel
E Allowed space for power cables.

Note: The input and output power cables must fit inside the area marked with diagonal lines to prevent
chafing of the cables when the drive module is inserted into the enclosure.
142 Installation example with full cabling panels (option +H381)

Installing the drive module into the enclosure

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

Handle the drive module carefully. Make sure that the module does not fall down when
moving it on the floor and during installation and maintenance work: Open the support
legs by pressing each leg a little down and turning it aside (1, 2). When ever possible
secure the module also with chains from top.
Do not tilt the drive module. It is heavy and its center of gravity is high. The module
will overturn from a sideways tilt of 5 degrees. Do not leave the module unattended
on a sloping floor.

1 3

3AUA0000086323
 Installation example with full cabling panels (option +H381) 143

￭ Installation procedure
1. Install the drive module and the LCL filter module into the Rittal enclosure as
shown in Step-by-step drawings for an installation example of standard drive
configuration in Rittal VX25 800 mm wide enclosure (Page 243).
2. Attach the grounding busbar that has been previously attached to the input cabling
panel to the drive module.
3. Remove the upper and lower left-hand side front covers of the drive module (M4×8
combi screws, 2 N·m [1.48 lbf·ft]).
4. Connect the busbars of the drive module to the busbars of the cabling panels
(M12 combi screw, 70 N·m [52 lbf·ft]).

5. Attach the enclosure roof on the spacers.

6. Attach the side panels.
7. Remove the filter mats from the air filters according to Rittal’s instructions. Install
the filters to the enclosure door.
8. Install the removed front covers of the drive module.
9. Connect the control cables (see section Connecting the control cables to the
terminals of the external control unit (Page 104)).
144 Installation example with full cabling panels (option +H381)

Assembly drawing of connecting the drive module to the cabling panels

3AXD50000248919

1 Combi screw M12×25 hex (delta) or equal (9 pcs)

2 Extraction/insertion ramp (3AXD50000476374)

 Installation example with full cabling panels (option +H381) 145

Installing air baffles (non-ABB parts)

See Air baffles for option +H381 in 800 mm wide Rittal VX25 enclosure (Page 216) for
the air baffle measurements.

4
3

1 Left 3 Front

2 Right 4 Rear

Miscellaneous
￭ Installing the rubber grommet
To get IP20 degree of protection for the drive module, install the input power cables
through the rubber grommet. Install the grommet as follows:
1. Cut adequate holes into the grommet for the input power cables.
2. Put the cables through the grommet.
3. Attach the grommet to the input cabling panel with five M4×8 Torx T20 screws
as shown below.
146 Installation example with full cabling panels (option +H381)
 Installation checklist 147

11
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!
Stop the drive and do the steps in section Electrical safety precautions (Page 19)
before you start the work.

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. See 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.
148 Installation checklist

Make sure that …

The drive module is fastened properly to the enclosure.
The cooling air can flow freely in and out of the drive. Air recirculation inside the cabinet is not
possible (air baffle plates are installed, or there is another air guiding solution).
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). See the electrical installation instructions.
The enclosures of the equipment in the cabinet have proper galvanic connection to the cabinet
protective earth (ground) busbar; The connection surfaces at the fastening points are bare (un-
painted) and the connections are tight, or separate grounding conductors have been installed.
The main circuit connections inside the drive cabinet correspond to the circuit diagrams.
The control unit has been connected. See the circuit diagrams.
Appropriate AC fuses and main disconnecting device are installed.
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.
The control cables are connected to the correct terminals, and the terminals are tightened to
the correct torque.
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 149

12
Start-up

Contents of this chapter

This chapter describes the start-up procedure of the drive.

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]).
12
Start-up procedure
1. Only qualified electrical professionals are allowed to start-up the drive.
2. Make sure that the installation of the drive module has been checked according
to the checklist in chapter Installation checklist, and that the motor and driven
equipment are ready for start.
3. Perform the start-up tasks instructed by the cabinet-installer of the drive module.
4. Switch the power on, setup the drive control program, and perform the first start
of the drive and motor. See ACS880-14 drive modules quick installation and start-up
guide (3AXD50000212446 [English]) or ACS880 primary control program firmware
manual (3AUA0000085967 [English]). If you need more information on the use of
the control panel, see ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels
user's manual (3AUA0000085685 [English]).
• For drives with ABB du/dt filter: Make sure that bit 13 of parameter 95.20 HW
options word 1 is switched on.
• For drives with ABB sine filter: Make sure that parameter 95.15 Special HW
settings is set to ABB sine filter. For other sine filters: See Sine filter hardware
manual (3AXD50000016814 [English]).
150 Start-up

5. For drives with ABB motors in explosive atmospheres: See also ACS880 drives
with ABB motors in explosive atmospheres (3AXD50000019585 [English]).
6. For drive modules in which the Safe torque off function is in use: Test and validate
the operation of the Safe torque off function. See Validation test
procedure (Page 229).
7. For drive modules with an FSO-xx safety functions module (options +Q972 and
Q973): Test and validate the operation of the safety functions. See the
delivery-specific circuit diagrams and FSO-12 safety functions module user’s
manual (3AXD50000015612 [English]) or FSO-21 safety functions module user’s
manual (3AXD50000015614 [English]).
 Fault tracing 151

13
Fault tracing

Contents of this chapter

This chapter describes the fault tracing possibilities of the drive.

LEDs
The table below describes the LEDs of the drive module with option +J410.

Where LED Color When the LED is lit

Control panel POWER Green Control unit is powered and +15 V is supplied to the control
mounting plat- panel
form
FAULT Red Drive in fault state

Warning and fault messages

See the quick installation and start-up guide or the firmware manual for the
descriptions, causes and remedies of the control program warning and fault messages.
152
 Maintenance 153

14
Maintenance

Contents of this chapter

This chapter contains maintenance instructions of the drive modules.

Maintenance intervals
The tables below show the maintenance tasks which can be done by the end user. The
complete maintenance schedule is available on the Internet
(new.abb.com/drives/services/maintenance/preventive-maintenance). For more
information, consult your local ABB Service representative
(www.abb.com/searchchannels).
The maintenance and component replacement intervals are based on the assumption
that the equipment is operated within the specified ratings and ambient conditions.
ABB recommends annual drive inspections to ensure the highest reliability and optimum
performance.

Note: Long term operation near the specified maximum ratings or ambient conditions
may require shorter maintenance intervals for certain components. Consult your local
ABB Service representative for additional maintenance recommendations.

￭ Descriptions of symbols

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

￭ Recommended annual maintenance actions by the user

ABB recommends these annual inspections to ensure the highest reliability and
optimum performance.

Recommended annual actions by the user Annually

Connections and environment
Quality of supply voltage P
Spare parts
Spare parts I
DC circuit capacitors reforming, spare modules and spare capacitors P
Inspections by the user
Tightness of terminals I
Dustiness, corrosion and temperature I
Heat sink cleaning I

￭ Recommended maintenance intervals after start-up

Component Years from start-up

3 6 9 12 15 18 21
Cooling
Main cooling fan
Main cooling fan R R
Auxiliary cooling fan
Circuit board compartment cooling fans LONG-LIFE R R
IP55 cooling fans R R
Aging
ZCU control unit battery (real-time clock) R R R
Control panel battery (real-time clock) R R
4FPS10000239703

￭ Recommended functional safety actions

Functional safety actions

Safety function test interval I

Safety component expiry (Mission time TM) 20 years R

 Maintenance 155

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 19)
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.
156 Maintenance

Cleaning the interior of the heatsink

The module heatsink fins pick up dust from the cooling air. The drive runs into
overtemperature warnings and faults if the heatsink is not clean.

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

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 19)
before you start the work.
2. Make sure that the drive is disconnected from the power line and all other
precautions described under Grounding (Page 21) have been taken into
consideration.
3. Undo the attaching screws of the handle plate of the drive module.
4. Remove the handle plate.
5. Vacuum the interior of the heatsink from the opening.
6. Blow clean compressed air (not humid or oily) upwards from the opening and, at
the same time, vacuum from the top of the drive module.

Note: If there is a risk of dust entering adjoining equipment, perform the cleaning
in another room.
7. Reinstall the handle plate.

4
5
2
 Maintenance 157

Cleaning the interior of the LCL filter

Clean the interior of the LCL filter in the same way as the heatsink in section Cleaning
the interior of the heatsink (Page 156).

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.
158 Maintenance

￭ Replacing the auxiliary cooling fans of the drive module

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

Fan in the front panel:

1. Stop the drive and do the steps in section Electrical safety precautions (Page 19)
before you start the work.
2. Loosen the mounting screw of the fan cassette.
3. Disconnect the power supply cable of the fan.
4. Undo the mounting screws of the fan.
5. Install the new fan in reverse order. Make sure that the arrow in the fan points to
the drive module.
6. Reset the counter (if used) in group 5 in the drive control program.

5
3

4
 Maintenance 159

Fan at the bottom of the circuit board compartment:

1. Stop the drive and do the steps in section Electrical safety precautions (Page 19)
before you start the work.
2. Loosen the mounting screw of the fan cassette.
3. Pull the fan cassette out.
4. Disconnect the power supply cable of the fan.
5. Undo the mounting screws of the fan.
6. Install the new fan in reverse order. Make sure that the arrow in the fan points up.
7. Reset the counter (if used) in group 5 in the drive control program.

3
2

6
5
160 Maintenance

￭ Replacing the drive module main cooling fans

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 19)
before you start the work.
2. Disconnect the power supply wires of the fans from the connector. FAN1:PWR1
and FAN2:PWR2.
3. Loosen the mounting screws of the fan cassette.
4. Pull the fan cassette out.
5. Loosen the mounting screws of the fan(s).

