ACS880-107LC Inverter Units: Hardware Manual

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ABB INDUSTRIAL DRIVES
ACS880-107LC inverter units

Hardware manual
ACS880-107LC inverter units
Hardware manual
Table of contents
3. Electrical installation
5. Start-up
3AXD50000196111 Rev D
EN
Original instructions
EFFECTIVE: 2023-06-30
Table of contents 5
Table of contents
1 Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Use of component designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Operation principle and hardware description

Overview diagram of the drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inverter unit hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inverter module hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Coolant connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connectors X50, X52 and X53; Auxiliary voltage selector X59 . . . . . . . . . . . . . . . . . . . 18
Fiber optic connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Coolant connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connectors X50…X59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fiber optic connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Overview of the control connections of the BCU control unit . . . . . . . . . . . . . . . . . . . . . . . 26
The control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control by PC tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inverter unit type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inverter module type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inverter unit type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Electrical installation
Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6 Table of contents
Optical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Measuring the insulation resistance of the motor and motor cable . . . . . . . . . . . . . . . 35
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Grounding the outer shields of the control cables 360° at the cabinet entry . 36
Routing the control cables inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connecting control cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Frame R7i – Connecting the motor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Motor cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removing the shrouding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Connecting the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Replacing the shrouding and connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Frame R8i and multiples – Connecting the motor cables (units without common
motor terminal cubicle or sine output filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Motor connection diagram (without option +H366) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Motor connection diagram (with option +H366) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removing the shrouds and fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Replacing shrouds and fans and connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Frame R8i and multiples – Connecting the motor cables (units with common motor
terminal cubicle or sine output filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Output busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Opening the door and removing the shrouding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Replacing the shrouding and connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Use of fasteners in cable lug connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Panel bus (Control of several units from one control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder
interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation of an FSO safety functions module onto BCU . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Wiring of optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4 Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5 Start-up
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6 Maintenance
Table of contents 7
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Description of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Recommended maintenance intervals after start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Maintenance timers and counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Frame R7i cabinet fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Inverter module cubicle with one module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Inverter module cubicle with two modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Frame R7i – internal module fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Frame R8i fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Replacing the common motor terminal cubicle fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Replacing an R7i inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Frame R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Assembling the service platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Removing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Reinstalling the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Activating the reduced run of the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inverter module cubicle with one module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inverter module cubicle with two modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
BCU control unit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Replacing the BCU control unit battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Functional safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7 Control units of the drive

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
BCU-x2 layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Default I/O diagram of the inverter control unit (BCU-x2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Additional information on the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Connecting motor temperature sensors to the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DIIL input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
The XD2D connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Safe torque off (XSTO, XSTO OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
FSO safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SDHC memory card slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
BCU-x2 ground isolation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8 The Safe torque off function

8 Table of contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Compliance with the European Machinery Directive and the UK Supply of Ma-
chinery (Safety) Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Dual-channel connection with internal power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Single-channel connection of activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Multiple drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Internal power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
External power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Start-up including validation test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Validation test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Validation test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Perfect proof test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Simplified proof test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
TÜV certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9 Internal cooling circuit

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Internal cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Connection to a cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Connection to an ACS880-1007LC cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Connection to a custom cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Coolant temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Filling up and bleeding the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Drive line-ups with an ACS880-1007LC cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Drive line-ups with a custom cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Draining the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Coolant specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Coolant type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Temperature limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Pressure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Coolant flow rate limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Cooling circuit materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Table of contents 9
10 Technical data
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Surrounding air temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Coolant temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Antifreeze content derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Supply voltage derating (frame n×R8i inverter units with diode supply unit) . 138
Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Output frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Inverter unit frame sizes and modules used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Input power (DC) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Motor (AC) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Terminal and cable entry data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Terminal data for the motor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Terminal data for the inverter control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Energy efficiency data (ecodesign) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Optical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Packaging of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Packaging of options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Mechanical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Insulation supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
11 Dimensions
Cabinet line-up dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Dimension drawing examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Cabinet height and depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10 Table of contents
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Location and size of output terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Units without common motor terminal cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Inverter module cubicle with one R7i module, bottom cable exit . . . . . . . . . . . . . . . 161
Inverter module cubicle with two R7i modules, bottom cable exit . . . . . . . . . . . . . 162
Inverter module cubicle with one R8i module, bottom cable exit . . . . . . . . . . . . . . . 163
Inverter module cubicle with two R8i modules, bottom cable exit . . . . . . . . . . . . . 164
Inverter module cubicle with three R8i modules, bottom cable exit . . . . . . . . . . . 165
Units with common motor terminal cubicle (+H359) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Cubicle width 300 mm, bottom cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Cubicle width 300 mm, top cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Cubicle width 400 mm, top cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Cubicle width 600 mm, top cable exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Further information
Introduction to the manual 11
1
Introduction to the manual
Contents of this chapter

This chapter gives basic information on the manual.
Applicability
This manual is applicable to ACS880-107LC inverter units that form a part of a drive
system.
Safety instructions
Obey all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, use or
service the drive. The complete safety instructions are given in ACS880
liquid-cooled multidrive cabinets and modules safety instructions
(3AXD50000048633 [English]).
• Read the software-function-specific warnings and notes before changing the
default settings of a function. For each function, the warnings and notes are given
in the section describing the related user-adjustable parameters.
• Read the task-specific safety instructions before starting the task. See the section
describing the task.
Target audience
This manual is intended for people who plan the installation, install, commission 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.
12 Introduction to the manual
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

Some descriptions, instructions, technical data and other information that concern
only a certain group of units may be marked with the frame size (such as "R8i", "4×R8i",
etc.) The marking derives from the quantity and basic construction of the modules
that form the unit. For example, the frame size "2×R8i" indicates that the unit consists
of two frame size R8i modules connected in parallel.
The frame size is marked on the type designation labels. The frame size of each unit
is also shown in the rating tables in chapter Technical data (page 135).
The information that concerns only certain optional selections is marked with option
codes (such as +E205). The options included in the unit can be identified from the
type code visible on the type designation label. The option selections are listed in
section Inverter unit type designation key (page 29).
Use of component designations

Some device names in the manual include the component designation in brackets (for
example, [Q20]). This will help you to identify the components in the circuit diagrams
of the drive.
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.
Manuals for ACS880 multidrives cabinets

Introduction to the manual 13
Terms and abbreviations

Term Description
BCU Type of control unit
CIO I/O module for controlling cooling fans
Drive Frequency converter for controlling AC motors
EMC Electromagnetic compatibility
EMI Electromagnetic interference
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
FIO-11 Optional analog I/O extension 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
FSO-12, FSO-21 Optional functional safety modules
IGBT Insulated gate bipolar transistor
Inverter unit Inverter module(s) under control of one control unit, and related components.
One inverter unit typically controls one motor.
Power module Common term for drive module, inverter module, supply module, brake
chopper module etc.
RFI Radio-frequency interference
STO Safe torque off (IEC/EN 61800-5-2)
Supply unit Supply module(s) under control of one control unit, and related components.
14
Operation principle and hardware description 15
2
Operation principle and hardware
description

This chapter describes a typical drive system and the hardware of the inverter unit.
Overview diagram of the drive system

This diagram shows an example of a multidrive. The supply unit connects the drive to
the AC supply network. It converts the AC voltage into DC. The DC voltage is distributed
through the DC bus to all inverter units and optional brake units. The inverter unit
converts the DC back to AC that rotates the motor. The brake unit (optional) conveys
energy to brake resistors whenever needed.
B C C D
5
7 7 7 7
6 9
4 8 8 10
3 12
1 13 11
A Incoming unit
B Supply unit
C Inverter unit
D Brake unit (optional)
1 AC supply
2 Main breaker, or main contactor and main switch-disconnector
3 Input (AC) fuses
4 Supply module
5 DC bus
6 Supply and inverter module DC fuses
7 DC switch/disconnector (optional)
8 Inverter modules
9 Brake chopper fuses
10 3-phase brake chopper module (optional)
11 Brake resistors (optional or acquired by user)
12 Fuses for the brake resistors
13 Motor(s) (acquired by user)
Inverter unit hardware

￭ General
An inverter unit contains the components required to control one motor. These include
one or more inverter modules connected in parallel, together with the necessary
auxiliary equipment such as control electronics, fusing, cabling and switchgear.
ACS880-107LC inverter units range from 55 to 6000 kW in power. The units employ
ACS880-104LC modules. Up to approximately 800 kW, inverter units consist of one
module only; higher power ratings are achieved by connecting multiple modules in
parallel.
All inverter modules have coated circuit boards as standard.
Inverter module hardware

￭ Frame R7i
Frame R7i modules provide output power in the range of 55 to 355 kW.
Each module is mounted in an installation frame. The frame has quick connectors for
both the DC and AC power connections, so the module can be easily extracted from
the cabinet. The module is secured to its frame by a locking screw that is accessible
from the front.
The front cover plate of the module can be pulled out for access to the circuit board
compartment without removing the module.
690 volt modules have internal du/dt filtering by default. For 500 volt modules this is
available as an option.
Control unit
R7i modules employ a separate control unit (BCU) that contains the BCON board with
basic I/Os and slots for optional I/O modules. A fiber optic link connects the BCU to
each inverter module. Any safety circuits utilizing the built-in Safe torque off
functionality are connected to the BCU. The forwarding connector of the BCU is wired
to the inverter module.
Module layout
7
3
4 3
W
–
V
+
6
5
U
1 8
1 Handle
2 Lifting eye, front
3 Locking screw (for 6 mm hex key). Torque: 5 N·m (3.7 lbf·ft) maximum.
4 Coolant out connector
5 Coolant in connector
6 Connectors X50, X52 and X53; fiber optic connectors; LEDs; auxiliary voltage selector X59.
7 Lifting ring, rear
8 Guide pin
+
DC connection busbars. The busbars engage with the quick connectors of the installation frame.
–
U
V AC connection busbars. The busbars engage with the quick connectors of the installation frame.
W
Coolant connectors
The coolant pipe inlet and outlet connectors are located at the bottom front and top
front of the module respectively. The connectors are for 16/13 millimeter PA (polyamide)
pipe.
Connectors X50, X52 and X53; Auxiliary voltage selector X59

R7i modules contain a power supply board that provides 24 V DC for the circuit boards
of the module.
The power supply board of the module is powered internally from the DC link.
Auxiliary voltage input for internal power supply of module. Voltage selected
by X59.
24 V DC output (for eg. BCU control unit)
Incoming STO signals from BCU control unit
Auxiliary voltage: 230 V AC

Fiber optic connectors
Name Description
V20
BCU
V10 BCU Control unit connection.
V60
BSFC BSFC Charging controller connection.
V50
LEDs
LED Color Indication
FAULT Continuous red There is an active fault in the module.
ENABLE / STO Continuous green The module is ready for use.
ENABLE / STO Continuous yellow XSTO connectors are de-energized.
POWER OK Continuous green Supply voltage of the internal circuit boards is OK (> 21 V).
Cabinet layout
Frame R7i inverter units are available in two different cubicles, ie. a 300 mm wide
cubicle for one module, and a 400 mm wide cubicle with two modules. Each module
has its own control unit and output terminals.
Single-module
cubicle Two-module cubicle
1
2
2 4 4
3 5
7
6
6
5
8
8 10 10
10 10 9
11 11
No. Description
1. DC switch-disconnector (optional for one-module cubicle)
2. DC fuses
3. Charging switch (one-module cubicle with DC switch-disconnector)
4. Control unit. In a two-module cubicle, each inverter module has its own control unit.
5. Cooling fan and heat exchanger. Single-module cubicles have one fan, two-module cubicles have
two fans.
6. Inverter module
7. CIO module for fan monitoring
8. Output terminals. In a two-module cubicle, the set of busbars closer to the back wall are the output
of the upper module.
9. Mounting plate for control circuit components (present if required by option selection)
10. Stop valves for incoming and outgoing coolant; drain valves and hoses
11. Power and control cable entries
￭ Frame R8i and multiples