Note: 690 V drive modules have only one fan in the cassette.
6. Install the new fans in reverse order. For 690 V drive modules, connect the fan
power supply to connector FAN1:PWR1. For other drive modules, connect the
power supply wires to both FAN1:PWR1 and FAN2:PWR2.
7. Reset the counter (if used) in group 5 in the drive control program.

5
 Maintenance 161

￭ Replacing the LCL filter module cooling fan

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 19)
before you start the work.
2. Disconnect the power supply wire of the fan from connector FAN3:LCL.
3. Loosen the attaching screw of the fan cassette.
4. Pull the fan cassette out.
5. Loosen the mounting screws of the fan. The finger guard of the fan is attached
by the same screws and is removed at the same time. Keep the finger guard for
reuse.
6. Install the new fan in reverse order. Make sure that the arrow in the fan points up.

3
4


162 Maintenance

Replacing the standard drive module

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

Handle the drive module carefully:

• Use safety shoes with a metal toe cap to prevent foot injury.
• Lift the drive module only by the lifting lugs.
• Make sure that the module does not fall over when you move it on the floor. To
open the support legs, press each leg a little down and turn it aside (1, 2). Whenever
possible secure the module also with chains.
• Do not tilt the drive module. It is heavy and its center of gravity is high. The module
overturns from a sideways tilt of 5°. Do not leave the module unattended on a
sloping floor.

1 3

3AUA0000086323

1. Stop the drive and do the steps in section Electrical safety precautions (Page 19)
before you start the work.
2. Remove the clear plastic shrouds on the power cables and parts in front of the
drive module (if present).
3. Disconnect the power cables.
4. Disconnect the cables between the drive module and the control unit. See section
Connecting the external control unit to the drive module (Page 100).
 Maintenance 163

5. Disconnect the cooling fan power supply cable from the LCL filter module. Pull
the cable inside the drive module.

6. Remove the screws that attach the drive module to the cabinet at the top and
behind the front support legs.
7. Remove the screws that connect the drive module to the LCL filter module from
top and at the side.
8. To prevent the drive module from falling, attach its top lifting lugs with chains to
the cabinet frame.
9. To open the support legs 90°, press each leg a little down and turn it aside.
10. Adjust the extraction/installation ramp to the correct height and attach it to the
cabinet base with the two mounting screws.
164 Maintenance

11. Pull the drive module carefully out of the cabinet preferably with help from another
person.

12. Install the new module in reverse order.

Replacing the LCL filter module

Replace the LCL filter module in the same way as the drive module.
 Maintenance 165

Replacing the drive module with option +H381

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

Handle the drive module carefully:

• Use safety shoes with a metal toe cap to prevent foot injury.
• Lift the drive module only by the lifting lugs.
• Make sure that the module does not topple over when you move it on the floor:
To open the support legs, press each leg a little down and turn it aside (1, 2).
Whenever possible secure the module also with chains.
• Do not tilt the drive module. It is heavy and its center of gravity is high. The module
overturns from a sideways tilt of 5°. Do not leave the module unattended on a
sloping floor

1 3

3AUA0000086323

1. Stop the drive and do the steps in section Electrical safety precautions (Page 19)
before you start the work.
2. To remove the left-hand side upper and lower front covers of the drive module,
undo the fastening screws. M4×10 combi screws, 2 N·m (18 lbf·in).
3. Disconnect the drive module busbars from the input cabling panel. Combi screw
M12, 70 N·m (52 lbf·ft).
4. Disconnect the drive module busbars from the output cabling panel. Combi screw
M12, 70 N·m (52 lbf·ft).
5. Remove the front air baffle.
6. See Step-by-step drawings for an installation example of standard drive
configuration in Rittal VX25 800 mm wide enclosure (Page 243):
166 Maintenance

• Disconnect the drive module from the LCL filter module.

• Loosen the screws that attach the drive module to the enclosure frame.
• Attach the extraction ramp to the enclosure base with two screws.
7. Disconnect the power supply cable and the fiber optic cables from the external
control unit and coil them on the top of the drive module.
8. To prevent the drive module from falling, attach its top lifting lugs with chains to
the enclosure frame.
9. Pull the drive module carefully out of the enclosure preferably with help from
another person.
10. Install the new module in reverse order.

Replacing the LCL filter module with option +H381

See Step-by-step drawings for an installation example of standard drive configuration
in Rittal VX25 800 mm wide enclosure (Page 243):
1. Disconnect the LCL filter module from the drive module.
2. Undo the screws that attach the LCL filter module to the enclosure frame.
3. Attach the extraction ramp to the enclosure base with two screws.
4. To prevent the LCL filter module from falling, attach its top lifting lugs with chains
to the enclosure frame.
 Maintenance 167

5. Pull the LCL filter module carefully out of the enclosure preferably with help from
another person.
6. Install the new module in reverse order.

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.

￭ 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]).

Control panel
Refer to ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels user’s manual
(3AUA0000085685 [English]).
168 Maintenance

Replacing the ZCU-14 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.

1. Stop the drive and do the steps in section Electrical safety precautions (Page 19)
before you start the work.
2. Remove the M4×8 (T20) screws at the ends of the control unit.
3. To see the battery, remove the XD2D terminal block.
4. Carefully lift the edge of the control unit cover on the side with the I/O terminal
blocks.
5. Pull the battery out of the battery holder.
6. Put a new CR2032 battery into the battery holder.
7. Close the control unit cover.
8. Tighten the M4×8 (T20) screws.
9. Install the XD2D terminal block.

2 8
3 9

7
4

5 6

2 8
 Maintenance 169

Memory unit
One memory unit is located in the external control unit, see Overview of power and
control connections (Page 41), another on the line-side converter control unit.

￭ Replacing the memory unit of ZCU-14

After replacing a control unit, you can retain the existing parameter settings by
transferring the memory unit from the defective control unit to the new control unit.
After power-up, the drive will scan the memory unit. This can take several minutes.

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

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 19)
before you start the work.
2. Pull the clip of the memory unit forward.

3. Take the unit off.

4. Replace the unit in reverse order.
170 Maintenance

￭ Replacing the memory unit of the line-side converter control unit

(ZCU-12)
1. Stop the drive and do the steps in section Electrical safety precautions (Page 19)
before you start the work.
2. Remove the cover on the memory unit.
3. Pull the memory unit out.
4. Install the new memory unit in reverse order.

2
3

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.
Contact your local ABB service representative for more information.
 Ordering information 171

15
Ordering information

Contents of this chapter

This chapter gives ordering information on additional components available from ABB
for the drive module installation.

Note: This chapter only lists the installation accessories available from ABB. All other
parts must be sourced from a third party by the system integrator.

ACS-AP-W and ACS-AP-I control panel

Type Description Ordering code Illustration

ACS-AP-W Control panel with Bluetooth 3AXD50000025965

ACS-AP-I Control panel 3AUA0000088311

Control panel mounting platforms

The control panel can be mounted on the cabinet door with the help of a door mounting
kit.
172 Ordering information

Type Description Ordering code Illustration

Door mounting kit for flush

mounting. Includes a control
DPMP-01 panel mounting platform, an 3AUA0000108878
IP54 cover and a 3- meter panel
connection cable.

Control panel mounting plat-

DPMP-04 3AXD50000217717
form

Output (du/dt) filters

See section du/dt filters (Page 241).

Sine filters
See section Sine filters (Page 242).

EMC filter ARFI-10

Ordering code: 68241561

Cabinet ventilation
￭ Air inlet kits
Mounting screws are included.

Enclosure width /
Kit code Ordering code Illustration
Degree of protection

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

Instruction code: 3AUA0000116887

 Ordering information 173

Enclosure width /
Kit code Ordering code Illustration
Degree of protection

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

Instruction code: 3AUA0000116875

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

Instruction code: 3AXD50000010001

174 Ordering information

￭ Air outlet kits

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

800 mm / IP20 2 A-4-X-062 3AUA0000125201

Instruction code: 3AXD50000001982

Note: Fan to be ordered separately

800 mm / IP42 2 A-4-X-060 3AUA0000114967

Instruction code: 3AUA0000115290

Note: Fan to be ordered separately

800 mm / IP54 (IEC) 2 A-4-X-064 3AXD50000009187

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately

 Ordering information 175

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

800 mm / IP54 (UL) 2 A-4-X-067 3AXD50000010362

Instruction code: 3AXD50000010284

Note: Fan to be ordered separately

800 mm / IP31 2 A-4-X-068 3AXD50000944088

Instruction code: 3AXD50000944712

Note: No fan available for this kit

Cooling fans
Two cooling fans must be installed inside the air outlet compartment to ensure
sufficient cooling of the cabinet.