Frame R8i modules are used to achieve output powers from approximately 350 kW
upwards in single or parallel configurations.
The DC connection of the module is by busbars and located at the top. The motor
connection is via a quick connector at the back of the module that couples when the
module is inserted into the cubicle. Each parallel-connected module is cabled separately
to the motor, or connected by busbars to adjacent modules to reduce the number of
cables. It is also possible to build an AC bus from each module to a separate output
cubicle.
Internal du/dt filtering is mandatory with all 690 volt units and all parallel-connected
modules. 690 volt modules have internal du/dt filtering as standard.
Control unit
Inverter units consisting of one or several R8i modules employ a separate control unit
(BCU) that contains the BCON board with basic I/Os and slots for optional I/O modules.
A fiber optic link connects the BCU to each inverter module. Any safety circuits utilizing
the built-in Safe torque off functionality are connected to the BCU. The forwarding
connector of the BCU is wired to the inverter module(s).
Module layout
1a 1b 2b
11 2a
7 9 8
10
3a 6
3b
No. Description
1. DC input busbars
2. Lifting eyes, front (a) and back (b)
3. Coolant in (a) and out (b) connectors. See section Coolant connectors.
4. Handle
5. Fiber optic connectors. See section Fiber optic connectors.
6. Quick connector (AC output) (the counterpart fastened to the cabinet behind the module)
7. Terminal block X50 (auxiliary power input for internal boards). See section Connectors X50…X59.
8. Terminal block X51 and X52 (Safe torque off). See section Connectors X50…X59.
9. Terminal block X53 (24 V DC power output). See section Connectors X50…X59.
10. Auxiliary voltage selector (115 or 230 V). See section Connectors X50…X59.
11. Unpainted fastening hole. The grounding point (PE) between module frame and cabinet frame.
Coolant connectors
The coolant pipe inlet and outlet connectors are located at the bottom front of the
module. The connectors are for 16/13 millimeter PA (polyamide) pipe.
WARNING!
For a reliable connection, the end of the pipe entering the connector must be
completely intact for a length of at least 5 cm (2”). Make sure the pipe is
perfectly round where it enters the connector, and not deformed eg. by any
bends nearby. The piping must not exert any tension or torque on the connector.
Connectors X50…X59
R8i modules contain a power supply (BDPS) that provides 24 V DC for the circuit boards
of the module. The 24 V DC voltage provided by the BDPS is also available on X53, and
can be used to power the BCU control unit of a single R8i inverter module.
Note: With an inverter unit consisting of parallel-connected R8i modules, it is strongly

recommended to use an external 24 V DC supply to power the BCU control unit.
The BDPS is powered internally from the DC link. An auxiliary voltage of 230 V AC or
115 V AC (selectable) can optionally be fed to terminal block X50 to power the BDPS
even when the DC link is not live. The selection between 115 V and 230 V is made with
selector plug X59. The setting can be changed by removing the two screws, turning
the plug 180 degrees, and reinstalling the screws.
If the Safe torque off (STO) function is not used, the “24V” inputs on X52 must be
connected to +24 V (on connector X53, for example) on each inverter module. On a
new module, a jumper wire set installed at the factory makes this connection.
If the STO function is to be implemented, the jumper wire set must be removed – a
mechanical interlocking device is factory-installed on connectors X51 and X52 to this
effect.
For STO, X52 (STO IN) is wired to the STO OUT connector on the BCU control unit.
Connector X51 on the module is wired to connector X52 on the next module (if present).
For details, see chapter The Safe torque off function (page 107).
AC IN
X50
N
Auxiliary voltage inputs for internal power supply (BDPS)
POWER
24V OUT
X53
GND 24 V DC output (for eg. BCU control unit)
+24V
GND
+24V
FE
STO IN
X52
STO signals from BCU control unit
+24V
GND
+24V
GND
FE
STO OUT
X51 STO signal forwarding output to next inverter module (if
present)
+24V
GND
+24V
GND
FE
Fiber optic connectors
BSFC V50← Name Description
V60→ BSFC Reserved.
BCU V10← BCU Control unit connection. Must be con-

nected by the installer.
V20→
Cooling system
See chapter Internal cooling circuit (page 127).
Control interfaces

￭ Overview of the control connections of the BCU control unit
The diagram shows the control connections and interfaces of the BCU control unit.
CLOSE
7
9 FXX
1
FXX
2
3
F XXX
6
5 10
1 Analog and digital I/O extension modules and 7 Control panel.

2 fieldbus communication modules can be in-
3 serted into slots 1, 2 and 3.
4 Memory unit 8 Fiber optic links to power modules (inverter,
supply, brake or converter)
5 Slot 4 for RDCO-0x 9 Ethernet port. Not in use.
6 Terminal blocks. 10 Safety option interface. Only in use for the
inverter units.
￭ The control panel

The AC…-AP-… control panel is the user interface of the inverter unit, providing the
essential controls such as Start/Stop/Direction/Reset/Reference, and the parameter
settings for the control program.
One control panel can be used to control several inverter units through a panel link
provided that each unit is equipped with panel holder or an FDPI-02 module.
Note: A control panel is required for the commissioning of an ACS880 drive system,
even if the Drive composer PC tool is used.
For details on the control panel, see ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant
control panels user’s manual (3AUA0000085685 [English]).
Control by PC tools
There is a USB connector on the front of the panel that can be used to connect a PC
to the drive. When a PC is connected to the control panel, the control panel keypad is
disabled.
For more information, see section Connecting a PC.
Type designation labels

￭ Inverter unit type designation label
Each inverter unit has a type designation label attached onto the inside of the cubicle
door. Note that an inverter unit may consist of several cubicles and inverter modules.
The type designation stated on the label contains information on the specifications
and configuration of the unit. The first digits express the basic construction of the
unit, for example “ACS880-107LC-0600A-7”. Any optional selections are given thereafter,
separated by plus signs.
Quote the complete type designation and serial number when contacting technical
support on the subject of individual inverter modules. An example of the label is shown
below.
4
5
2
3 6
No. Description
1 Type designation (see Inverter unit type designation key)
2 Frame size
3 Cooling method, degree of protection, additional UL/CSA specifications
4 Ratings (see also section Ratings (page 136))
5 Valid markings. See ACS880 liquid-cooled multidrive cabinets and modules electrical planning
(3AXD50000048634 [English]).
6 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.
￭ Inverter module type designation label

Each inverter module has a type designation label attached to it. The type designation
stated on the label contains information on the specifications and configuration of
the unit. The first digits express the basic construction of the unit, for example
“ACS880-104LC-0850A-7”. Any optional selections are given thereafter, separated by
plus signs.
Quote the complete type designation and serial number when contacting technical
support on the subject of individual inverter modules.
Inverter unit type designation key

The type designation contains information on the specifications and configuration
of the unit. The first digits from left express the basic configuration (for example,
ACS880-107LC-0850A-7). The optional selections are given thereafter, separated by
plus signs. The main selections are described below. Not all selections are available
for all types.
Code Description
B054 IP42 (UL Type 1 Filtered)
C121 Marine construction
C128 Air inlet through bottom of cabinet
C129 UL Listed (evaluated to both U.S. and Canadian safety requirements)
E205 du/dt filtering
E208 Common mode filtering
F286 DC switch-disconnector
G300 Cabinet and module heating elements (external supply)
G301 Cabinet lighting
G304 Control (auxiliary) voltage 115 V AC
G313 Output for motor space heater (external supply)
G330 Halogen-free wiring and materials
G338 Wire marking class A1
G341 Wire marking class B1
G342 Wire marking class C1
H353 Power cabling exit from top
H359 Common motor terminal cubicle
H366 Common output terminals (for inverter modules mounted in the same cubicle)
H394 Cable entry, Roxtec frame without sealing components
J400 ACS-AP-W control panel (with Bluetooth)
J410 Control panel mounting platform
K450 Panel bus (control of several units from one control panel)
K451 FDNA-01 DeviceNet™ adapter module
K452 FLON-01 LonWorks® adapter module
K454 FPBA-01 PROFIBUS DP® adapter module
K457 FCAN-01 CANopen® adapter module
K458 FSCA-01 RS-485 (Modbus/RTU) adapter module
K462 FCNA-01 ControlNet™ adapter module
K469 FECA-01 EtherCAT® adapter module
K470 FEPL-02 Ethernet POWERLINK adapter module
K473 FENA-11 Ethernet adapter module for EtherNet/IP™, Modbus TCP® and PROFINET IO® protocols
FENA-21 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols,
K475
2-port
K480 Ethernet switch for PC tool or control network (for max. 6 inverter units)
Code Description
K483 Ethernet switch with optical link for PC tool or control network (for max. 6 inverter units)
L500 FIO-11 analog I/O extension module
L501 FIO-01 digital I/O extension module
L502 FEN-31 HTL incremental encoder interface module
L503 FDCO-01 optical DDCS communication adapter module
L504 Additional I/O terminal block
L505 Thermal protection with PTC relays (1 or 2 pcs)
L506 Thermal protection with Pt100 relays (3, 5 or 8 pcs)
L508 FDCO-02 optical DDCS communication adapter module
L513 ATEX-certified thermal protection with PTC relays (1 or 2 pcs)
L514 ATEX-certified thermal protection with Pt100 relays (3, 5 or 8 pcs)
L515 FEA-03 I/O extension adapter
L516 FEN-21 resolver interface module
L517 FEN-01 TTL incremental encoder interface module
L518 FEN-11 TTL absolute encoder interface module
L521 FSE-31 pulse encoder interface module
L525 FAIO-01 analog I/O extension module
L526 FDIO-01 digital I/O extension module
L536 FPTC-01 thermistor protection module
L537 FPTC-02 ATEX-certified thermistor protection module
M602 Starter for auxiliary motor fan, trip limit 2.5 … 4 A
M603 Starter for auxiliary motor fan, trip limit 4 … 6.3 A
M604 Starter for auxiliary motor fan, trip limit 6.3 … 10 A
M605 Starter for auxiliary motor fan, trip limit 10…16 A
N5000 Winder control program
N5050 Crane control program
N5100 Winch control program
N5200 PCP (Progressive Cavity Pump) control program
N5300 Test bench control program
N5450 Override control program
N5600 ESP (Electrical Submersible Pump) control program
N7502 Control program for synchronous reluctance motors (SynRM)
N8010 IEC 61131-3 application programmability
P902 Customized
P904 Extended warranty (30 months from delivery or 24 months from commissioning)
P912 Seaworthy packaging
P913 Special color (RAL Classic)
P929 Container packaging
P966 Special color (other than RAL Classic)
Q965 Safely-limited speed with FSO-21 and encoder
Code Description
Q966 Safely-limited speed without encoder
Q971 ATEX-certified safe disconnection function
Q972 FSO-21 safety functions module
Q973 FSO-12 safety functions module
Q982 PROFIsafe with FSO safety functions module and FPNO-21 Ethernet adapter module
Q986 FSPS-21 PROFIsafe safety functions module
32
Electrical installation 33
3
Electrical installation
11

This chapter gives instructions on the wiring of the drive.
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.)
• If the drive is equipped with a DC/DC converter unit (optional) or a DC feeder
unit (optional): Open the DC switch-disconnector ([Q11], option +F286 or
+F290) of the unit. Open the disconnecting device of the energy storage
connected to the unit (outside 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.
• In the liquid cooling unit (if present), open the switch-disconnector of the
cooling pumps.
• 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. In cabinet-built drives, measure
between the drive DC busbars (+ and -) and the grounding (PE) busbar.
WARNING!
The busbars inside the cabinet of liquid-cooled drives are partially coated.
Measurements made through the coating are potentially unreliable, so only
measure at uncoated portions. Note that the coating does not constitute
a safe or touch-proof insulation.
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.
General notes
￭ 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.
￭ Optical components
WARNING!
Obey these instructions. If you ignore them, damage to the equipment can
occur.
• Handle the fiber optic cables with care.