Enclosure width / Component Qty Ordering code

Degree of protection Name Data
800 mm / IP20, IP42 Fan R2E225-RA92-17 (230 V) 2 3AXD50000000514
Capacitor MSB MKP 3,5/603/E1679 2 3AXD50000000882
Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724
176 Ordering information

Enclosure width / Component Qty Ordering code

Degree of protection Name Data
800 mm / IP54 Fan RB4C-355/170 2 3AXD50000006934
Capacitor MSB MKP 6/603/E1679 2 3AXD50000006959
Connector SPB2,5/7 (2.5 mm2, 12AWG) 2 3AXD50000000723
Connector SC 2,5-RZ/7 (2.5 mm2, 12AWG) 2 3AXD50000000724

FSO accessories kit

Kit code Ordering code Illustration

A-X-X-279 3AXD50000025495

Instruction code: 3AXD50000025583

Retrofit accessory kits

Kit Option code Ordering code
Common mode filter kit +E208 3AXD50000026145
Full size cable connection terminals for input power cables +H370 3AXD50000019542
Full size cable connection terminals for output power cables 1) 3AXD50000019544

For frame R11: IP20 shrouds for covering the input and motor 2) 3AXD50000019538
cabling area

1) The drive module is delivered with full size cable connection terminals for output power cables as standard. They
can be excluded with option +0H371.
2) The drive module is delivered with IP20 shrouds for covering the input and motor cabling area as standard. The
shrouds can be excluded with option +0B051.
 Technical data 177

16
Technical data

Contents of this chapter

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

Electrical ratings
This section gives ratings for the standard drive. For ratings of marine-type approved
drives (option +C132), refer to ACS880-01…, ACS880-04…, ACS880-11…, ACS880-31…,
ACS880-14… and ACS880-34… +C132 marine type-approved drives supplement
(3AXD50000010521 [English]).
The nominal rating for the drive modules with 50 Hz and 60 Hz supply are given below.

IEC RATINGS
ACS880- Frame Input Output ratings
14-… size current1)
Nominal use Light-duty use Heavy-duty use
I1 Imax I2 Pn Sn ILd PLd IHd PHd
A A A kW kVA A kW A kW
Un = 400 V
246A-3 R11 212 350 246 132 170 234 132 206 110
293A-3 R11 257 418 293 160 203 278 160 246 132
363A-3 R11 321 498 363 200 251 345 200 293 160
442A-3 R11 401 621 442 250 306 420 250 363 200
505A-3 R11 401 631 505 250 350 480 250 363 200
585A-3 R11 505 751 585 315 405 556 315 442 250
650A-3 R11 569 859 650 355 450 618 355 505 250
178 Technical data

IEC RATINGS
ACS880- Frame Input Output ratings
14-… size current1)
Nominal use Light-duty use Heavy-duty use
I1 Imax I2 Pn Sn ILd PLd IHd PHd
A A A kW kVA A kW A kW
Un = 500 V
240A-5 R11 169 350 240 132 208 228 132 180 110
260A-5 R11 205 418 260 160 225 247 160 240 132
361A-5 R11 257 542 361 200 313 343 200 260 160
414A-5 R11 321 614 414 250 359 393 250 361 200
460A-5 R11 404 660 460 315 398 450 315 414 250
503A-5 R11 455 725 503 355 436 492 355 460 315
Un = 690 V
142A-7 R11 123 250 142 132 170 135 132 119 110
174A-7 R11 149 274 174 160 208 165 160 142 132
210A-7 R11 186 384 210 200 251 200 200 174 160
271A-7 R11 232 411 271 250 324 257 250 210 200
330A-7 R11 293 480 330 315 394 320 315 271 250
370A-7 R11 330 520 370 355 442 360 355 330 315
430A-7 R11 375 555 430 400 514 420 400 370 355

UL (NEC) RATINGS
ACS880- Frame size Input Output ratings
14-… current1)
Max. App. Light-duty use Heavy-duty use
current power
I1 Imax Sn ILd PLd IHd PHd
A A kVA A hp A hp
Un = 480 V
240A-5 R11 169 350 208 240 200 228 150
260A-5 R11 205 418 225 260 200 240 200
302A-5 R11 239 498 262 302 250 260 200
361A-5 R11 257 542 313 361 300 302 250
414A-5 R11 321 614 359 414 350 361 300
460A-5 R11 404 660 398 450 350 414 350
503A-5 R11 455 725 436 492 400 483 400
Un = 575 V
142A-7 R11 123 250 170 144 150 125 125
174A-7 R11 149 274 208 168 175 144 150
210A-7 R11 186 384 251 192 200 168 175
271A-7 R11 232 411 324 242 250 192 200
330A-7 R11 293 480 394 289 300 242 250
370A-7 R11 330 520 442 336 350 289 300
430A-7 R11 375 555 514 412 450 336 350
 Technical data 179

1) When the DC voltage is boosted, the drive can draw more input current than shown on the type designation label.
This is the case when the motor is running continuously at or near the field weakening area and when the drive is
running at or near nominal load. It can be a result of certain combinations of DC voltage boost levels and drive-type-
specific derating curves.
The rise in input current can heat the input cable and fuses. To avoid heating, select an input cable and fuses according
to the increased input current caused by the DC voltage boost. For more information, refer to ACS880-11, ACS880-
31, ACS880-14, ACS880-34, ACS880-17, ACS880-37 drives product note on voltage boost (3AXD50000691838 [English]).

Un Nominal voltage of the drive

I1 Nominal input current (rms) at 40 °C (104 °F)
Sn Apparent power (no overload)
Imax Maximum output current. Available for 10 seconds at start, otherwise as long as allowed by
drive temperature. 140% … 200% of IHd, depending on power rating.
I2 Continuous rms output current. No overload capability at 40 °C (104 °F). This is indicated in
the type designation label as output current I2.
Pn Typical motor power in no-overload use
ILd Continuous rms output current allowing 10% overload for 1 minute every 5 minutes
PLd Typical motor power for light-duty use
IHd Continuous rms output current allowing 50% overload for 1 minute every 5 minutes
PHd Typical motor power for heavy-duty use

Note: 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 power ratings apply to most IEC 34 motors at the nominal
voltage of the drive.
ABB recommends to select the drive, motor and gear combination for the required motion profile with
the DriveSize dimensioning tool available from ABB.

￭ Deratings
When is derating necessary
Derate the continuous output current of the drive if
• ambient temperature exceeds +40 °C (+104 °F) or
• drive is installed higher than 1000 m (3280 ft) above sea level
• switching frequency is other than default
• the minimum requirements of motor cable length are not met (see chapter du/dt
filters and sine filters)
• DC voltage boost feature is used.

Note: The final derating factor is a multiplication of all applicable derating factors.
180 Technical data

Surrounding air temperature derating

In the temperature range +40…55 °C (+104…131 °F), the rated output current is derated
by 1% for every added 1 °C (1.8 °F) as follows. Calculate the output current by multiplying
the current given in the rating table by the derating factor.

1.00

0.95

0.90

0.85

0.80
-15 °C … +40 °C +50 °C +55 °C T
+5°F +104 °F +122 °F +131 °F
 Technical data 181

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
Derating factor 0.90
Derating factor 0.85
Derating factor 0.80

For a more accurate derating, use the DriveSize PC tool.

182 Technical data

Deratings for special settings in the drive control program

Enabling special settings in the drive control program can require output current
derating.

Ex motor, sine filter, low noise

Table below gives the deratings for these cases:
• drive is used with an ABB motor for explosive atmospheres (Ex) and EX motor in
parameter 95.15 Special HW settings is enabled
• sine filter given in the selection table (see section Sine filters) is used and ABB
sine filter in parameter 95.15 Special HW settings is enabled
• Low noise optimization is selected in parameter 97.09 Switching freq mode.
With other than recommended sine filters (see section Sine filters (Page 242)) and
non-ABB Ex motors, contact ABB.

ACS880- Output ratings for special settings

14-…
Ex motor (ABB Ex motor) ABB sine filter Low noise mode
Nominal use Light- Heavy- Nominal use Light- Heavy- Nominal use Light- Heavy-
duty duty duty duty duty duty
use use use use use use
In Pn ILd IHd In Pn ILd IHd In Pn ILd IHd
A kW A A A kW A A A kW A A
Un = 400 V
246A-3 234 132 222 196 221 132 210 185 217 132 204 180
293A-3 278 160 264 234 264 160 251 221 258 160 243 215
363A-3 345 200 328 278 327 200 310 264 320 200 301 256
442A-3 420 250 399 345 398 250 378 327 390 250 367 317
505A-3 480 315 456 345 455 250 432 327 445 250 419 317
585A-3 556 315 528 420 527 315 500 398 516 315 485 386
650A-3 618 355 587 480 585 355 556 455 573 315 539 441
Un = 480 V
302A-5 287 250 287 247 272 250 272 234 266 250 hp 264 277
hp hp
Un = 500 V
240A-5 228 132 217 171 216 132 205 162 212 132 199 157
260A-5 247 160 235 228 234 160 222 216 229 160 216 210
361A-5 343 200 326 247 325 200 309 234 318 200 300 227
414A-5 393 250 373 343 373 250 354 325 365 250 343 315
460A-5 437 315 428 393 414 315 405 373 406 250 393 362
503A-5 478 355 467 437 453 315 443 414 443 315 430 402
Un = 690 V
142A-7 125 132 119 105 128 132 122 107 66 75 63 55
174A-7 153 160 145 125 157 160 149 128 81 90 77 66
210A-7 185 200 176 153 189 200 180 157 98 110 93 81
271A-7 238 250 226 185 244 250 231 189 126 132 119 98
330A-7 290 315 282 238 297 315 288 244 154 160 149 126
 Technical data 183

ACS880- Output ratings for special settings

14-…
Ex motor (ABB Ex motor) ABB sine filter Low noise mode
Nominal use Light- Heavy- Nominal use Light- Heavy- Nominal use Light- Heavy-
duty duty duty duty duty duty
use use use use use use
In Pn ILd IHd In Pn ILd IHd In Pn ILd IHd
A kW A A A kW A A A kW A A
370A-7 326 355 317 290 333 355 324 297 172 200 167 153
430A-7 378 400 370 326 387 400 378 333 200 200 195 172

Un Nominal voltage of the drive

In Continuous rms output current. No overload capability at 40 °C (104 °F)
Pn Typical motor power in no-overload use
ILd Continuous rms output current allowing 10% overload for 1 minute every 5 minutes
PLd Typical motor power for light-duty use
IHd Continuous rms output current allowing 50% overload for 1 minute every 5 minutes

High speed mode

The selection High speed mode of parameter 95.15 Special HW settings improves
control performance at high output frequencies. ABB recommends it to be selected
with output frequency of 120 Hz and above.
This table gives the drive module ratings for 120 Hz output frequency and the maximum
output frequency for the drive ratings when High speed mode in parameter 95.15
Special HW settings is enabled: With output frequencies smaller than this recommended
maximum output frequency, the current derating is less than the values given in the
table. Contact ABB for operation above the recommended maximum output frequency
or for the output current derating with output frequencies above 120 Hz and below
the maximum output frequency.