• When you unplug the fiber optic cables, always hold the connector, not the cable
itself.
• Do not touch the ends of the fibers with bare hands as the ends are extremely
sensitive to dirt. 11
• Do not bend the fiber optic cables too tightly. The minimum allowed bend radius
is 35 mm (1.4 in).
Checking the insulation of the assembly

￭ Inverter unit
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 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 33) 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
Connecting the control cables

See the chapter on control units for the default I/O connections. Note that the default
I/O connections can be affected by some options. See the circuit diagrams delivered
with the drive for the actual wiring.
￭ Control cable connection procedure
WARNING!
Obey the safety instructions given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
If you ignore the safety instructions, injury or death, or damage to the
If you are not a qualified electrical professional, do not do installation
or maintenance work.
1. Stop the drive (if running) and do the steps in section Electrical safety
precautions (page 33) before you start the work.
2. Run the control cables into the cabinet as described in section Grounding the
outer shields of the control cables 360° at the cabinet entry below.
3. Route the control cables as described in section Routing the control cables inside
the cabinet.
4. Connect the control cables as described in section Connecting control cabling.
Grounding the outer shields of the control cables 360° at the cabinet entry
Ground the outer shields of all control cables 360° with the EMI conductive cushions
at the cabinet entry. The grounding principle is the same for top and bottom entry
cables. The illustrations show the bottom entry. The actual design details can vary.
1. If necessary, remove the shrouding in front of the cable entry.
2. Put the cables in sequence from the smallest to the largest. This will help to achieve
a good contact with the cushions.
3. Loosen the tightening bolts of the EMI conductive cushions and pull them apart.
4. Cut holes in the grommets and put the cables through the grommets.
5. Peel the insulation from the part of the cable that will be in contact with the EMI
conductive cushion.
6. Put the cables between the cushions and attach them with cable ties for strain
relief.
7. Move the cushions back together.
8. Tighten the bolts to make sure that the EMI conductive cushions press tightly
around the peeled part of the cables.
11
If the outer surface of the shield is non-conductive:

• Cut the shield at the midpoint of the peeled part. Be careful not to cut the
conductors or the grounding wire.
• Turn the conductive side of the shield inside out over the insulation.
• Cover the exposed shield and the peeled cable with copper foil to keep the shielding
continuous.
A B C
A Stripped cable
B Conductive surface of the shield exposed
C Stripped part covered with copper foil
1 Cable shield
2 2
1
3 2 Copper foil
4
3 Shielded twisted pair
4 Grounding wire
Routing the control cables inside the cabinet

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

Connect the conductors to the appropriate terminals. Refer to the wiring diagrams
delivered with the drive.
With option +L504, the terminals of the inverter control unit are available on terminal
block X504.
Obey these instructions:
• Connect the inner twisted pair shields and all separate grounding wires to the
grounding clamps near the terminals.
• Ground the outer shield of the cable at the cable entry, not at the grounding clamps
near the terminals.
• Keep any signal wire pairs twisted as close to the terminals as possible. Twisting
the wire with its return wire reduces disturbances caused by inductive coupling.
• At the other end of the cable, leave the shields unconnected or ground them
indirectly via a high-frequency capacitor with a few nanofarads, eg. 3.3 nF / 630 V.
The shield can also be grounded directly at both ends if they are in the same
ground line with no significant voltage drop between the end points.
The drawing below represents the grounding of the control cabling when connecting
to a terminal block inside the cabinet. The grounding is done in the same way when
connecting directly to a component such as the control unit.
11
Frame R7i – Connecting the motor cables

￭ Diagram
OUTPUT
U2 V2 W2
2 U2 V2 W2
PE
1)
2)
U1 V1 W1
3~
Motor
1. Inverter module
2. Cabinet
1) 360° grounding at cable lead-through

2) Use a separate grounding cable if the conductivity of the cable shield is less than 50% of the conduct-
ivity of the phase conductor in a cable with no symmetrically constructed grounding conductor (see
the document ACS880 liquid-cooled multidrive cabinets and modules, Electrical planning instructions
[3AXD50000048634 English]).
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.
￭ Motor 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. If you are not a qualified electrical
professional, do not do installation, commissioning or maintenance work.
WARNING!
Do the steps in section Electrical safety precautions (page 33) before you start
the work.
Removing the shrouding

1. Unplug the wiring coming to the lower mounting plate. Remove the plate.
2. Remove the shroud behind the mounting plate.
Single-module cubicle Two-module cubicle
11
Single-module cubicle Two-module cubicle
2
U2 V2 W2
U2 V2 W2
Connecting the cables

This section describes the power cable connecting procedure for a bottom cable entry
with the standard cable entry plate. The standard cable entry plate has conductive
sleeves for the 360 degree grounding of the cable shields. If the drive or unit has
another type of cable entry plate, such as a Roxtec cable entry plate (option +H394),
or cable gland plate (option +H358), refer also to the instruction of the related non-ABB
installation accessories. For example, the Roxtec instructions or the instructions by
the cable gland manufacturer.
1. IP54 cabinet: Remove the rear horizontal cable support and the cable entry plate.
2. IP54 cabinet: Remove a sealing grommet from the cable entry plate for each cable.
Cut hole into the rubber grommet and slide it onto the cable.
1 2
3. Lead the cables inside the cabinet through the cable entry plate. If there are several
cables, use the rear 3 holes first.
IP54 cabinet: Attach the the sealing grommets to the cable entry plate. Attach
also the cable entry plate, and the cable support.
4. For each cable, strip off 3…5 cm (1.2 … 2 inches) of the outer insulation above the
cable entry plate. Strip also the end of the cable, and the end of the phase
conductors. Twist the shield to form a PE conductor, and mark it with yellow-green
tape or heat-shrink tubing.
5. For each cable, attach cable lugs at the end of the PE conductor (twisted shield)
and phase conductors.
4 5
11
WARNING!
Apply grease to stripped aluminum conductors before attaching them to
non-coated aluminum cable lugs. Obey the grease manufacturer’s
instructions. Aluminum-aluminum contact can cause oxidation in the
contact surfaces.
6. For each cable, attach the conductive sleeve to the bare cable shield with a cable
tie. Attach the cable to the support bracket with a clamp.
7. For each cable, connect the PE conductor to the PE busbar, and the phase
conductors to the phase terminals. Tighten the screws to the torque given in the
technical data. Use the bolts and washers in the delivery. Refer to Use of fasteners
in cable lug connections (page 54).
6 7
8. If there are more than 3 cables, attach additional cable support brackets for them.
Replacing the shrouding and connecting the motor

1. Refit any shrouding removed earlier and close the cubicle doors.
2. At the motor, connect the cables according to instructions from the motor
manufacturer. Pay special attention to the phase order. For minimum
radio-frequency interference, ground the cable shield 360 degrees at the
lead-through of the motor terminal box, or ground the cable by twisting the shield
so that the flattened shield is wider than 1/5 of its length.
Frame R8i and multiples – Connecting the motor cables

(units without common motor terminal cubicle or sine
output filter)
On units without a common motor terminal cubicle or a sine output filter, the motor
cables connect to busbars located in the inverter module cubicles. To access the
terminals, the cooling fans and other equipment in front of the terminals must be
removed from the cubicle.
The location and dimensions of the busbars are visible in the dimension drawings
delivered with the drive, as well as the example drawings presented in this manual in
chapter Dimensions.
If the drive is equipped with a common motor terminal cubicle (option +H359) or a
sine output filter (option +E206), follow the instructions in section Frame R8i and
multiples – Connecting the motor cables (units with common motor terminal cubicle
or sine output filter) (page 51).
￭ Motor connection diagram (without option +H366)

All parallel-connected inverter modules are to be cabled separately to the motor.
360° earthing is to be used at the cable entries. 11
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
Inverter unit cubicle(s)
The recommended cable types are given in the technical data.
WARNING!
The cabling from all inverter modules to the motor must be physically identical
considering cable type, cross-sectional area, and length.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
￭ Motor connection diagram (with option +H366)

With option +H366, the output busbars of the inverter modules within the same cubicle
are connected by bridging busbars. The bridging balances the motor current between
the modules, which allows more cabling options. For example, it is possible to use a
number of cables that could not otherwise be evenly distributed between the inverter
modules.
PE
W2
V2
U2
Bridging busbars W1
V1
M
U1 3~
W2 PE
V2
U2
The recommended cable types are given in the technical data.
WARNING!
The bridging can carry the nominal output of one inverter module. In case of
three parallel modules, ensure that the load capacity of the bridging is not
exceeded. For example, if the cabling connects to the output busbars at one
module only, use the module in the middle.
Note: The +H366 option only interconnects the outputs of inverter modules within
the same cubicle, not modules installed in different cubicles. Therefore, when the drive
has more than three inverter modules, make sure that the load is distributed evenly
between the modules:
• In case of two inverter cubicles of two modules, connect the same number of
cables to each cubicle.
• In case of one inverter cubicle with three modules and another with two, each
cubicle requires a number of cables proportional to the number of modules within.
For example, connect three out of five (or six out of ten, etc.) cables to the cubicle
with three modules, the remaining two out of five (four out of ten) cables to the
cubicle with two modules.
￭ Procedure
WARNING!
11
WARNING!
the work.
Removing the shrouds and fan(s)

1. Open the inverter module cubicle door.
2. Remove the shrouding at the lower part of the cubicle (not shown).
3. Unplug the wiring from the lower front mounting plate. Remove the plate.
4. Disconnect the wiring from the cooling fans.
5. Undo the two retaining screws (a) of each fan.
6. Pull each fan outwards to separate them from the heat exchanger housing.
7. Remove the inner shroud.
7 5
3

1 2
4 5
WARNING!
contact surfaces.
11
6 7
Replacing shrouds and fans and connecting the motor

1. Refit the inner shroud.
2. With each fan, align the guide pins (b) at the rear of the fan cowling with the slots
in the module bottom guide, then reinstall the retaining screws (a).
3. Refit the lower front mounting plate. Reconnect the wiring to the components on
the mounting plate.
4. Refit the outer shroud (not shown).
5. Make sure there are no tools, debris or any other foreign objects in the cubicle.
Close the cubicle door.
radio-frequency interference, ground the cable shield 360 degrees at the cable
entry of the motor terminal box, or ground the cable by twisting the shield so that
the flattened shield is wider than 1/5 of its length.
1 b a
3
Frame R8i and multiples – Connecting the motor cables

(units with common motor terminal cubicle or sine output
filter)
￭ Output busbars
Ifthe drive is equipped with option +H359, the motor cables connect to a common
motor terminal cubicle. Similarly, if the drive is equipped with option +E206 (sine
output filter), the motor cables connect to the output busbars in the sine filter cubicle.
The location and dimensions of the busbars for either case are visible in the dimensional
drawings delivered with the drive, as well as the example dimension drawings in the
manual.
￭ Connection diagram
PE
U2 11
V2
U1
V1
M
W2
W1 3~
PE
Inverter unit cubicle Common motor terminal or

sine filter cubicle
The recommended cable types are given in chapter Technical data.
￭ Procedure
WARNING!

WARNING!
the work.
Opening the door and removing the shrouding

1. Open the door of the common motor terminal or sine filter cubicle.
2. Remove the shrouding.

1 2
4 5
WARNING!
contact surfaces.
6 7
11
Replacing the shrouding and connecting the motor

1. Refit any shrouding removed earlier and close the cubicle doors.
radio-frequency interference, ground the cable shield 360 degrees at the
lead-through of the motor terminal box, or ground the cable by twisting the shield
so that the flattened shield is wider than 1/5 of its length.
Use of fasteners in cable lug connections

Use the bolts, nuts and washers delivered with the drive. Install all the fasteners in the
correct order. See the figure below. Tighten the cable lug to the torque specified for
the connection.
Cable lug on one side of the busbar
1 2 3 4 2 5 6
Cable lugs on both sides of the busbar
1 5 2 4 3 4 2 5 6
1 Bolt 4 Cable lug

2 Plain washer 5 Spring washer
3 Busbar 6 Nut
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.
11
USB connected 4
2
?
Stop Loc/Rem Start
Stop Loc/Rem Start
2 3a 3b
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 the FDPI-02 module: move termination switch S1 on the FDPI-02 module
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.
With twin connectors in the control panel holder:
1 2 3
1
With FDPI-02 modules:
1 ED
AT
IN
RM
TE N
E
OP
11
2 2
ED
AT
IN
RM
TE EN
OP
Installing option modules

￭ Mechanical installation of I/O extension, fieldbus adapter and pulse
encoder interface modules
See hardware description for the available slots for each module. Install the option
modules as follows:
WARNING!
1. Stop the drive and do the steps in section Electrical safety precautions (page 33)
before you start the work.
2. Open the door of the auxiliary control cubicle (ACU).
3. Remove the shrouding at the top of the cubicle.
4. Locate the inverter control unit (A41).
5. Insert the module carefully into its position on the control unit.
6. Fasten the mounting screw.
Note: The screw secures and grounds the module. It is essential for fulfilling the
EMC requirements and for proper operation of the module.
￭ Installation of an FSO safety functions module onto BCU
WARNING!
This procedure describes the installation of an FSO safety functions module onto the
BCU control unit. As an alternative, the FSO module can be installed adjacent to the
control unit, which is the standard method for factory-installed FSO modules. For
instructions, refer to the applicable FSO module user's manual.
2. The FSO module comes with alternative bottom plates for installation onto
different control units. For installation onto a BCU control unit, the mounting
points should be located at the long edges of the module as shown in the
illustration below. If necessary, replace the bottom plate of the FSO module.

3. Attach the FSO module onto slot 3 of the BCU control unit [A41] with four screws.
11
4. Tighten the FSO module electronics grounding screw.
Note: The screw tightens the connections and grounds the module. It is essential
for fulfilling the EMC requirements and for proper operation of the module.
5. Connect the FSO module data cable between FSO connector X110 and BCU
connector X12.
6. To complete the installation, refer to the instructions in the applicable FSO module
user's manual.