Deratings with selection High speed mode of parameter 95.15 Special HW settings
120 Hz output frequency Maximum output frequency
Light- Heavy- Maxim- Light- Heavy-
ACS880- Fre-
Nominal use duty duty um fre- Nominal use duty duty
14- quency
use use quency use use
f In Pn ILd IHd fmax In Pn ILd IHd
Hz A kW A A Hz A kW A A
Un = 400 V
246A-3 120 246 132 234 206 500 201 110 193 170
293A-3 120 293 160 278 246 500 240 132 229 203
363A-3 120 363 200 345 293 500 297 200 284 241
442A-3 120 442 250 420 363 500 362 250 346 299
505A-3 120 505 250 480 363 500 413 250 395 299
582A-3 120 585 315 556 442 500 479 315 458 364
650A-3 120 650 355 618 505 500 532 315 509 416
Un = 480 V
302A-5 120 302 250 (hp) 302 260 500 247 200 (hp) 249 214
184 Technical data

Deratings with selection High speed mode of parameter 95.15 Special HW settings
120 Hz output frequency Maximum output frequency
Light- Heavy- Maxim- Light- Heavy-
ACS880- Fre-
Nominal use duty duty um fre- Nominal use duty duty
14- quency
use use quency use use
f In Pn ILd IHd fmax In Pn ILd IHd
Hz A kW A A Hz A kW A A
Un = 500 V
240A-5 120 240 132 228 180 500 196 132 188 148
260A-5 120 260 160 247 240 500 213 160 203 198
361A-5 120 361 200 343 260 500 295 250 283 214
414A-5 120 414 250 393 361 500 339 250 324 297
460A-5 120 460 315 450 414 500 376 315 371 341
503A-5 120 503 355 492 460 500 412 315 405 379
Un = 690 V
142A-7 120 142 132 135 119 500 82 75 78 68
174A-7 120 174 160 165 142 500 100 110 95 82
210A-7 120 210 200 200 174 500 121 132 115 100
271A-7 120 271 250 257 210 500 156 160 148 121
330A-7 120 330 315 320 271 500 190 200 184 156
370A-7 120 370 355 360 330 500 213 250 207 190
430A-7 120 430 400 420 370 500 247 250 241 213
3AXD00000588487

f Output frequency
fmax Maximum output frequency with High speed mode
Un Nominal voltage of the drive
In Continuous rms output current. No overload capability at 40 °C (104 °F).
Pn Typical motor power in no-overload use
ILd Continuous rms output current allowing 10% overload for 1 minute every 5 minutes
IHd Continuous rms output current allowing 50% overload for 1 minute every 5 minutes
 Technical data 185

Derating for output voltage boost

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.

400 V and 500 V drives

This drawing shows the required derating for -3 and -5 (400 V and 500 V) drive types.

P/Pn
1.10
1.05
1.00
0.975
0.95
0.90
0.85
0.80
0.75
0.70
0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00
U/Un
0.875

Example 1: Pn for ACS880-14-650A-3 is 355 kW. The input voltage (U) is 350 V. -> U/Un
= 350 V / 400 V = 0.875. -> P/Pn = 0.975 -> The derated power P = 0.975 × 355 kW =
346 kW.
To boost the output voltage to correspond the nominal supply voltage 400 V, increase
the DC voltage to 400 V × √2 = 567 V.
Example 2: Pn for ACS880-14-503A-5 is 355 kW. The input voltage (U) is 450 V. -> U/Un
= 450 V / 500 V = 0.9. -> P/Pn = 1.00 -> The derated power P = 1.00 × 355 kW = 355 kW.
To boost the output voltage to correspond the nominal supply voltage 500 V, increase
the DC voltage to 500 V × √2 = 707 V.

575 V and 690 V drives

This drawing shows the required derating for -7 (575 V and 690 V) drive types.

P/Pn
1.10
1.05
1.00
0.96 0.95
0.90
0.85
0.80
0.75
0.70
0.60
0.70 0.75 0.80 0.85 0.90 0.95 1.00 1.05 1.10
U/Un
0.96

Example 1: Pn for ACS880-14-430A-7 is 400 kW. The input voltage (U) is 660 V. -> U/Un=
660 V / 690 V = 0.96 -> P/Pn = 0.96 -> The derated power P = 0.96 × 400 kW = 384 kW.
To boost the output voltage to correspond the nominal supply voltage 690 V, increase
the DC voltage to 690 V × √2 = 977 V.
186 Technical data

U Input voltage of the drive

Un Nominal supply voltage of the drive. For -3 types Un = 400 V, for -5 types Un = 500 V. For -7
types Un = 690 V but 575 V when Pn refers to nominal power ratings in the UL (NEC) 575 V
rating table.
P Derated output power of the drive
Pn Nominal power rating of the drive

For more information, see ACS880-11, ACS880-31, ACS880-14, ACS880-34, ACS880-17,

ACS880-37 drives product note on voltage boost (3AXD50000691838 [English]).
 Technical data 187

Fuses (IEC)
aR fuses by Cooper Bussmann for protection against short-circuit in the input power
cable of drive are listed below.

Ultrarapid (aR) fuses per drive module

Min.
short- Input
Fuse
ACS880- circuit current
14-… current 1)
Bussmann
A A A A2s V Size
type
Un = 400 V
246A-3 1500 212 400 74000 690 170M5408 2
293A-3 2200 257 500 145000 690 170M5410 2
363A-3 2600 321 630 210000 690 170M6410 3
442A-3 3100 401 700 300000 690 170M6411 3
505A-3 4000 401 800 465000 690 170M6412 3
585A-3 5400 505 1000 945000 690 170M6414 3
650A-3 5400 569 1000 945000 690 170M6414 3
Un = 500 V
240A-5 1100 169 315 42000 690 170M4410 1
260A-5 1500 205 400 74000 690 170M5408 2
361A-5 2600 257 630 210000 690 170M6410 3
414A-5 3100 321 700 300000 690 170M6411 3
460A-5 3100 404 700 300000 690 170M6411 3
503A-5 4000 455 800 465000 690 170M6412 3
Un = 690 V
142A-7 900 123 250 21000 690 170M4409 1
174A-7 1100 149 315 42000 690 170M4410 1
210A-7 1500 186 400 74000 690 170M5408 2
271A-7 2200 232 500 145000 690 170M5410 2
330A-7 2600 293 630 210000 690 170M6410 3
370A-7 3100 330 700 300000 690 170M6411 3
430A-7 3100 375 700 300000 690 170M6411 3

1) Minimum short-circuit current of the electrical power system

Note:
• See also sections:
• Protecting the drive and the input power cable in short-circuits (Page 85)
• Protecting the drive against thermal overload (Page 85)
• Protecting the input power cable against thermal overload (Page 86).
• In multicable installations, install only one fuse per phase (not one fuse per
conductor).
• Fuses with higher current rating than the recommended ones must not be used.
Fuses with lower current rating can be used.
188 Technical data

• Fuses from other manufacturers can be used if they agree with the ratings and
the melting curve of the fuse does not exceed the melting curve of the fuse
mentioned in the table.

￭ Calculating the short-circuit current of the installation

Make sure that the short-circuit current of the installation is at least the value given
in the fuse table.
The short-circuit current of the installation can be calculated as follows:

U
Ik2-ph =
2· Rc2 + (Zk + Xc)2

where

Ik2-ph Short-circuit current in symmetrical two-phase short-circuit

U Network line-to-line voltage (V)
Rc Cable resistance (ohm)
Zk Zk = zk · Un2/Sn = transformer impedance (ohm)
zk Transformer impedance (%)
Un Transformer rated voltage (V)
Sn Nominal apparent power of the transformer (kVA)
Xc Cable reactance (ohm)
 Technical data 189

Fuses (UL)
UL fuses by Cooper Bussman for branch circuit protection per NEC per drive module
are listed below. Obey local regulations.

ACS880- Input cur- Fuse

14-… rent (A) A V Type DIN 43653 Type US Style Type French Style Size
Un = 500 V
240A-5 169 315 690 170M4010 170M4610 170M4310 1
260A-5 205 400 690 170M5008 170M5608 170M5308 2
302A-5 249 500 690 170M5010 170M5610 170M5310 2
361A-5 257 630 690 170M6010 170M6610 170M6310 3
414A-5 321 700 690 170M6011 170M6611 170M6311 3
460A-5 404 700 690 170M6011 170M6611 170M6311 3
503A-5 455 800 690 170M6012 170M6612 170M6212 3
Un = 690 V
142A-7 123 250 690 170M4009 170M4609 170M4309 1
174A-7 149 315 690 170M4010 170M4610 170M4310 1
210A-7 186 400 690 170M5008 170M5608 170M5308 2
271A-7 232 500 690 170M5010 170M5610 170M5310 2
330A-7 293 630 690 170M6010 170M6610 170M6310 3
370A-7 330 700 690 170M6011 170M6611 170M6311 3
430A-7 375 700 690 170M6011 170M6611 170M6311 3

Note:
• See also sections:
• Protecting the drive and the input power cable in short-circuits (Page 85)
• Protecting the drive against thermal overload (Page 85)
• Protecting the input power cable against thermal overload (Page 86).
• In multicable installations, install only one fuse per phase (not one fuse per
conductor).
• Fuses with higher current rating than the recommended ones must not be used.
Fuses with lower current rating can be used.
• Alternative fuses can be used if they meet certain characteristics. For acceptable
fuses, see the manual supplement (3AXD50000645015).

Circuit breakers (UL)

Note: Circuit breakers must not be used without fuses. For suitable circuit breakers,
contact your local ABB representative.
190 Technical data

Dimensions, weights and free space requirements

Standard drive module configuration (drive module + LCL filter module) – IP20 (UL Open Type)
Frame Height Width Depth Weight
size
mm in mm in mm in kg lb
R11 1741 68.54 713 28.07 512 20.16 373 822

Optional selection +0B051+0H371 (without shrouds and full-size output power cable connection ter-
minals) with LCL filter module – IP00 (UL Open Type)
Frame Height Width Depth Weight
size
mm in mm in mm in kg lb
R11 1726 67.93 642 25.27 508 20.00 365 804

Drive module
Frame Height Width Depth Weight
size
mm in mm in mm in kg lb
R11 1726 67.93 404 15.92 508 20.00 185 408

LCL filter module

Frame Height Width Depth Weight
size
mm in mm in mm in kg lb
R11 1722 67.80 239 9.40 505 19.86 180 396

Optional selection +H381 (full power cabling panels) with LCL filter module
Frame Height Width Depth Weight
size
mm in mm in mm in kg lb
R11 1780 70.08 709 27.91 517 20.35 401 884

Weight of optional selections

Frame +E208 +0H371 +H370 +0B051
size
kg lb kg lb kg lb kg lb
R11 3 7 -2.9 -6 2.9 6 -1.5 -3

For requirements of free space around the drive module, see Required free
space (Page 54).
 Technical data 191

￭ Package
Drive package

Weight: 36 kg (79 lb).

LCL filter module package

Weight: 32 kg (71 lb).

192 Technical data

Losses, cooling data and noise

The air flow direction is from bottom to top.
This table shows typical heat loss values, required air flow and noise at the nominal
ratings of the drive. The heat loss values can vary depending on voltage, cable
conditions, motor efficiency and power factor. To obtain more accurate values for
given conditions, use ABB DriveSize tool
(http://new.abb.com/drives/software-tools/drivesize).

ACS880- Frame Air flow Heat dissipation Noise

14- size m3/h ft3/min W dB(A)
Un = 400 V
246A-3 R11 2100 1236 5280 75
293A-3 R11 2100 1236 6400 75
363A-3 R11 2100 1236 8000 75
442A-3 R11 2100 1236 10000 75
505A-3 R11 2100 1236 10000 75
585A-3 R11 2100 1236 12600 75
650A-3 R11 2100 1236 14200 75
Un = 500 V
240A-5 R11 2100 1236 5280 75
260A-5 R11 2100 1236 6400 75
302A-5 R11 2100 1236 8000 75
361A-5 R11 2100 1236 8000 75
414A-5 R11 2100 1236 10000 75
460A-5 R11 2100 1236 12600 75
503A-5 R11 2100 1236 14200 75
Un = 690 V
142A-7 R11 2100 1236 5280 75
174A-7 R11 2100 1236 6400 75
210A-7 R11 2100 1236 8000 75
271A-7 R11 2100 1236 10000 75
330A-7 R11 2100 1236 12600 75
370A-7 R11 2100 1236 14200 75
430A-7 R11 2100 1236 16000 75

These losses are not calculated according to IEC 61800-9-2.

The cooling air temperature rises 30 °C when it goes through the drive module if the
temperature of the input cooling air is 40 °C.
 Technical data 193

Typical power cable sizes

The table below gives copper and aluminum cable types with concentric copper shield
for the drives with nominal current. See also section Terminal and entry data for the
power cables (Page 194).

IEC 1) US 2)
ACS880- Cu cable type Al cable type Cu cable type Al cable type
14-…
mm2 mm2 AWG/kcmil AWG/kcmil
Un = 400 V
246A-3 2 × (3 × 50) 2 × (3 × 95) 250 MCM or 2 × 1 350 MCM or 2 × 2/0
293A-3 2 × (3 × 70) 2 × (3 × 120) 350 MCM or 2 × 2/0 500 MCM or 2 × 3/0
363A-3 3 × (3 × 50) 3 × (3 × 95) 500 MCM or 2 × 3/0 700 MCM or 2 × 4/0 or 3 × 2/0
442A-3 3 × (3 × 70) 3 × (3 × 120) 700 MCM or 2 × 4/0 or 3 × 2/0 2 × 300 MCM or 3 × 3/0
505A-3 3 × (3 × 70) 3 × (3 × 120) 700 MCM or 2 × 4/0 or 3 × 2/0 2 × 300 MCM or 3 × 3/0
585A-3 3 × (3 × 120) 3 × (3 × 150) 2 × 350 MCM or 3 × 4/0 2 × 500 MCM or 3 × 250 MCM
650A-3 3 × (3 × 120) 3 × (3 × 185) 2 × 400 MCM or 3 × 4/0 2 × 600 MCM or 3 × 300 MCM
Un = 500 V
240A-5 1 × (3 × 120) 2 × (3 × 70) 3/0 250 MCM or 2 × 1
260A-5 2 × (3 × 50) 3 × (3 × 70) 250 MCM or 2 × 1 350 MCM or 2 × 2/0
302A-5 2 × (3 × 70) 3 × (3 × 70) 300 MCM or 2 × 1/0 500 MCM or 2 × 3/0
361A-5 2 × (3 × 120) 3 × (3 × 70) 350 MCM or 2 × 2/0 500 MCM or 2 × 3/0
414A-5 3 × (3 × 50) 2 × (3 × 150) 500 MCM or 2 × 3/0 700 MCM or 2 × 4/0 or 3 × 2/0
460A-5 3 × (3 × 70) 3 × (3 × 120) 700 MCM or 2 × 4/0 or 3 × 2/0 2 × 300 MCM or 3 × 3/0
503A-5 3 × (3 × 95) 3 × (3 × 120) 2 × 250 MCM or 3 × 2/0 2 × 400 MCM or 3 × 4/0
Un = 690 V
142A-7 1 × (3 × 70) 2 × (3 × 50) 1/0 3/0
174A-7 2 × (3 × 50) 2 × (3 × 50) 2/0 4/0
210A-7 2 × (3 × 50) 2 × (3 × 70) 4/0 300 MCM or 2 × 1/0
271A-7 2 × (3 × 70) 3 × (3 × 50) 300 MCM or 2 × 1/0 400 MCM or 2 × 2/0
330A-7 2 × (3 × 50) 2 × (3 × 120) 400 MCM or 2 × 2/0 600 MCM or 2 × 4/0 or 3 × 1/0
370A-7 3 × (3 × 70) 2 × (3 × 150) 500 MCM or 2 × 3/0 700 MCM or 2 × 4/0 or 3 × 2/0
430A-7 3 × (3 × 70) 2 × (3 × 185) 700 MCM or 2 × 4/0 or 3 × 2/0 2 × 300 MCM or 3 × 3/0

1) The cable selection 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 (86 °F) PVC insulation, surface temperature 70 °C (158 °F) (EN 60204-1 and
IEC 60364-5-52). For other conditions, select the cables according to local safety regulations, appropriate input
voltage and the load current of the drive.
2) The cable selection is based on NEC Table 310-16 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, dimension the cables according to local safety regulations, appropriate input voltage and
the load current of the drive.

Temperature: For IEC, select a cable rated for at least 70 °C maximum permissible
temperature of conductor in continuous use. For North America, power cables must
be rated for 75 °C (167 °F) or higher.
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.
194 Technical data

Terminal and entry data for the power cables

Maximum accepted 4 × (3 × 240) mm2 or 4 × (3 × 500 MCM)
cable size

Screw size for connect- M12

ing busbars to the drive
module input and output
busbars

Tightening torque 50…75 N·m (37…55 lbf·ft)

￭ Units with optional cabling panels (+H381)

The maximum accepted cable size is 4 × (3 × 240) mm2 or 4 × (3 × 500 AWG). The
cabling panels are connected to the drive module busbars with M12 serpress nuts,
tightening torque 30 N·m (20 lbf·ft).
Input, motor and brake resistor cable terminal sizes and tightening torques are given
below.

L1/U1, L2/V1, L3/W1, T1/U2, T2/V2, T3/W2, UDC+, UDC- Grounding busbar
Screw Tightening torque Screw Tightening torque
N·m lbf·ft N·m lbf·ft
M12 1/2 50…75 37…55 M10 3/8 30…44 22…32

Two-hole 1/2 inch diameter cable lugs can be used.

￭ Units without full-size output cable connection terminals (+0H371)

and with a common mode filter (+E208)
It is possible to use the maximum cable size (4 × [3 × 240] mm2 or 4 ×[(3 × 500 AWG])
only with special cable lugs and additional insulation. For more information, contact
your local ABB representative.

Terminal data for the control cables

See Connector data (Page 120).

Electrical power network specification

Voltage (U1) ACS880-14-xxxx-3 drive modules: 380…415 VAC 3-phase +10%…-15%. This
is indicated in the type designation label as typical input voltage level
3~400 V AC.
ACS880-14-xxxx-5 drive modules: 380…500 V AC 3-phase +10%…-15%. This
is indicated in the type designation label as typical input voltage levels
3~400/480/500 V AC.
ACS880-14-xxxx-7 drive modules: 525…690 V AC 3-phase +10%…-15%. This
is indicated in the type designation label as typical input voltage levels
3~525/600/690 V AC (600 V AC UL, CSA).