￭ Wiring of optional modules

See the appropriate optional module manual for specific installation and wiring
instructions.
Installation checklist 61
4
Installation checklist

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!
maintenance work.
WARNING!
Stop the drive and do the steps in section Electrical safety precautions (page 33)
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.
62 Installation checklist
Make sure that …

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 in the supply unit
manual.
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.
If the drive is equipped with a DC/DC converter unit: There is an adequately sized protective
earth (ground) conductor between the energy storage and the DC/DC converter, the conductor
has been connected to appropriate terminal, and the terminal has been tightened to the proper
torque. Proper grounding has also been measured according to the regulations.
If the drive is equipped with a DC/DC converter unit: The energy storage cable has been connected
to the correct terminals of the DC/DC converter and energy storage, and the terminals have
been tightened to the proper torque.
If the drive is equipped with a DC/DC converter unit: The energy storage has been equipped with
fuses for protecting energy storage cable in a cable short-circuit situation.
If the drive is equipped with a DC/DC converter unit: The energy storage has been equipped with
a disconnecting device.
The input power cable is connected to the correct terminals, the phase order is correct, and the
terminals are tightened to the correct torque.
There is an adequately sized protective earth (ground) conductor between the motor and the
drive. The conductor is connected to the correct terminal, and the terminal is tightened to the
correct torque.
Grounding has also been measured according to the regulations.
The motor cable is connected to the correct terminals, the phase order is correct, and the terminals
are tightened to the correct torque.
The motor cable is routed away from other cables.
No power factor compensation capacitors are connected to the motor cable.
If an external brake resistor is connected to the drive: There is an adequately sized protective
earth (ground) conductor between the brake resistor and the drive, and the conductor is connec-
ted to the correct terminal, and the terminals are tightened to the correct torque. Grounding
has also been measured according to the regulations.
If an external brake resistor is connected to the drive: The brake resistor cable is connected to
the correct terminals, and the terminals are tightened to the correct torque.
If an external brake resistor is connected to the drive: The brake resistor cable is routed away
from other cables.
The control cables are connected to the correct terminals, and the terminals are tightened to
the correct torque.
The voltage setting of the auxiliary voltage transformers (if any) is correct. See the electrical in-
stallation instructions.
If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive
output contactor are either mechanically and/or electrically interlocked, that is, they cannot be
closed at the same time. A thermal overload device must be used for protection when bypassing
the drive. Refer to local codes and regulations.
There are no tools, foreign objects or dust from drilling inside the drive.
The 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.
The coolant connections between cubicles (if any) and to the cooling circuit are tight.
If the drive is equipped with a cooling unit: Make sure that the mechanical and electrical installation
of the cooling unit is completed. Refer to the cooling unit documentation.
Start-up 63
5
Start-up

This chapter describes the hardware commissioning of the inverter unit. For 12
information on setting up the control program, refer to the appropriate firmware
manual. For information on commissioning the supply unit, refer to its hardware
manual.
Start-up procedure
The tasks which are needed in certain cases only are marked with underlining, and
option codes are given in brackets. Default device designations (if any) are given in
brackets after the name, for example “main switch-disconnector (Q1)”. The same
device designations are also used in the circuit diagrams.
These instructions cannot and do not cover all possible start-up tasks of a customized
drive. Always refer to the delivery-specific circuit diagrams when proceeding with the
start-up.
WARNING!
Only qualified electricians are allowed to do the work described in this chapter.
Note: For certain options (such as functional safety options +Q950, +Q951, +Q952,
+Q957, +Q963, +Q964, +Q978, +Q979), additional start-up instructions are given in
their separate manuals.
64 Start-up
Action
Safety
WARNING!
Obey the safety instructions during the start-up procedure.
See the ACS880 liquid-cooled multidrive cabinets and modules safety instructions
(3AXD50000048633 [English]).
Pre-requisites
The mechanical and electrical installation of the drive has been inspected and approved. See In-
stallation checklist (page 61).
The insulation resistance of the assembly has been checked according to instructions. See
Electrical installation (page 33).
The supply unit of the drive system has been started up according to the instructions in its
hardware manual.
Checks/Settings with no voltage connected
Do the steps listed in Electrical safety precautions (page 33). Refer to the hardware manual of
the supply unit for more information.
Check the settings of breakers/switches in the auxiliary circuits. See the circuit diagrams delivered
with the drive.
Check that the auxiliary voltage selector [X59] on the front plate of the inverter modules is set
according to actual auxiliary voltage (230 or 115 V AC).
Disconnect any unfinished or uninspected auxiliary voltage (115/230 V AC) cables that lead from
the terminal blocks to the outside of the equipment.
Check that both channels of the Safe torque off circuit connected to the STO input of the inverter
control unit (A41) are closed. Refer to the wiring diagrams delivered with the drive.
With parallel-connected frame R8i inverter modules, check that the STO OUT output on the in-
verter control unit (A41) is chained to the STO inputs of all inverter modules.
If the Safe torque off functionality is not used, check that the STO input on all inverter modules
is correctly wired to +24 V and ground.
Drives with Pt100 relays (option +(n)L506):
• Check the connections against the circuit diagrams of the delivery.
• Set the alarm and trip levels of the Pt100 relays.
Set the alarm and trip levels of the Pt100 relay as low as possible based on the operating temper-
ature and test results of the machine. The trip level can be set, for example, 10 °C higher than
what the temperature of the machine is at maximal load in the maximum environmental temper-
ature.
We recommend to set the operating temperatures of the relay, typically for example, as follows:
• 120…140 °C when only tripping is in use
• alarm 120…140 °C and trip 130…150 °C when both alarm and tripping are used.
Powering up the auxiliary circuit of the drive
Make sure that it is safe to connect voltage. Ensure that
• nobody is working on the drive or circuits that have been wired from outside into the drive
cabinet
• the cover of the motor terminal box is in place.
Close the circuit breakers and/or fuse disconnectors supplying the auxiliary voltage circuits.
Close the cabinet doors.
Close the main breaker of the supply transformer.
Switch on the auxiliary voltage.
Setting up the inverter unit parameters, and performing the first start
Set up the inverter control program. See the appropriate start-up guide and/or firmware
manual. There is a separate start-up guide only for some control programs.
Start-up 65
Action
With inverter units consisting of frame R7i or R8i modules, check the setting of parameter 95.09
Switch fuse controller.
Drives with an fieldbus adapter module (optional): Set the fieldbus parameters. Activate the
appropriate assistant (if present) in the control program, or see the user’s manual of the fieldbus
adapter module, and the drive firmware manual. Check that the communication works between
the drive and the PLC.
Drives with an encoder interface module (optional): Set the encoder parameters. Activate the
appropriate assistant (if present) in the control program, or see the user’s manual of the encoder
interface module, and the drive firmware manual.
Powering up the main circuit of the drive
Start the supply unit according to the instructions in its hardware manual.
On-load checks
Start the motor to perform the ID run.
Check that the cooling fans rotate freely in the right direction, and the air flows upwards.
Check that the motor starts. stops and follows the speed reference in the correct direction when
controlled with the control panel.
Check that the motor starts. stops and follows the speed reference in the correct direction when
controlled through the customer-specific I/O or fieldbus.
Drives in which the Safe torque off control circuit is in use: Test and validate the operation of
the Safe torque off function. See section Validation test procedure (page 116).
12
66
Maintenance 67
6
Maintenance

This chapter contains maintenance instructions.
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
(https://new.abb.com/drives/services/maintenance/preventive-maintenance). For
more information, consult your local ABB Service representative
(www.abb.com/searchchannels).
￭ Description 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
68 Maintenance
￭ Recommended maintenance intervals after start-up
Years from start-up

Maintenance task/object
0 1 2 3 4 5 6 7 8 9 10 11 12 …
Coolant
Checking coolant antifreeze concentration P P P P P P P P P P P P
Checking coolant quality P P P P P P
Coolant draining and replacement R R
See ACS880-1007LC cooling unit user’s manual
ABB cooling unit (if present)
(3AXD50000129607 [English]).
Cooling fans
Cooling fans 230 V AC 50/60 Hz and 24 V DC R
Cooling fans 115 V AC 50/60 Hz R R
Frame R7i: Internal cooling fan for circuit
R
boards
CIO module for fan control (230 V AC) 1) R

CIO module for fan control (115 V AC)1) I/R R
Batteries
Control unit battery R R
Control panel battery R
Cabinet auxiliary power supplies R
Connections and environment
Quality of supply voltage P P P P P P P P P P P P P
Spare parts
Spare parts I I I I I I I I I I I I I
DC circuit capacitor reforming (spare mod-
P P P P P P P P P P P P P
ules and spare capacitors)
Inspections
Checking tightness of cable and busbar ter-
I I I I I I I I I I I I I
minals. Tightening if needed.
Checking ambient conditions (dustiness,
I I I I I I I I I I I I I
corrosion, temperature)
Checking coolant pipe connections I I I I I I I I I I I I I
Functional safety
I
Safety function test
See the maintenance information of the safety function.
Safety component expiry (Mission time, TM) 20 years
3AXD10000578918 rev S
1) To replace CIO module or to reset fan counters, see CIO-01 I/O module for distributed I/O bus control user's manual
(3AXD50000126880 [English]).
Maintenance 69
Note:
• 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.
• Long term operation near the specified maximum ratings or ambient conditions
may require shorter maintenance intervals for certain components. Consult your
local ABB Service representative for additional maintenance recommendations.
Maintenance timers and counters

The control program has maintenance timers and counters that can be configured to
generate a warning when a pre-defined limit is reached. Each timer/counter can be
set to monitor any parameter. This feature is especially useful as a service reminder.
For more information, see the firmware manual.
70 Maintenance
Cooling 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. See also CIO-01 I/O module for distributed I/O bus control
user's manual (3AXD50000126880 [English]).
Replacement fans are available from ABB. Do not use other than ABB-specified spare
parts.
￭ Frame R7i cabinet fan replacement
WARNING!
maintenance work.
WARNING!
Use the required personal protective equipment. Wear protective gloves and
long sleeves. Some parts have sharp edges.
Inverter module cubicle with one module

2. Remove the four screws that hold the finger guard to the fan. Remove the finger
guard.
3. Disconnect the wiring of the fan.
4. Remove the four screws that hold the fan. Remove the fan.
5. Install a new fan in reverse order to the above. Note that the direction of airflow
is up.
Maintenance 71
Inverter module cubicle with two modules

2. At the top part of the cubicle, remove the three shrouds shown.
3. Disconnect the wiring of the fans.
4. Remove the two screws that hold the base plate.
5. Remove the base plate from the cubicle, along with the fans.
6. Remove the finger guards from each fan (four screws each).
7. Undo the nuts that hold the fans to their base plate (four nuts each).
8. Install new fans in reverse order to the above. Note that the direction of airflow
is up.
72 Maintenance
7
4
Maintenance 73
￭ Frame R7i – internal module fan replacement
WARNING!
maintenance work.
WARNING!
2. Detach and move aside the wiring in front of the module.
3. Remove the four screws that hold the faceplate of the module. Remove the
faceplate.
4. Remove the two screws that attach the circuit board holder to the module frame.
5. Carefully pull the circuit board holder outward until you have access to the cooling
fan at the bottom of the holder. Detach the wiring coming to the circuit boards
if necessary.
6. Disconnect the wiring of the fan.
7. Remove the two screws that hold the fan. Remove the fan.
8. Install a new fan in reverse order to the above. Note that the direction of airflow
is up.
Circuit board holder

viewed from left
3
74 Maintenance
￭ Frame R8i fan replacement
WARNING!
maintenance work.
WARNING!
2. Remove any shrouding in front of the cooling fan in case of marine construction
(+C121).
3. Disconnect the fan wiring. Remove the CIO module.
4. Undo the two retaining screws (a).
5. Pull the fan outwards to separate it from the heat exchanger housing.
6. Install new fan in reverse order. Align the guide pins (b) at the rear of the fan
cowling with the slots (c) in the module bottom guide, then reinstall the retaining
screws (a).
a b
Maintenance 75
￭ Replacing the common motor terminal cubicle fan
WARNING!
maintenance work.
WARNING!
2. Remove any shrouding in front of the cooling fan.
3. Disconnect the fan wiring. Remove the CIO module.
4. Undo the fastening screws.
5. Pull the fan housing up and out.
6. Install a new fan in reverse order to the above.
76 Maintenance
Inverter modules
￭ Frame R7i
Replacing an R7i inverter module
WARNING!
WARNING!
Make sure that the replacement module has exactly the same type code as the
old module.
WARNING!
Beware of hot coolant. Do not work on the liquid cooling system until the
pressure is lowered down by stopping the pumps and draining the coolant.
High-pressure warm coolant (6 bar, max. 50 °C) is present in the internal cooling
circuit when it is in operation.
WARNING!
Removing the module

1. Do the steps in section Electrical safety precautions (page 33).
2. Disconnect the wiring from the CIO module and the R7i module. Move the wiring
aside. Use cable ties to keep the wiring out of the way.
3. Remove the CIO module mounting plate.
Maintenance 77
4. Close the inlet and outlet valves of the cubicle.

5. Lead the drain hoses (on the left-hand and right-hand sides of the cubicle) into a
suitable container. Open the drain valves. This will drain all the equipment in the
cubicle.
6. After the module has drained, disconnect the coolant piping from the module.
7. Assemble and install the service platform included in the delivery. Instructions are
included in the platform kit. See also section Assembling the service
platform (page 78).
8. Remove the module retaining screws at the top and the bottom of the module
(two screws each). Undo the locking screw (6 mm hex key) at the top of the module.
Locking screw
9. Pull the module carefully out onto the service platform.

78 Maintenance
WARNING! Move the module with another person as it is heavy. Keep the
module secured to a hoist or equivalent to prevent the module from falling.
Reinstalling the module

1. Push the module carefully into its bay.
2. Tighten the locking screw (6 mm hex key) at the top of the module to 5 N·m
(3.6 lbf·ft) maximum.
3. Fasten the module retaining screws at the top and the bottom of the module (two
screws each).
4. Reconnect the coolant pipes to the module. Tighten to 20 N·m (14.75 lbf·ft).
5. Reconnect the control wiring to the module.
6. Reinstall the CIO module mounting plate and reconnect the CIO wiring.
7. Fill up the cooling system. For instructions, see section Filling up and bleeding
the internal cooling circuit.
8. If the Safe torque off function is in use, perform a validation test as described
under Start-up including validation test (page 116).
￭ Frame R8i
Assembling the service platform
The service platform is included in the cabinet delivery. It can be used when installing
or servicing liquid-cooled R8i modules.
Maintenance 79
1. Fasten the triangular supports to the cabinet frame (5 × M6 screws for each
support). Make sure that the guide pins are properly inserted in the holes of the
frame. Tighten the screws to torque (max 5.5 N·m / 4 lb·ft).
2. Select the braces (4 pcs) according to the width of the cubicle and attach them
to the supports.
3. Attach the support feet to the platform and adjust them to the correct height.
4. Attach the slide plate. Put the hooks (a) at the back of the slide plate through the
holes in the cabinet frame. Align the slots (b) in the slide plate with the braces.
5. Fix the slide plate into place with the index screws (c) at the bottom of the slide
plate.
1 2
3 4
c
b
a
WARNING!
80 Maintenance
WARNING!
Make sure that the replacement module has exactly the same type code as the
old module.
WARNING!
Beware of hot coolant. Do not work on the liquid cooling system until the
pressure is lowered down by stopping the pumps and draining the coolant.
High-pressure warm coolant (6 bar, max. 50 °C) is present in the internal cooling
circuit when it is in operation.
WARNING!
Removing the module

1. Do the steps in section Electrical safety precautions (page 33).
2. Assemble the service platform delivered with the drive. Refer to section Assembling
the service platform (page 78).
3. Remove the shrouding in front of the module.
4. Remove the locking screws of the swing-out frame (if present) and open it.
5. Disconnect the wiring from the module and move it aside. Use cable ties to keep
the wiring out of the way.
6. Remove the L-shaped DC busbars at the top of the module. Make note of the
orientation of the screws as well as the order of the washers.
Maintenance 81
7. Close the inlet valve (a) and outlet valve (located on the right-hand side of the
cubicle). Lead the drain hoses (b, on both sides of the cubicle) into a suitable
container. Open the drain valves (c, on both sides of the cubicle). This will drain
all modules in the cubicle.
8. After the module has drained, disconnect the piping from the module.
82 Maintenance
9. Remove the module retaining screws at the top and the bottom of the module.
10. Pull the module carefully out onto the service platform. Keep the module secured
to a hoist or equivalent to prevent the module from falling. For information on
using the lifting device, see Converter module lifting device for drive cabinets
hardware manual (3AXD50000210268 [English]).
Reinstalling the module

1. Push the module carefully into its bay.
2. Fasten the retaining screws at the top and the bottom of the module.
3. Reinstall the DC busbars at the top of the module.
4. Reconnect the coolant pipes to the module. Tighten to specified torque. R8i module
coolant connections: 15 N·m (11.1 lbf·ft). Other connections: 20 N·m (14.75 lbf·ft).
5. Reconnect the control wiring to the module.
6. Fill up the cooling system. For instructions, see section Filling up and bleeding
the internal cooling circuit.
Maintenance 83
7. Close the swing-out frame (if present). Reinstall all shrouds removed earlier.
8. If the Safe torque off function is in use, perform a validation test as described
under Start-up including validation test (page 116).
Activating the reduced run of the inverter unit

A “reduced run” function is available for inverter units consisting of parallel-connected
inverter modules. The function makes it possible to continue operation with limited
current even if one (or more) module is out of service, for example, because of
maintenance work. In principle, reduced run is possible with only one module, but the
physical requirements of operating the motor still apply; for example, the modules
remaining in use must be able to provide the motor with enough magnetizing current.
Note: The wiring accessories and the air baffle needed during the procedure are
included in the delivery, and separately available from ABB.
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them,
injury or death, or damage to the equipment can occur.
2. Remove the shrouding above the module bay (in front of the DC fuses).
3. Remove the DC fuses and the busbar assembly connecting the fuses to the inverter
module. Store these parts – they are to be reinstalled only with the inverter module.
Make note of the order of washers.
4. Remove the faulty module from its bay. See the module replacement instructions.
5. Plug the coolant pipes disconnected from the module using the plugs that are
included in the drive delivery.
6. Install the air baffle (included) to the underside of the top module guide. Align the
holes at the rear edge of the baffle with the guide pins of the rear support. Fasten
the front edge of the baffle to the module mounting holes using the module
mounting screws (2 × M8). Tighten to 9 N·m (6.6 lbf·ft).
6
84 Maintenance
7. If the inverter control unit (A41) is powered from the faulty module, connect the
power supply wiring to another module using the extension wire set included.
8. If the Safe torque off (STO) function is in use, install the jumper wire set included
in the STO wiring in place of the missing module. (This is not needed if the module
was the last on the STO wire chain.)
8
Removed module
BCU
X51 X51 X51
X52 X52 X52
Jumper wire set
R8i (R8i) R8i
9. Open the circuit breaker of the cooling fan of the removed module. Disconnect
the control and power wiring of the fan.
10. Cover or remove the cooling fan.
11. Deactivate the control IOs of the fan in parameters 206.20 … 206.23.
12. Reinstall all shrouding removed earlier.
Note: Do not reinstall the DC fuses or busbars but store them elsewhere until the
module can be reinstalled.
13. In case the inverter unit has a DC switch/disconnector with a charging circuit,
locate the BSFC-xx charging controller. On the controller, disable the channel of
the removed module by using the appropriate DIP switch.
14. Switch on the power to the drive.
15. Enter the number of inverter modules present into parameter 95.13 Reduced run
mode.
16. Reset all faults and start the drive.
17. If the Safe torque off (STO) function is in use, perform a validation test. See the
instructions in chapter The Safe torque off function (page 107).
The maximum current is now automatically limited according to the new inverter
configuration. A mismatch between the number of detected modules (parameter
95.14) and the value set in 95.13 will generate a fault.
Maintenance 85
Returning the module

1. Install the module in reverse order. Use the following tightening torques:
• DC busbar assembly to upper insulators (2 × M8): 9 N·m (6.6 lbf·ft)
• DC busbar assembly to lower insulators (2 × M10): 18 N·m (13.3 lbf·ft)
• Fuses to DC busbars: 50 N·m (37 lbf·ft) (Bussmann), 46 N·m (34 lbf·ft)
(Mersen/Ferraz-Shawmut)
• Module to cabinet frame (4 × M8): 22 N·m (16 lbf·ft)
• DC busbar assembly to module DC input (2 × M12): 70 N·m (52 lbf·ft)
2. Remove the plugs from the coolant pipes and reconnect the pipes to the module.
See the module replacement instructions.
3. Restore the original wiring (STO and control unit power supply whenever needed).
4. Reinstall any removed fan(s). Reconnect the control and power supply wiring of
the fan.
5. Set parameter 95.13 to 0 to disable the reduced run function.
6. Activate the control IOs of the fan in parameters 206.20 … 206.23.
7. If the Safe torque off (STO) function is in use, perform an acceptance test. See
the instructions in chapter The Safe torque off function (page 107).
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]).
86 Maintenance
DC fuses
￭ Frame R7i
WARNING!
maintenance work.
WARNING!
Inverter module cubicle with one module

2. Open the cubicle door. At the top part of the cubicle, remove the shroud shown.
3. Slacken the nuts of the headless screws of the fuses so that you can slide out the
fuse blocks. Make note of the order of the washers on the screws.
4. Remove the screws, nuts and washers from the old fuses and attach them to the
new fuses. Make sure to keep the washers in the original order.
5. Insert the new fuses into their slots in the cubicle. Pre-tighten the nuts first by
hand or by applying a torque of no more than 5 N·m (3.7 lbf·ft).
6. Tighten the nuts to torque as follows:
• Bussmann fuses: 50 N·m (37 lbf·ft)
• Mersen (Ferraz Shawmut) fuses: 46 N·m (34 lbf·ft)
• Other fuses: Refer to fuse manufacturer's instructions.
7. Reinstall the shrouding removed earlier and close the door.
Maintenance 87
Inverter module cubicle with two modules

2. Open the cubicle door. At the top part of the cubicle, remove the three shrouds
shown.
3. Locate the fuses. The two leftmost fuses are for the upper module, the two
rightmost for the lower module.
88 Maintenance

• Other fuses: Refer to fuse manufacturer's instructions.
8. Reinstall the shrouding removed earlier and close the door.
DC fuses of upper module DC fuses of lower module

Maintenance 89
￭ Frame R8i and multiples

WARNING!
Read the safety instructions given in ACS880 liquid-cooled multidrive
If you ignore them, injury or death, or damage to the equipment can
occur.
2. Open the door of the cubicle in which the fuses are.
3. Remove the shrouding from in front of the fuses.
• Other fuses: Refer to fuse manufacturer’s instructions.
8. Reinstall the shroud and close the door.
4
90 Maintenance
Control panel
Refer to ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels user’s manual
(3AUA0000085685 [English]).
Maintenance 91
Control units
￭ BCU control unit types
There are three variants of the BCU control unit used in ACS880 drives: BCU-02, BCU-12
and BCU-22. These have a different number of converter module connections (2, 7 and
12 respectively) but are otherwise identical. The three BCU types are interchangeable
as long as the number of connections is sufficient. For example, the BCU-22 can be
used as a direct replacement for both BCU-02 and BCU-12.
￭ Replacing the memory unit

After replacing a control unit, you can keep the existing parameter settings by
transferring the memory unit from the defective control unit to the new control unit.
WARNING!
Do not remove or insert the memory unit when the control unit is powered.
2. Make sure that the control unit is not powered.
3. Remove the fastening screw and pull the memory unit out.
4. Install a memory unit in reverse order.
￭ Replacing the BCU control unit battery

Replace the real-time clock battery if the BATT OK LED is not illuminated when the
control unit is powered.
2. Undo the fastening screw and remove the battery.
3. Replace the battery with a new BR2032 battery.
92 Maintenance
4. Dispose of the old battery according to local disposal rules or applicable laws.
5. Set the real-time clock.
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.
Control units of the drive 93
7
Control units of the drive

This chapter
• describes the connections of the control unit(s) used in the drive,
• contains the specifications of the inputs and outputs of the control unit(s).
General
The BCU-x2 is used with frame sizes R7i and R8i in single and parallel configurations.
The BCU-x2 consists of a BCON-12 control board (and a BIOC-01 I/O connector board
and power supply board) built in a metal housing. The control unit is connected to the
inverter module(s) by fiber optic cables.
In this manual, the name “BCU-x2” represents the control unit types BCU-02, BCU-12
and BCU-22. These have a different number of power module connections (2, 7 and 12
respectively) but are otherwise similar.
BCU-x2 layout

Description
I/O I/O terminals (see following diagram)
SLOT 1 I/O extension, encoder interface or

fieldbus adapter module connection.
(This is the sole location for an FDPI-02
diagnostics and panel interface.)
SLOT 2 I/O extension, encoder interface or
fieldbus adapter module connection
SLOT 3 I/O extension, encoder interface, field-
bus adapter or FSO safety functions
module connection
SLOT 4 RDCO-0x DDCS communication option
module connection
X205 Memory unit connection

BATTERY Holder for real-time clock battery
(BR2032)
AI1 Mode selector for analog input AI1 (I =

current, U = voltage)
AI2 Mode selector for analog input AI2 (I =
current, U = voltage)
D2D TERM Termination switch for drive-to-drive link
(D2D)
DICOM= Ground selection. Determines whether
DIOGND DICOM is separated from DIOGND (ie.
the common reference for the digital in-
puts floats). See the ground isolation
diagram.
7-segment display
Multicharacter indications are displayed as repeated
sequences of characters
(“U” is indicated briefly before “o”.)
Control program running
Control program startup in progress
(Flashing) Firmware cannot be started.