Network type TN (grounded) and IT (ungrounded) systemsS

Rated conditional short- Maximum allowable prospective short-circuit current is 100 kA when protected
circuit current Icc (IEC by the fuses given in the fuse table.
61800-5-1)
 Technical data 195

Maximum prospective The drive is suitable for use on a circuit capable of delivering not more than
short-circuit current rat- 100 kA rms symmetrical amperes at 600 V maximum when protected by the
ing (SCCR) (UL 61800-5- fuses given in the fuse table.
1, CSA C22.2 No. 274-17)

Frequency (f1) 50/60 Hz. Variation ±5% of nominal frequency.

Imbalance Max. ± 3% of nominal phase to phase input voltage

Fundamental power 1 (at nominal load)

factor (cos phi1)

Harmonic distortion
Harmonics are below the limits defined in IEEE 519-2014, and G5/4. The drive
complies with IEC 61000-3-2, IEC 61000-3-4 and IEC 61000-3-12.
The table below shows typical values of the drive for short-circuit ratio (Isc/I1)
of 20 to 100. The values will be met if the supply network voltage is not dis-
torted by other loads and when the drive operates at nominal load.
Nominal bus voltage V at PCC THDi (%) THDv (%)

V ≤ 690 V 3* < 3**

PCC Point on a public power supply system, electrically nearest to a par-

ticular load, at which other loads are, or could be, connected. The
PCC is a point located upstream of the considered installation.
THDi Indicates the total harmonic current distortion of the wave form.
This value is defined as the ratio (in %) of the harmonic current to
the fundamental (non-harmonic) current measured at a load point
at the particular moment when the measurement is taken:
40 2
∑ In
2
THDi = • 100%
I1

THDv Indicates the total magnitude of the voltage distortion. This value
is defined as the ratio (in %) of the harmonic voltage to the funda-
mental (non-harmonic) voltage:
40 2
∑U n
2
THDv = • 100%
U1

Isc/I1 Short-circuit ratio

Isc Maximum short-circuit current at PCC
I1 Continuous rms input current of the drive
In Amplitude of the current harmonic n
U1 Supply voltage
Un Amplitude of the voltage harmonic n
* The short-circuit ratio can influence the THDi value
** Other loads can influence the THDv value
196 Technical data

Motor connection data

Motor types Asynchronous AC induction motors, permanent magnet motors, AC induction
servomotors and ABB synchronous reluctance motors (SynRM motors)
Voltage (U2) 0 to U1, 3-phase symmetrical. This is indicated in the type designation label
as typical output voltage level as 3 0…U1, Umax at the field weakening point.
Frequency (f2) 0…500 Hz

Note: Operation above 150 Hz can require type-specific derating. For more
information, contact your local ABB representative.
For drives with du/dt filter: 120 Hz
For drives with sine filter: 120 Hz
Frequency resolution 0.01 Hz
Current See section Electrical ratings (Page 177).
Switching frequency 3 kHz (typically)
Maximum recommended DTC control: 500 m (1640 ft)
motor cable length Scalar control: 500 m (1640 ft)

Note: For restrictions due to EMC compatibility, see section EMC compliance
(IEC/EN 61800-3:2004) (Page 201).
Longer motor cables cause a motor voltage decrease which limits the available
motor power. The decrease depends on the motor cable length and character-
istics. Contact ABB for more information. Note that a sine filter (optional) at
the drive output also causes a voltage decrease.

DC connection data
ACS880-14-… Capacitance (mF)
Un = 400 V
246A-3 10.5
293A-3 10.5
363A-3 10.5
442A-3 10.5
505A-3 10.5
585A-3 14.0
650A-3 14.0
Un = 500 V
240A-5 10.5
260A-5 10.5
302A-5 10.5
361A-5 10.5
414A-5 10.5
460A-5 14.0
503A-5 14.0
Un = 690 V
142A-7 5.3
174A-7 5.3
210A-7 5.3
 Technical data 197

271A-7 5.3
330A-7 5.3
370A-7 5.3
430A-7 5.3

Control panel type

ACS-AP-W assistant control panel

Efficiency
Approximately 96.5% at nominal power level.

Ecodesign data (EU 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 for module

Degrees of protection (IEC/EN IP20 (standard)
60529) IP00 (option +0B051)
Enclosure types (UL 50/50E) UL Open Type
Overvoltage category III
(IEC/EN 60664-1)
Protective class (IEC/EN 61800- I
5-1)

Ambient conditions
The table shows environmental limits for the drive. The drive must be used in a heated,
indoor, controlled environment.

Operation Storage Transportation

installed for stationary in the package in the package
use

Installation site altitude For TN and TT neutral- - -

grounded network sys-
tems and IT ungrounded
network systems: 0 to
4000 m (13123 ft) above
sea level
Derating is needed
above 1000 m [3281 ft]):
refer to Altitude derat-
ing (Page 181)
198 Technical data

Surrounding air -15…+55 °C (5…131 °F). -40…+70 °C -40…+70 °C

temperature No frost allowed. Refer (-40…+158 °F) (-40…+158 °F)
to Surrounding air tem-
perature derat-
ing (Page 180)

Relative humidity 5…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 3C2 Class 1C2 Class 2C2

Solid particles Class 3S2. No conductive Class 1S3. (packing must Class 2S2
dust allowed. support this, otherwise
1S2)

Pollution degree 2

Atmospheric pressure 70…106 kPa 70…106 kPa 60…106 kPa

0.7 … 1.05 atmospheres 0.7 … 1.05 atmospheres 0.6 … 1.05 atmospheres

Vibration Max. 0.1 mm (0.004 in) Max. 1 mm (0.04 in) (5 … Max. 3.5 mm (0.14 in)
IEC 60068-2-6:2007, (10…57 Hz), max. 13.2 Hz), max. 7 m/s2 (2…9 Hz), max. 15 m/s2
10 m/s2 (33 ft/s2) (23 ft/s2) (13.2 … 100 Hz) (49 ft/s2) (9…200 Hz) si-
EN 60068-2-6:2008
(57…150 Hz) sinusoidal sinusoidal nusoidal

Shock Not allowed With packing max. With packing max.

IEC 60068-2-27:2008, 100 m/s2 (330 ft/s2), 100 m/s2 (330 ft/s2),
11 ms 11 ms
EN 60068-2-27:2009

Free fall Not allowed 100 mm (4 in) for weight 100 mm (4 in) for weight
over 100 kg (220 lb) over 100 kg (220 lb)

Storage conditions
Store the drive in humidity controlled enclosed environments. Keep the drive in its
package.

Colors
Drive enclosure: NCS 1502-Y (RAL 9002 / PMS 420 C).

Materials
￭ Drive
Refer to ACS880-04, ACS880-14, ACS880-34, ACS580-04, ACH580-04, ACH580-34,
ACQ580-04 and ACQ580-34 drives Recycling instructions and environmental
information (3AXD50000137688 [English]).

￭ Package materials for module products

This is a complete list of the package materials. The materials vary depending on the
frame size (packages do not contain all materials listed below).
 Technical data 199

• Cardboard (heavy duty quality with wet strength glue in large modules)
• Molded pulp
• Plywood
• Wood
• PP (strapping)
• EPP (foam)
• PE (plastic bag and/or VCI film)
• Metal (fixing clamps, screws).

￭ Package materials for options, accessories and spare parts

• 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.

￭ Materials of 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 large electrolytic capacitors
need selective treatment according to IEC 62635 guidelines. To aid recycling, plastic
parts are marked with an appropriate identification code.
Contact your local ABB distributor for further information on environmental aspects
and recycling instructions for professional recyclers. End of life treatment must follow
international and local regulations.

Applicable standards
The drive complies with these standards.

IEC 61800-5-1:2007 + Adjustable speed electrical power drive systems. Part 5-1: Safety requirements
AMD1:2016 – electrical, thermal and energy
EN 61800-5-1:2007 +
+A1:2017+A11:2021
200 Technical data

IEC 60204-1:2016 Safety of machinery. Electrical equipment of machines. Part 1: General require-
EN 60204-1:2018 ments.
Provisions for compliance: The final assembler of the machine is responsible
for installing:
• emergency-stop device
• supply disconnecting device
• IP00 drive module into a cabinet.

IEC 60529:1989 Degrees of protection provided by enclosures (IP code)

EN 60529:1991 + A2:2013

IEC/EN 61800-3:2004 + Adjustable speed electrical power drive systems. Part 3: EMC requirements
A1:2012 and specific test methods

UL 61800-5-1 First edi- UL Standard for Safety, Adjustable Speed Electrical Power Drive Systems –
tion Part 5-1: Safety Requirements – Electrical, Thermal and Energy

CSA C22.2 No. 0-10 General Requirements - Canadian Electrical Code, Part II

CSA C22.2 No. 274-17 Adjustable Speed Drives

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).

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.

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.

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.
 Technical data 201

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 61800-3:2004)

￭ Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic
equipment to operate without problems within an electromagnetic environment.
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 EMC filter +E202 / ARFI-10 and common mode filter
(+E208).
2. The motor and control cables are selected as specified in the hardware manual.
3. The drive is installed according to the instructions given in the hardware manual.
4. Maximum motor cable length is 150 meters.
202 Technical data

WARNING!
The drive may cause radio interference if used in a residential or domestic
environment. The user 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 EMC filter +E202 grounding
wire connected on IT (ungrounded) systems. The supply network becomes
connected to ground potential through the EMC filter capacitors which may
cause danger or damage to the unit.