Memory unit missing or corrupted
Firmware download from PC to control

unit in progress
At power-up, the display may show short

indications of eg. “1”, “2”, “b” or “U”.
These are normal indications immedi-
ately after power-up. If the display ends
up showing any other value than those
described, it indicates a hardware failure.
Description
XAI Analog inputs
XAO Analog outputs
XDI Digital inputs, Digital input interlock (DIIL)
XRO3
XD24 XPOW XDIO Digital input/outputs
XD2D Drive-to-drive link
XRO2 XD24 +24 V output (for digital inputs)
XDIO XAO
XETH Ethernet port – Not in use
XRO1 XPOW External power input

XRO1 Relay output RO1
XDI XAI XRO2 Relay output RO2
X485
XRO3 Relay output RO3
XSTO Safe torque off connection (input signals)
XSTO OUT Safe torque off connection (to inverter
XD2D XSTO XSTO
OUT modules)
X12 (On the opposite side) Connection for FSO
safety functions module (optional)
X13 Control panel / PC connection
X485 Not in use
V1T/V1R, Fiber optic connection to modules 1 and 2

V2T/V2R (VxT = transmitter, VxR = receiver)
V3T/V3R Fiber optic connection to modules 3…7
… (BCU-12/22 only)
V8T/V8R Fiber optic connection to modules 8…12
… (BCU-22 only)
SD CARD Data logger memory card for inverter

module communication
BATT OK Real-time clock battery voltage is higher

than 2.8 V. If the LED is off when the con-
trol unit is powered, replace the battery.
FAULT The control program has generated a fault.
See the firmware manual of the supply/in-
verter unit.
PWR OK Internal voltage supply is OK
WRITE Writing to memory card in progress. Do
not remove the memory card.
Default I/O diagram of the inverter control unit (BCU-x2)

The table below describes the use of the connections in the inverter unit. Under normal
circumstances, the factory-made wiring should not be changed.
The wire size accepted by all screw terminals (for both stranded and solid wire) is
0.5 … 2.5 mm2 (22…12 AWG). The tightening torque is 0.45 N·m (4 lbf·in).
Terminal Description
XD2D Drive-to-drive link
1 1 B
2 2 A
Drive-to-drive link. Refer to section The XD2D connector (page 100).
3 3 BGND
4
4 Shield
Drive-to-drive link termination switch. Must be set to ON when the inverter
OFF
ON
D2D.TERM unit is the first or last unit in the drive-to-drive (D2D) link. On intermediate
units, set termination to OFF.
X485 RS485 connection
5 5 B
6 6 A
Not in use by default
7 7 BGND
8
8 Shield
XRO1, XRO2, XRO3 Relay outputs
11 NC Norm. closed
11 XRO1: Ready (Energized = Ready)
12 COM Common
12 250 V AC / 30 V DC, 2 A
13 NO Norm. open
13
21 21 NC Norm. closed
XRO2: Running (Energized = Running)
22 22 COM Common
250 V AC / 30 V DC, 2 A
23 23 NO Norm. open
31
31 NC Norm. closed
32 XRO3: Fault (-1) (Energized = No fault)
32 COM Common
33 250 V AC / 30 V DC, 2 A
33 NO Norm. open
XSTO, XSTO OUT Safe torque off
1 OUT
1 XSTO: Factory connection. Both circuits must be closed for the drive to
2 SGND
2 start (IN1 and IN2 must be connected to OUT). Refer to chapter The Safe
3 IN1 torque off function.
3
4 4 IN2
5 5 IN1
6 6 SGND
7 XSTO OUT: Safe torque off output to inverter modules.
7 IN2
8
8 SGND
XDI Digital inputs
1 DI1 Stop (0) / Start (1)
1 2 DI2 Forward (0) / Reverse (1)
2
3 DI3 Reset
3
4 4 DI4 Acceleration & deceleration select 1)
5 5 DI5 Constant speed 1 select (1 = on) 2)
6
6 DI6 Not in use by default.
7
7 DIIL Run enable 3)
XDIO Digital input/outputs
1 DIO1 Output: Ready
1
2 2 DIO2 Output: Running
3 3 DIOGND Digital input/output ground
4 4 DIOGND Digital input/output ground
XD24 Auxiliary voltage output
5
5 +24VD +24 V DC 200 mA 4)
6 6 DICOM Digital input ground
7 7 +24VD +24 V DC 200 mA
4)
8
8 DIOGND Digital input/output ground
Ground selection switch. Determines whether DICOM is separated from
OFF
ON
DICOM=DIOGND DIOGND (ie, common reference for digital inputs floats). ON: DICOM con-
nected to DIOGND. OFF: DICOM and DIOGND separate.
XAI Analog inputs, reference voltage output
1 +VREF 10 V DC, RL 1 … 10 kohm
1
2 -VREF -10 V DC, RL 1 … 10 kohm
2
3 3 AGND Ground
4 4 AI1+
Speed reference. 0(2)…10 V, Rin > 200 kohm 5)
5 5 AI1-
6
6 AI2+
7 Not in use by default. 0(4)…20 mA, Rin = 100 ohm 6)
7 AI2-
AI1 AI1 current/voltage selection switch
U
I
AI2 AI2 current/voltage selection switch

U
I
XAO Analog outputs

1 AO1
1 Motor speed rpm 0 … 20 mA, RL < 500 ohm
2 2 AGND
3 3 AO2
4
Motor current 0 … 20 mA, RL < 500 ohm
4 AGND
XPOW External power input
1 +24VI
1
2 2 GND 24 V DC, 2.05 A
3 3 +24VI Two supplies can be connected for redundancy.
4 4 GND
X12 Safety functions module connection
X13 Control panel connection
X205 Memory unit connection
1) 0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use.

1 = Acceleration/deceleration ramps defined by parameters 23.14/23.15 in use.
2) Constant speed 1 is defined by parameter 22.26.
3) The DIIL input is configured to stop the unit when the input signal is removed. This input does not have a SIL or PL
classification.
4) Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and DIO2.
5) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected by switch AI1. Change
of setting requires reboot of control unit.
6) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected by switch AI2. Change
of setting requires reboot of control unit.
The diagram below shows the default I/O connections on the inverter control unit
(A41).
XRO1…XRO3
NC 11
COM 12
NO 13
NC 21
COM 22
NO 23
1)
NC 31
COM 32
NO 33
XSTO
OUT 1
2)
SGND 2
IN1 3
IN2 4
XDI
DI1 1
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
DIIL 7
XD24
+24VD 5
DICOM 6
+24VD 7
DIOGND 8
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5
AI2+ 6
AI2- 7
XAO
AO1 1
AGND 2
AO2 3
AGND 4
1) Fault
2) If necessary, you can connect an emergency stop button to the XSTO terminal. Refer to chapter
The Safe torque off function.
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 ACS880 liquid-cooled multidrives cabinets
and modules electrical planning instructions (3AXD50000048634) and the module
manual.
￭ Power supply for the control unit (XPOW)

The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW.
With a type BCU/UCU control unit, a second supply can be connected to the same
terminal block for redundancy.
Using a second 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 classified.
￭ The XD2D connector

The XD2D connector provides an RS-485 connection that can be used for
• basic master/follower communication with one master drive and multiple
followers,
• fieldbus control through the embedded fieldbus interface (EFB), or
• drive-to-drive (D2D) communication implemented by application programming.
See the firmware manual 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, for example, 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.
BCU-x2
XD2D
XD2D
XD2D
B 1
A 2
BGND 3
SHIELD 4
B 1
A 2
BGND 3
SHIELD 4
B 1
A 2
BGND 3
SHIELD 4
Termination ON Termination OFF Termination ON
￭ Safe torque off (XSTO, XSTO OUT)

See chapter The Safe torque off function (page 107).
Note: The XSTO input only acts as a true Safe torque off input on the inverter control
unit. De-energizing the STO input terminals of other units (supply, DC/DC converter,
or brake unit) will stop the unit but not constitute a SIL/PL classified safety function.
￭ FSO safety functions module connection (X12)

Refer to the applicable FSO module user's manual. Note that the FSO safety functions
module is not used in supply, DC/DC converter or brake units.
￭ SDHC memory card slot

The BCU-x2 has an on-board data logger that collects real-time data from the power
modules to help fault tracing and analysis. The data is stored onto the SDHC memory
card inserted into the SD CARD slot and can be analyzed by ABB service personnel.
Connector data
Power supply (XPOW) Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
Maximum tightening torque 0.45 N·m (4 lbf·in)
24 V (±10%) DC, 2 A
External power input.
Two supplies can be connected to the BCU-x2 for redundancy.
Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
(XRO1…XRO3) Maximum tightening torque 0.45 N·m (4 lbf·in)
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) Maximum tightening torque 0.45 N·m (4 lbf·in)
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 (XDI:7) 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
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) Maximum tightening torque 0.45 N·m (4 lbf·in)
Input/output mode selection by As inputs: 24 V logic levels: "0" < 5 V, "1" > 15 V. Rin: 2.0 kohm.
parameters. Filtering: 1 ms.
DIO1 can be configured as a frequency As outputs: Total output current from +24VD is limited to 200
input (0…16 kHz with hardware mA
filtering of 4 microseconds) for 24 V
level square wave signal (sinusoidal or +24VD
other wave form cannot be used). DIO2
can be configured as a 24 V level square
wave frequency output. See the
firmware manual, parameter group 11. DIOx
RL
DIOGND
Reference voltage for analog inputs Connector pitch 5 mm, wire size 0.5 … 2.5 mm2 (22…12 AWG)
+VREF and -VREF (XAI:1 and XAI:2) Maximum tightening torque 0.45 N·m (4 lbf·in)
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). Maximum tightening torque 0.45 N·m (4 lbf·in)
Current/voltage input mode selection Current input: -20…20 mA, R = 100 ohm
in
by switches
Voltage input: -10…10 V, Rin > 200 kohm
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…500 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 switch
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)
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 SIL/PL classified Safe
torque off functionality is only achieved through the XSTO con-
nector of the drive/inverter control unit.
Current consumption: 66 mA (continuous) per STO channel per
inverter module
Current consumption: 66 mA (continuous) per STO channel per
inverter module
EMC (immunity) according to IEC 61326-3-1 and IEC 61800-5-2
See also chapter The Safe torque off function (page 107).
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)
Ethernet connection (XETH) Connector: RJ-45

This connection is not supported by the firmware
SDHC memory card slot (SD CARD) Memory card type: SDHC
Maximum memory size: 4 GB
Battery Real-time clock battery type: BR2032
The terminals of the control unit fulfill the Protective Extra Low Voltage (PELV) requirements. The PELV
requirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay
output.
￭ BCU-x2 ground isolation diagram
XPOW
+24VI 1
GND 2
+24VI 3
GND 4
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5 **
AI2+ 6
AI2- 7
XAO
AO1 1
AGND 2
AO2 3
AGND 4
XD2D
B 1
A 2
BGND 3
SHIELD 4
XRO1, XRO2, XRO3
NC 11
COM 12
NO 13
NC 21
COM 22
NO 23
NC 31
COM 32
NO 33
XD24
+24VD 5
DICOM 6
+24VD 7
DIOGND 8
XDIO
DIO1 1
DIO2 2
DIOGND 3
DIOGND 4
XDI
DI1 1 *
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
DIIL 7
XSTO
OUT 1
SGND 2
IN1 3
IN2 4
XSTO OUT
IN1 5
SGND 6
IN2 7
SGND 8
*Ground selector (DICOM=DIOGND) settings
DICOM=DIOGND: ON
All digital inputs share a common ground (DICOM connected to DIOGND). This is the default setting.
DICOM=DIOGND: OFF
Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from DIO signal ground (DIOGND). Isolation
voltage 50 V.
**The maximum common mode voltage between each AI input and AGND is +30 V
106
The Safe torque off function 107
8
The Safe torque off function

This chapter describes the Safe torque off (STO) function of the drive and gives
instructions for its use.
Note: In this chapter, the term 'drive' refers to one inverter unit of the drive system.
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
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
See Electrical planning instructions for ACS880 liquid-cooled multidrive cabinets and
modules (3AXD50000048634 [English]).
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
• 30 m (100 ft) between control unit and last inverter module in the chain.
Note: A short-circuit in the wiring between the switch and an STO terminal causes a
dangerous fault. Therefore, it is recommended to use a safety relay (including wiring
diagnostics) or a wiring method (shield grounding, channel separation) which reduces
or eliminates the risk caused by the short-circuit.
Note: The voltage at the STO input terminals of the control unit (or frame R8i inverter
module) must be at least 17 V DC to be interpreted as “1”.
The pulse tolerance of the input channels is 1 ms.
￭ Grounding of protective shields

• Ground the shield in the cabling between the activation switch and the control
unit at the control unit only.
• Ground the shield in the cabling between two control units at one control unit
only.
• Do not ground the shield in the cabling between control unit and inverter module,
or between inverter modules.