￭ Category C3
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter +E200 or +E201.
2. The motor and control cables are selected as specified in the hardware manual.
3. The drive is installed according to the instructions given in the hardware manual.
4. Maximum motor cable length is 150 meters.

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.
 Technical data 203

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.

UL 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.
204 Technical data

• The maximum surrounding air temperature is 40 °C at rated output current. The

output current is derated for 40…55 °C.
• 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 integral solid state short circuit protection of the drive does not provide
branch circuit protection. Branch circuit protection must be provided in accordance
with the National Electrical Code and any additional local codes.
• 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.

Marine approval
Refer to ACS880-01…, ACS880-04…, ACS880-11…, ACS880-31…, ACS880-14… and
ACS880-34… +C132 marine type-approved drives supplement (3AXD50000010521
[English]).

Declarations of conformity
See the chapter The Safe torque off function (Page 221).

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

￭ Cybersecurity disclaimer
This product can be connected to and communicate information and data via a network
interface. The HTTP protocol, which is used between the commissioning tool (Drive
Composer) and the product, is an unsecured protocol. For independent and continuous
operation of product such connection via network to commissioning tool is not
 Technical data 205

necessary. However 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, prevention of physical
access, 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.
Notwithstanding any other provision to the contrary and regardless of whether the
contract is terminated or not, ABB and its affiliates are under no circumstances liable
for damages and/or losses related to such security breaches, any unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
206
 Dimension drawings 207

17
Dimension drawings

Contents of this chapter

This chapter contains dimension drawings of the drive modules with optional parts
for Rittal VX25 enclosure.
208 Dimension drawings

Standard configuration
 Dimension drawings 209

Location of power cable connection terminals with option

+H370

3AXD50000038012
210 Dimension drawings

Configuration with options +0B051+0H371

 Dimension drawings 211

Drive module with options +0B051+0H371

212 Dimension drawings

LCL filter module

 Dimension drawings 213

Configuration with option +H381

3AXD50000323210
214 Dimension drawings

Bottom plate
This drawing shows the dimensions of the bottom plate for 800 mm Rittal VX25
enclosure. It is not an ABB product.
 Dimension drawings 215

Air baffles
This drawing shows the dimensions of the air baffles around the standard drive module
for 800 mm Rittal VX25 enclosure.
These are not ABB products.

LEFT RIGHT

REAR FRONT

3AXD50000453931

￭ Material of the air baffles

0.75 mm polycabonate (PC) film LEXAN® FR60 (GE) with UL94 V–0 listing, UV stability.
(LEXAN® FR700 or Valox FR1 only with special permission). Unmarked bend radii
0.6 mm.
216 Dimension drawings

Air baffles for option +H381 in 800 mm wide Rittal VX25

enclosure
This drawing shows the dimensions of the air baffles for the full cabling panels option
(+H381) in 800 mm Rittal VX25 enclosure. These are not ABB products.

LEFT RIGHT

REAR FRONT

3AXD50000453931
 Dimension drawings 217

External control unit

3AXD50000011687
218
 Example circuit diagrams 219

18
Example circuit diagrams

Contents of this chapter

This chapter shows an example circuit diagram for a cabinet-installed drive module.

Example circuit diagram

This diagram is an example for the main wiring of a drive cabinet. Note that the diagram
includes components which are not included in a basic delivery (* plus code options,
** other options, *** to be acquired by the customer).
220 Example circuit diagrams

X7 X8 1 2 V2 V1 V21 V20
X3
ZBIB

3
4
V13 V8 V7 V2 X2 INU
QOIA STO

5
6
9
7

10 11 12

3~
13

1 Cabinet
2 *ACS-AP-W control panel
3 ZCU control unit
4 ***Main contactor
5 **Motor temperature supervision
6 ***Switch fuse disconnector
7 *Common mode filter
8 **du/dt filter or sine filter
9 Drive module
10 Input and output signals
11 Alarm
12 Supply
13 360° grounding recommended
 The Safe torque off function 221

19
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.
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
222 The Safe torque off function

Standard Name

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
The Declarations of conformity are shown at the end of this chapter.
 The Safe torque off function 223

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 safety functions module, an FSPS safety functions module or an FPTC
thermistor protection 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

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 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.
224 The Safe torque off function

￭ Single drive (internal power supply)

Dual-channel connection

2 +24 V OUT
SGND K

IN1
IN2

1 Drive
2 Control unit
K Activation switch
 The Safe torque off function 225

Single-channel connection

1
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.
226 The Safe torque off function

￭ Multiple drives
Internal power supply

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
* Terminal designation may vary depending on drive type
 The Safe torque off function 227

External power supply

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
* Terminal designation may vary depending on drive type
228 The Safe torque off function

Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay
contacts open).
2. The STO inputs 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 (see
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.
 The Safe torque off function 229

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 +Q972, +Q973 or +Q982, also do the
procedure shown in the FSO module documentation.
If an FSPS-21 module is installed, refer to its documentation.

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.

230 The Safe torque off function

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 (see 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 (see 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 (see 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.
 The Safe torque off function 231

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 (see
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 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
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.
232 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; see section Safety data (Page 235).
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: See also the Recommendation of Use CNB/M/11.050 (published by the European
co-ordination of Notified Bodies) concerning dual-channel safety-related systems
with electromechanical outputs:
• When the safety integrity requirement for the safety function is SIL 3 or PL e (cat.
3 or 4), the proof test for the function must be performed at least every month.
• When the safety integrity requirement for the safety function is SIL 2 (HFT = 1) or
PL d (cat. 3), the proof test for the function must be performed at least every 12
months.

The STO function of the drive does not contain any electromechanical components.
In addition to proof testing, it is a good practice to check the operation of the function
when other maintenance procedures are carried out on the machinery.
Include the Safe torque off operation test described above in the routine maintenance
program of the machinery that the 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 229).
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 233

￭ 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.
234 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.
See 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 235

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
R11 3 3 e 3.65E-09 8.00E-05 1.60E-04 3.20E-04 18327 ≥90 99.65 3 1 80 20 7.50E-11 7.70E-07 7.50E-09
3AXD10001609379 A
236 The Safe torque off function
 The Safe torque off function 237

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

• 670 on/off cycles per year with ΔT = 71.66 °C
• 1340 on/off cycles per year with ΔT = 61.66 °C
• 30 on/off cycles per year with ΔT = 10.0 °C
• 32 °C board temperature at 2.0% of time
• 60 °C board temperature at 1.5% of time
• 85 °C board temperature at 2.3% of time.
• The STO is a type 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), 30 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
238 The Safe torque off function

Term or Reference Description

abbreviation
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
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 at www.abb.com/drives/documents.
 The Safe torque off function 239

￭ Declarations of conformity

ABB
EU Declaration of Conformity
Machinery Directive 2006/42/EC
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxx
We
Manufacturer: ABB Oy
Address: Hiomotie 13, 00380 Helsinki, Finland.
Phone: +358 10 22 11
declare under our sole responsibility that the following products:

Frequency converters

ACS880-01/-11/-31
ACS880-04/-04F/-M04/-14/-34
with regard to the safety functions

- Safe Torque Off

- Safe stop 1, Safe stop emergency, Safely-limited speed, Safe maximum speed, Safe brake control, Prevention of unexpected start-up
(with FSO-12 option module, +Q973, encoderless)
- Safe stop 1, Safe stop emergency, Safely-limited speed, Safe maximum speed, Safe brake control, Safe speed monitor, Safe direction,
Prevention of unexpected start-up (with FSO-21 and FSE-31 option modules, +Q972 and +L521, encoder supported)
- Safe motor temperature (with FPTC-01 thermistor protection module, +L536)
- Safe stop 1 (SS1-t, with FSPS-21 PROFIsafe module, +Q986)

are in conformity with all the relevant safety component requirements of EU Machinery Directive 2006/42/EC, when the listed safety functions are
used for safety component functionality.

The following harmonized standards have been applied:

EN 61800-5-2:2007 Adjustable speed electrical power drive systems – Part 5-2: Safety 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
requirements
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of the control systems. Part 2:
Validation
EN 60204-1:2018 Safety of machinery – Electrical equipment of machines – Part 1: General
requirements
The following other standards have been applied:

IEC 61508:2010, parts 1-2 Functional safety of electrical / electronic / programmable electronic safety-
related systems
IEC 61800-5-2:2016 Adjustable speed electrical power drive systems – Part 5-2: Safety requirements -
Functional

The product(s) referred in this Declaration of conformity fulfil(s) the relevant provisions of other European Union Directives which are notified in
Single EU Declaration of conformity 3AXD10000497831.

Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland.

Helsinki, August 31, 2022

Signed for and on behalf of:

Mika Vartiainen Aaron D. Wade

Local Division Product Unit Manager
Manager ABB Oy
ABB Oy

Document number 3AXD10000099646

Page 1 of 1
240 The Safe torque off function

ABB
Declaration of Conformity
Supply of Machinery (Safety) Regulations 2008
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxx
We
Manufacturer: ABB Oy
Address: Hiomotie 13, 00380 Helsinki, Finland.
Phone: +358 10 22 11
declare under our sole responsibility that the following products:

Frequency converters

ACS880-01/-11/-31
ACS880-04/-04F/-M04/-14/-34
with regard to the safety functions

- Safe Torque Off

- Safe stop 1, Safe stop emergency, Safely-limited speed, Safe maximum speed, Safe brake control, Prevention of unexpected start-up
(with FSO-12 option module, +Q973, encoderless)
- Safe stop 1, Safe stop emergency, Safely-limited speed, Safe maximum speed, Safe brake control, Safe speed monitor, Safe direction,
Prevention of unexpected start-up (with FSO-21 and FSE-31 option modules, +Q972 and +L521, encoder supported)
- Safe motor temperature (with FPTC-01 thermistor protection module, +L536)
- Safe stop 1 (SS1-t, with FSPS-21 PROFIsafe module, +Q986)

are in conformity with all the relevant safety component requirements of the Supply of Machinery (Safety) Regulations 2008, when the listed
safety functions are used for safety component functionality.