￭ Dual-channel connection with internal power supply

Frame R7i
1
XSTO
+24 V OUT
SGND K
IN1
IN2
2
XSTO OUT STO (X52)
IN1 +24V
SGND GND
IN2 +24V
SGND GND
FE
1 Drive control unit

2 Inverter module
K Activation switch

Frame R8i and multiples
1
XSTO
+24 V OUT
SGND K
IN1
IN2
2
XSTO OUT STO IN (X52)
IN1 24VDC CH1
SGND GND CH1
IN2 24VDC CH2
SGND GND CH2
FE
2
STO IN (X52) STO OUT (X51)
24VDC CH1 24VDC CH1
GND CH1 GND CH1
24VDC CH2 24VDC CH2
GND CH2 GND CH2
FE FE
STO OUT (X51)

24VDC CH1
GND CH1
24VDC CH2 3
GND CH2
FE
1 Drive control unit

2 Inverter module(s)
3 To remaining inverter modules
K Activation switch
￭ Single-channel connection of activation switch
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.
￭ 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
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
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.
Start-up including validation test

To ensure the safe operation of a safety function, validation is required. The final
assembler of the machine must validate the function by performing a validation test.
The test must be performed
1. at initial start-up of the safety function
2. after any changes related to the safety function (circuit boards, wiring,
components, settings, replacement of inverter module, etc.)
3. after any maintenance work related to the safety function
4. after a drive firmware update
5. at the proof test of the safety function.
￭ Competence
The validation test of the safety function must be carried out by a competent person
with adequate expertise and knowledge of the safety function as well as functional
safety, as required by IEC 61508-1 clause 6. The test procedures and report must be
documented and signed by this person.
￭ Validation test reports

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

After wiring the Safe torque off function, validate its operation as follows.
Note: If the drive is equipped with safety option +L513, +L514, +L536, +L537, +Q950,
+Q951, +Q952, +Q957, +Q963, +Q964, +Q965, +Q966, +Q978, +Q979 or +Q984, also
do the procedure shown in the documentation of the option.
If an FSO or FSPS module is installed, refer to its documentation.
Note: All inverter modules of the drive must be powered and connected to the STO
circuit during the validation test.
Action
WARNING!
Obey the safety instructions. If you ignore them, injury or death, or damage to the equip-
ment can occur.
Make sure that the motor can be run and stopped freely during start-up.
Stop the drive (if running), switch the input power off and isolate the drive from the power line
using a disconnector.
Check the STO circuit connections against the wiring diagram.
Close the disconnector and switch the power on.
In case the drive consists of parallel-connected modules, check that the number of modules
detected (parameter 95.14) matches the actual number of modules, and that the drive type is
correctly set in parameter 95.31.
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.
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).
should not start.
• Open the STO circuit (both channels).
• Give a reset command.
• Close the STO circuit (both channels).
• Open the 2nd input channel of the STO circuit. If the motor was running, it should coast to a
should not start.
Document and sign the validation test report which verifies that the safety function is safe and
accepted for operation.
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 Safe torque off functionality is only achieved through the XSTO connector
of the inverter control unit (A41). True Safe torque off functionality is not
achieved through the XSTO connectors of other control units (such as the
supply control unit or the brake control unit).
The Safe torque off function is supported by any ACS880 inverter or drive
control program. It is not supported by supply, DC/DC converter or brake
firmware.
WARNING!
The drive cannot detect or memorize any changes in the STO circuitry when
the drive control unit is not powered or when the main power to the drive is
off. If both STO circuits are closed and a level-type start signal is active when
the power is restored, it is possible that the drive starts without a fresh start
command. Take this into account in the risk assessment of the system.
WARNING!
Permanent magnet or synchronous reluctance [SynRM] motors only:
In case of a multiple IGBT power semiconductor failure, the drive can produce
an alignment torque which maximally rotates the motor shaft by 180/p degrees
(with permanent magnet motors) or 180/2p degrees (with synchronous
reluctance [SynRM] motors) regardless of the activation of the Safe torque off
function. p denotes the number of pole pairs.
Notes:
• If a running drive is stopped by using the Safe torque off function, the drive will
cut off the motor supply voltage and the motor will coast to a stop. If this causes
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.
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 123).
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 116).
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.
￭ Perfect proof test procedure
Action
WARNING!
ment can occur.
Test the operation of the STO function. If the motor is running, it will stop during the test.
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
• Reset any active faults.
• Open the 2nd input channel of the STO circuit. If the motor was running, it should coast to a
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!
ment can occur.
Test the operation of the STO function. If the motor is running, it will stop during the test.
Document and sign the test report to verify that the safety function has been tested according
to the procedure.
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.
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
R7i 3 3 e 1.30E-10 2.86E-06 5.71E-06 1.14E-05 23970 ≥90 >99 3 1 80 20 2.13E-09 1.84E-07 2.14E-07
R8i 3 3 e 1.30E-10 2.86E-06 5.71E-06 1.14E-05 23970 ≥90 >99 3 1 80 20 2.13E-09 1.84E-07 2.14E-07
2×R8i 3 3 e 1.39E-10 3.06E-06 6.11E-06 1.22E-05 16330 ≥90 >99 3 1 80 20 2.92E-09 3.02E-07 2.92E-07
3×R8i 3 3 e 1.48E-10 3.26E-06 6.51E-06 1.30E-05 12390 ≥90 >99 3 1 80 20 3.71E-09 4.19E-07 3.71E-07
4×R8i 3 3 e 1.57E-10 3.46E-06 6.91E-06 1.38E-05 9980 ≥90 >99 3 1 80 20 4.50E-09 5.36E-07 4.50E-07
5×R8i 3 3 e 1.66E-10 3.66E-06 7.31E-06 1.46E-05 8360 ≥90 >99 3 1 80 20 5.28E-09 6.54E-07 5.29E-07
6×R8i 3 3 e 1.76E-10 3.86E-06 7.71E-06 1.54E-05 7190 ≥90 >99 3 1 80 20 6.07E-09 7.71E-07 6.07E-07
7×R8i 3 3 e 1.85E-10 4.07E-06 8.10E-06 1.62E-05 6310 ≥90 >99 3 1 80 20 6.86E-09 8.88E-07 6.86E-07
8×R8i 3 3 e 1.94E-10 4.27E-06 8.50E-06 1.70E-05 5620 ≥90 >99 3 1 80 20 7.65E-09 1.01E-06 7.65E-07
3AXD10000078136 K
• The STO is a type B safety component as defined in IEC 61508-2.

• Relevant failure modes:
• The STO trips spuriously (safe failure)
• The STO does not activate when requested
• A fault exclusion on the failure mode “short circuit on printed circuit board”
has been made (EN 13849-2, table D.5). The analysis is based on an assumption
that one failure occurs at one time. No accumulated failures have been
analyzed.
• STO response times:
• STO reaction time (shortest detectable break): 1 ms
• STO response time: 2 ms (typical), 25 ms (maximum)
• Fault detection time: Channels in different states for longer than 200 ms
• Fault reaction time: Fault detection time + 10 ms.
• Indication delays:
• STO fault indication (parameter 31.22) delay: < 500 ms
• STO warning indication (parameter 31.22) delay: < 1000 ms.
￭ Terms and abbreviations
Term or Reference Description

abbreviation
Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in
respect of their resistance to faults and their subsequent behavior
in the fault condition, and which is achieved by the structural
arrangement of the parts, fault detection and/or by their
reliability. The categories are: B, 1, 2, 3 and 4.
CCF EN ISO 13849-1 Common cause failure (%)
DC EN ISO 13849-1 Diagnostic coverage (%)
HFT IEC 61508 Hardware fault tolerance
MTTFD EN ISO 13849-1 Mean time to dangerous failure: (Total number of life units) /
(Number of dangerous, undetected failures) during a particular
measurement interval under stated conditions
PFDavg IEC 61508 Average probability of dangerous failure on demand, that is, mean
unavailability of a safety-related system to perform the specified
safety function when a demand occurs
PFH IEC 61508 Average frequency of dangerous failures per hour, that is, average
frequency of a dangerous failure of a safety related system to
perform the specified safety function over a given period of time
PFHdiag IEC/EN 62061 Average frequency of dangerous failures per hour for the
diagnostic function of STO
PL EN ISO 13849-1 Performance level. Levels a…e correspond to SIL
Proof test IEC 61508, IEC 62061 Periodic test performed to detect failures in a safety-related
system so that, if necessary, a repair can restore the system to
an "as new" condition or as close as practical to this condition
SC IEC 61508 Systematic capability (1…3)
SFF IEC 61508 Safe failure fraction (%)
SIL IEC 61508 Safety integrity level (1…3)
STO IEC/EN 61800-5-2 Safe torque off
Term or Reference Description

abbreviation
T1 IEC 61508-6 Proof test interval. T1 is a parameter used to define the
probabilistic failure rate (PFH or PFD) for the safety function or
subsystem. Performing a proof test at a maximum interval of T1
is required to keep the SIL capability valid. The same interval must
be followed to keep the PL capability (EN ISO 13849) valid.
See also section Maintenance.
TM EN ISO 13849-1 Mission time: the period of time covering the intended use of the
safety function/device. After the mission time elapses, the safety
device must be replaced. Note that any TM values given cannot
be regarded as a guarantee or warranty.
λDiag_d IEC 61508-6 Dangerous failure rate (per hour) of the diagnostics function of
STO
λDiag_s IEC 61508-6 Safe failure rate (per hour) of the diagnostics function of STO
￭ TÜV certificate
The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
Internal cooling circuit 127
9
Internal cooling circuit

The cooling system of a liquid-cooled drive consists of two circuits: the internal cooling
circuit and the external cooling circuit. The internal cooling circuit covers the
heat-generating electrical components of the drive and transfers the heat to the
cooling unit. In the cooling unit, the heat is transferred to the external cooling circuit
which is usually part of a larger external cooling system. This chapter deals with the
internal cooling circuit.
Applicability
The information in this chapter is applicable to cabinet-built ACS880 liquid-cooled
drives. Except where otherwise indicated, the information is also applicable to drives
built out of ACS880 liquid-cooled multidrives modules.
Internal cooling system

Each cubicle has an inlet and an outlet manifold, fitted with a stop valve and a drain
valve. The stop valves can be closed to isolate all modules in the cubicle from the main
cooling circuit.
In cabinet line-ups built by ABB, valves are color-coded:
• Blue – Open during operation
• Red – Closed during operation
The following diagram shows the coolant pipe connections in a drive system consisting
of a supply unit and an inverter unit. Other units, such as brake units, DC/DC converter
units have similar cooling arrangements. Other cubicles containing components that
require cooling may also contain heat exchangers.
1 2 2
A/L A/L
HS
HS HS
HS
A/L A/L A/L
a b d c a b d c
3
1 Supply modules. The drawing shows the configuration of a diode supply unit with two modules,
ie. there is a common air-to-liquid exchanger in the cubicle. With an IGBT supply unit, each
module has a dedicated air-to-liquid exchanger as shown for item 2.
2 Inverter modules
3 To/From cooling unit
A/L Air-to-liquid heat exchanger
HS Heat sink
a Inlet valve
b Inlet-side drain valve
c Outlet valve
d Outlet-side drain valve
The coolant used with ACS880 liquid-cooled drive systems is Antifrogen® L 25% or
50% mixture. See Coolant specification (page 132).
Connection to a cooling unit

￭ Connection to an ACS880-1007LC cooling unit
Refer to ACS880-1007LC cooling unit user’s manual (3AXD50000129607 [English]).
￭ Connection to a custom cooling unit

General requirements
Equip the system with an expansion vessel to damp pressure rise due to volume
changes when the temperature varies. Equip the system with a pump that provides
a nominal flow and pressure. Keep the pressure within the limits specified in Technical
data (page 132). Install a pressure regulator to make sure that the maximum permissible
operating pressure is not exceeded.
Install a bleed valve at the highest point of the cooling circuit, and a drain valve at the
lowest point.
The materials that can be used are listed in Cooling circuit materials (page 134).
Coolant temperature control

The temperature of the coolant in the internal cooling circuit must be kept within the
limits specified in Technical data (page 132). Note that the minimum temperature is
dependent on ambient temperature and relative humidity.
Filling up and bleeding the internal cooling circuit

Both the drive and coolant must be at room temperature before filling up the cooling
circuit.
WARNING!
Make sure that the maximum permissible operating pressure is not exceeded.
When necessary regulate the pressure to appropriate level by draining excess
coolant out of the system.
WARNING!
Bleeding of the cooling circuit is very important and has to be done with great
care. Air bubbles in the cooling circuit may reduce or completely block coolant
flow and lead to overheating. Let the air out of the cooling system while filling
in coolant and, eg. after any power module replacements.
￭ Drive line-ups with an ACS880-1007LC cooling unit

Obey the filling up and bleeding instructions in ACS880-1007LC cooling unit user’s
manual (3AXD50000129607 [English]).
￭ Drive line-ups with a custom cooling unit
Note:
• In filling up the system, the drain valves in the line-up are used only to vent the air
from the circuit so that it can be displaced by the coolant. The actual bleeding of
the circuit must be done via an external bleed valve installed at the highest point
of the cooling circuit. The most practical location for the valve is usually near or
at the cooling unit.
• Observe the instructions given by the manufacturer of the cooling unit. Pay special
attention to filling up and bleeding the pumps properly as they may be damaged
if operated when dry.
• Draining coolant into the sewer system is not allowed.
1. Open the bleed valve at the cooling unit.
2. Open the inlet valve and the outlet-side drain valve of one cubicle. Keep the outlet
valve and the inlet-side drain valve closed.
3. Attach a hose to the outlet-side drain valve and lead it into a suitable container.
4. Fill the circuit with coolant. For the coolant specification, refer to section Coolant
specification (page 132).
To minimize foaming, do not exceed the filling flow rate of 5 l/min
(1.3 US gallon/min).
5. As the piping and modules in the cubicle fills up, coolant starts to flow from the
hose. Let some coolant flow out, then close the drain valve.
6. Close the inlet valve.
7. Repeat steps 2…6 for all cubicles in the line-up.
8. Open the inlet and outlet valves in all cubicles. Let any air remaining in the system
out through the bleed valve at the cooling unit.
9. Close the bleed valve at the cooling unit.