The following designated standards have been applied:

EN 61800-5-2:2007 Adjustable speed electrical power drive systems – Part 5-2: Safety 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
requirements
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of the control systems. Part 2:
Validation
EN 60204-1:2018 Safety of machinery – Electrical equipment of machines – Part 1: General
requirements
The following other standards have been applied:
EN 61508:2010, parts 1-2 Functional safety of electrical / electronic / programmable electronic safety-
related systems
EN 61800-5-2:2017 Adjustable speed electrical power drive systems – Part 5-2: Safety requirements -
Functional

The product(s) referred in this declaration of conformity fulfil(s) the relevant provisions of other UK statutory requirements, which are notified in
a single declaration of conformity 3AXD10001326405.

Authorized to compile the technical file: ABB Limited, Daresbury Park, Cheshire, United Kingdom, WA4 4BT.

Helsinki, August 31, 2022

Signed for and on behalf of:

Mika Vartiainen Aaron D. Wade

Local Division Product Unit Manager
Manager ABB Oy
ABB Oy

Document number 3AXD10001329538

Page 1 of 1
 Filters 241

20
Filters

Contents of this chapter

This chapter describes how to select du/dt and sine filters for the drive.

du/dt filters
￭ When is a du/dt filter necessary?
See section Examining the compatibility of the motor and drive (Page 68).

￭ Selection table
du/dt filter types for the drive modules are given below.

ACS880-14-… du/dt filter type ACS880-14-… du/dt filter type ACS880-14-… du/dt filter type
Un = 400 V Un = 500 V Un = 690 V
246A-3 FOCH0260-7x 240A-5 FOCH0260-7x 142A-7 FOCH0260-7x
293A-3 FOCH0260-7x 260A-5 FOCH0260-7x 174A-7 FOCH0260-7x
363A-3 FOCH0320-5x 302A-5 FOCH0320-5x 210A-7 FOCH0260-7x
442A-3 FOCH0320-5x 361A-5 FOCH0320-5x 271A-7 FOCH0260-7x
505A-3 FOCH0610-7x 414A-5 FOCH0320-5x 330A-7 FOCH0610-7x
585A-3 FOCH0610-7x 460A-5 FOCH0320-5x 370A-7 FOCH0610-7x
650A-3 FOCH0610-7x 503A-5 FOCH0610-7x 430A-7 FOCH0610-7x

￭ Ordering codes

Filter type Degree of protection ABB ordering code

FOCH0320-50 IP00 68612209
FOCH0320-52 IP22 3AXD50000030047
242 Filters

Filter type Degree of protection ABB ordering code

FOCH0260-70 IP00 68490308
FOCH0260-72 IP22 3AXD50000030048
FOCH0610-70 IP00 68550505

￭ Description, installation and technical data of the FOCH filters

See FOCH du/dt filters hardware manual (3AFE68577519 [English]).

Sine filters
￭ When is a sine filter necessary?
See section Examining the compatibility of the motor and drive (Page 68).

￭ Selection table
Sine filter types for the drive modules are given below.

ACS880-14-… Sine filter type ACS880-14-… Sine filter type ACS880-14-… Sine filter type
Un = 400 V Un = 500 V Un = 690 V
246A-3 B84143V0230S229 240A-5 B84143V0230S229 142A-7 B84143V0130S230
293A-3 B84143V0390S229 260A-5 B84143V0230S229 174A-7 B84143V0207S230
363A-3 B84143V0390S229 302A-5 B84143V0390S229 210A-7 B84143V0207S230
442A-3 B84143V0390S229 361A-5 B84143V0390S229 271A-7 B84143V0207S230
505A-3 NSIN0900-6 414A-5 B84143V0390S229 330A-7 NSIN0485-6
585A-3 NSIN0900-6 460A-5 NSIN0485-6 370A-7 NSIN0485-6
650A-3 NSIN0900-6 503A-5 NSIN0900-6 430A-7 NSIN0485-6
3AXD00000588487

￭ ABB ordering codes

Filter type ABB ordering code

NSIN0485-6 64254936
NSIN0900-6 64254961

￭ Derating
See section Deratings for special settings in the drive control program.

￭ Description, installation and technical data of the sine filters

See Sine filters hardware manual (3AXD50000016814 [English]) and manufacturer’s
site on the Internet:
https://en.tdk.eu/tdk-en/1029890/products/product-catalog/emccomponents/
output-filters--epcos-.
 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure 243
Step-by-step drawings for an installation example of standard drive configuration
in Rittal VX25 800 mm wide enclosure
See:
• Handling the drive module, power cable connection diagram (Page 243)
• Installing the drive module and LCL filter module into a Rittal VX25 enclosure (Page 244)
• Connecting the motor cables and installing the shrouds (Page 249)
• Connecting the input power cables and installing the shrouds (Page 252)
• Connecting the external control cables to the control unit (Page 254)
• Installing the air baffles and removing the cardboard covers (Page 255)
244 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure
Handling the drive module, power cable connection diagram

(PE) PE (PE) L1 L2 L3

L1 L2 L3
PE

3AUA0000086323

ACS880-14
L1/ L2/ L3/
UDC- UDC+
1 3 U1 V1 W1
INPUT
PE
OUTPUT
T1/ T2/ T3/
U2 V2 W2

V1
U1 W1

3 ~
M

WARNING! The UDC+ and UDC- terminals of the drive

module must not be used for any other than optional
external brake chopper connection.
 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure 245
Installing the drive module and LCL filter module into a Rittal VX25 enclosure
See instructions in section Installing the drive module and LCL filter module into an enclosure (Page 128).

Rittal 8806.000

non-ABB part (see dimension drawings)

Rittal 8617.140
3 80.5
(3.17)

4 280.5
(11.04)

5
Tapping screw M6×12

1705.5 (67.15)
Torx T30 8 N·m (71 lbf·in)

3 360 °

6
246 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure

9
8
11

Tapping screw M6×12 Torx T30

(Hex) 8 N·m (71 lbf·in)

Combi screw
M8×30 Hex
20 N·m
(14.75 lbf·ft)

10 12
 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure 247

15

16

Combi screw M4×8

Torx T20 2 N·m (18 lbf·in)
18

17

Combi screw M4×8

Torx T20 2 N·m
(18 lbf·in)

17

14

Combi screw M4×8

Torx T20 2 N·m
(18 lbf·in)
19
248 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure

21
21

M6 Serpress
8 N·m (71 lbf·in)

M6 Serpress
8 N·m (71 lbf·in)

22

23 23
Screw M10x30
and washer

Combi screw M8
Combi screw M8
24 N·m (17.70 lbf·ft)
24 N·m (17.70 lbf·ft)
 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure 249

25

M10×30

24
Combi screw M4×8
Torx T20 2 N·m
(18 lbf·in)

Combi screw
M12×25 70 N·m (52 lbf·ft)

26

FAN3:LCL
Combi screw
M4×8 Torx T20
2 N·m (18 lbf·in)
250 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure
Connecting the motor cables and installing the shrouds
See instructions in section Connecting the motor cables and installing the shrouds (Page 129).

2
4
 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure 251

5 7 9

T3/W2 T3/W2 T3/W2

T2/V2 T2/V2 T2/V2

T1/U2 T1/U2 T1/U2

252 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure

13

14

10
Combi screw
M4×10 Torx T20
2 N·m (18 lbf·in)

Combi screw M6×20

15
Torx T25 2 N·m (18 lbf·in)

12

11

Combi screw M6×20

Torx T25 2 N·m (18 lbf·in)

16
 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure 253
Connecting the input power cables and installing the shrouds
See instructions in section Connecting the input cables and installing the shrouds (Page 130)

5
UDC+ UDC+ UDC+
UDC- UDC- UDC-
L1/U1 L3/W1 L1/U1 L3/W1 L2/V1 L1/U1
L2/V1 Hex screw M12×35 L2/V1
L3/W1 full thread
70 N·m (52 lbf·ft)

4
Hex nut M12
70 N·m (52 lbf·ft)
254 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure

15

13
UDC+
UDC-
L3/W1 L2/V1 L1/U1
Combi screw
14
M4×10 Torx T20
2 N·m (18 lbf·in)

Combi screw
M4×10 Torx T20
2 N·m (18 lbf·in)

Combi screw
M6×20 Torx T25
2 N·m (18 lbf·in)
 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure 255
Connecting the external control cables to the control unit
See instructions in section Connecting the control cables to the terminals of the external control unit (Page 104).

@
@

8
5
256 Step-by-step drawings for an installation example of standard drive configuration in Rittal VX25 800 mm wide enclosure
Installing the air baffles and removing the cardboard covers
See instructions in section Air baffles (Page 215)
—
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and service
contacts can be found by navigating to www.abb.com/searchchannels.

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
new.abb.com/drives/manuals-feedback-form.

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.

a6 (frozen)
PDF-A4
Created 2023-04-03, 15:43:05
www.abb.com/drives

3AXD50000035160E

3AXD50000035160 Rev E (EN) 2023-04-03

© Copyright 2023 ABB. All rights reserved.

Specifications subject to change without notice.