10. Continue to fill in coolant until a base pressure of approximately 250 kPa is
achieved.
11. Open the bleed valve of the pump to let out any air.
12. Re-check the pressure and add coolant if necessary.
13. Start the coolant pump. Let any air remaining in the system out through the bleed
valve at the cooling unit.
14. After one to two minutes, stop the pump or block the coolant flow with a valve.
15. Re-check the pressure and add coolant if necessary.
16. Repeat steps 13…15 a few times until all air is let out of the cooling circuit. Listen
for a humming sound and/or feel the piping for vibration to find out if there is
still air left in the circuit.
Draining the internal cooling circuit

The modules in each cubicle can be drained through the drain valves without draining
the whole internal cooling circuit.
WARNING!
Hot, pressurized coolant can be present in the cooling circuit. Do not work on
the cooling circuit before the pressure is released by stopping the pumps and
draining coolant.
1. Attach hoses to each drain valve in the cubicle to be drained. Lead the hoses into
a suitable container. Make sure the ends of the hoses are not immersed in coolant
at any point so that air can displace the coolant in the system.
2. Open the drain valves. Wait until all coolant has drained.
Note: Draining coolant into the sewer system is not allowed.

3. If required, dry the piping with compressed oil-free air of less than 6 bar.
4. If the drive is to be stored in temperatures below 0 °C (32 °F),
• dry the cooling circuit with air,
• fill the cooling circuit with coolant specified under Coolant
specification (page 132).
• drain the cooling circuit again.
Maintenance intervals
As a general rule, the quality of the coolant should be checked at intervals of two years.
This can be done by distributors of Antifrogen® L (see www.clariant.com) if a 250
milliliter sample is provided.
Technical data
￭ Coolant specification
Coolant type
Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% mixture,
available from Clariant distributors and ABB Service representatives.
Note: Do not dilute the coolant. It is ready to use.

Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F).
Antifrogen® L 50% mixture is usable in storage temperatures down to -40 °C (-40 °F).
Note that operation below 0 °C (32 °F) is not permitted regardless of the freezing
point of the coolant.
WARNING!
The warranty does not cover damage that occurs from the use of incorrect
coolant.
￭ Temperature limits
Ambient temperature: See the technical data of the drive/unit.
Freeze protection: The freezing point of the coolant is determined by the concentration
of heat transfer fluid in the mixture.
The higher the concentration of heat transfer fluid, the higher the viscosity of the
coolant. This results in a higher pressure loss in the system. See Pressure
limits (page 134).
The nominal current ratings of drive system modules apply to an Antifrogen® L / water
solution of 25/75% (volume). With the Antifrogen® L concentration between 25% and
50%, the drive output current must be derated by 1/3 percentage point per 1 p.p.
increase in Antifrogen® L concentration. The drawing below shows the derating factor
(k) in relation to Antifrogen® L concentration.
1.00
0.95
0.90
25% 30% 35% 40% 45% 50% Antifrogen® L concentration
Incoming coolant temperature:

• 0…40 °C (32…104 °F): no drive output current derating required
• 40…45 °C (104…113 °F): drive output current must be derated by 2 percentage
points per 1 °C (1.8 °F) temperature increase, as shown by curve (a).
• 45…50 °C (113…122 °F):
• If components with a maximum operating temperature of 55 °C (131 °F) are
installed in the same space as the drive modules, drive output current must
be derated by 6 percentage points per 1 °C (1.8 °F) temperature increase, as

shown by curve (c).
• If there are no components with a maximum operating temperature of 55 °C
(131 °F) installed in the same space as the drive modules, drive output current
must be derated by 2 percentage points per 1 °C (1.8 °F) temperature increase,
as shown by curve (b).
The drawing below shows the derating factor (k) in relation to coolant temperature.
1.00
(a)
0.90
(b)
0.80
(c)
0.70
0.60
+40 °C +45 °C +50 °C T

+104 °F +113 °F +122 °F
Condensation is not permitted. The minimum coolant temperature to avoid

condensation (at an atmospheric pressure of 1 bar) is shown below as a function of
relative humidity (RH) and ambient temperature (Tair).
Tair Min. Tcoolant (°C)

(°C)
RH = 95% RH = 80% RH = 65% RH = 50% RH = 40%
5 4.3 1.9 -0.9 -4.5 -7.4
10 9.2 6.7 3.7 -0.1 -3.0
15 14.2 11.5 8.4 4.6 1.5
20 19.2 16.5 13.2 9.4 6.0
25 24.1 21.4 17.9 13.8 10.5
30 29.1 26.2 22.7 18.4 15.0
35 34.1 31.1 27.4 23.0 19.4
40 39.0 35.9 32.2 27.6 23.8
45 44.0 40.8 36.8 32.1 28.2
50 49.0 45.6 41.6 36.7 32.8
55 53.9 50.4 46.3 42.2 37.1
= Not permitted as standard but the coolant temperature must be 0 °C (32 °F) or more.
At an air temperature of 45 °C and relative humidity of 65% the coolant temperature

Example:
must not be less than +36.8 °C
Maximum temperature rise: Depends on heat losses and mass flow. Typically 10 °C
(18 °F) with nominal losses and flow.
￭ Pressure limits
Base pressure: 250 kPa (recommended); 300 kPa (maximum). “Base pressure” denotes
the pressure of the system compared with the atmospheric pressure when the cooling
circuit is filled with coolant.
Air counterpressure in expansion vessel (with ACS880-1007LC cooling unit): 80 kPa
Design pressure (PS): 600 kPa
Nominal pressure difference: 120 kPa with Antifrogen® L 25% coolant solution, 140
kPa with Antifrogen® L 50% coolant solution. This has to be taken into account when
dimensioning the liquid cooling circuit.
Maximum pressure difference: 160 kPa
￭ Coolant flow rate limits

The maximum coolant flow rate for all drive equipment is 1.3 × nominal. See the
technical data chapter for nominal values.
￭ Cooling circuit materials

Materials used in the internal cooling circuit are listed below.
• stainless steel AISI 316L (UNS 31603)
• heavy gauge aluminum
• plastic materials such as PA, PEX and PTFE
Note: PVC hoses are not suitable for use with antifreeze.
• rubber gasketing NBR (nitrile rubber).
WARNING!
If you connect external piping to the internal cooling circuit, use only
materials that are specified above. Other materials can cause galvanic
corrosion. If the external piping contains other materials, use a cooling
unit with a heat exchanger (for example, ACS880-1007LC) to keep the
external piping separate from the internal cooling circuit.
Technical data 135
10
Technical data

This chapter contains the technical specifications of the drive, for example, the ratings,
fuse data, sizes and technical requirements, provisions for fulfilling the requirements
for CE and other markings.
136 Technical data
Ratings
Output
Input
No-overload use Light-overload use Heavy-duty use
ACS880-107LC-… Imax
I1 I2 PN SN ILd PLd IHd PHd
A A A kW hp kVA A kW hp A kW hp
UN = 500 V
0094A-5 106 150 94 55 60 81 90 55 60 70 45 50
0120A-5 129 180 115 75 75 100 110 75 75 86 55 60
0140A-5 158 210 140 90 100 121 134 90 100 105 55 75
0170A-5 191 260 170 110 125 147 163 110 125 127 75 100
0200A-5 225 300 200 132 150 173 192 132 150 150 90 100
0240A-5 270 360 240 160 200 208 230 160 200 180 110 150
0300A-5 340 460 302 200 250 262 290 200 200 226 132 150
0380A-5 428 570 380 250 300 329 365 200 250 284 160 200
0460A-5 519 700 461 315 400 399 443 315 350 345 200 250
UN = 690 V
0062A-7 70 93 62 55 60 74 60 55 60 46 45 40
0082A-7 92 130 82 75 75 98 79 75 75 61 55 50
0100A-7 111 150 99 90 100 118 95 90 75 74 55 60
0130A-7 141 190 125 110 125 149 120 110 100 94 75 75
0140A-7 162 220 144 132 150 172 138 132 125 108 90 100
0190A-7 216 290 192 160 200 229 184 160 150 144 132 125
0220A-7 244 330 217 200 250 259 208 200 200 162 160 150
0290A-7 325 440 289 250 300 345 277 250 250 216 200 200
0340A-7 383 510 340 315 350 406 326 250 300 254 200 250
0389A-7 439 590 390 355 400 466 374 355 350 292 250 300
0390A-7 439 590 390 355 400 466 374 355 350 292 250 300
0430A-7 484 650 430 400 450 514 413 355 450 322 250 300
0480A-7 540 720 480 450 500 574 461 400 450 359 315 350
0530A-7 596 800 530 500 550 633 509 450 500 396 355 400
0600A-7 675 900 600 560 600 717 576 560 600 449 400 450
0670A-7 754 1010 670 630 700 801 643 630 700 501 450 500
0750A-7 844 1130 750 710 800 896 720 710 700 561 500 600
0850A-7 956 1280 850 800 900 1016 816 800 900 636 560 600
1030A-7 1159 1550 1030 1000 1000 1231 989 900 1000 770 710 800
1170A-7 1316 1760 1170 1100 1250 1398 1123 1100 1250 875 800 900
1310A-7 1474 1970 1310 1200 1250 1566 1258 1200 1250 980 900 1000
1470A-7 1654 2210 1470 1400 1500 1757 1411 1200 1500 1100 1000 1000
1660A-7 1868 2490 1660 1600 1750 1984 1594 1400 1750 1242 1200 1250
1940A-7 2183 2910 1940 1800 2000 2319 1862 1800 2000 1451 1400 1500
2180A-7 2453 3270 2180 2000 2605 2093 2000 1631 1400 1750
2470A-7 2779 3710 2470 2300 2952 2371 2300 1848 1800 2000
Technical data 137
Output
Input
No-overload use Light-overload use Heavy-duty use
ACS880-107LC-… Imax
I1 I2 PN SN ILd PLd IHd PHd
A A A kW hp kVA A kW hp A kW hp
2880A-7 3240 4320 2880 2700 3442 2765 2700 2154 2000
3260A-7 3668 4890 3260 3000 3896 3130 3000 2438 2300
3580A-7 4028 5370 3580 3400 4279 3437 3200 2678 2600
4050A-7 4556 6080 4050 3800 4840 3888 3800 3029 2800
4840A-7 5445 7260 4840 4400 5784 4646 4400 3620 3500
5650A-7 6356 8480 5650 5200 6752 5424 5200 4226 4000
6460A-7 7268 9690 6460 6000 7720 6202 6000 4832 4700
￭ Definitions
UN Nominal AC supply voltage of drive system
I1 Nominal rms input current
I2 Nominal output current (available continuously with no over-loading)
PN Typical motor power in no-overload use

The horsepower ratings are typical NEMA motor sizes at 460 V (ACS880-107LC-xxxxA-5) and
575 V (ACS880-107LC-xxxxA-7) respectively.
SN Apparent power in no-overload use
ILd Continuous rms output current allowing 10% overload for 1 minute every 5 minutes
PLd Typical motor power in light-overload use
Imax Maximum output current. Available for 10 seconds at start; otherwise as long as allowed by
drive temperature.
IHd Continuous rms output current allowing 50% overload for 1 minute every 5 minutes
PHd Typical motor power in heavy-duty use
Note:
• The ratings apply at an ambient temperature of 40 °C (104 °F).
• The ratings apply at an ambient temperature of 45 °C (113 °F) and a coolant
temperature of 40 °C (104 °F).
• To achieve the rated motor power given in the table, the rated current of the drive
must be higher than or equal to the rated motor current.
• The DriveSize dimensioning tool available from ABB is recommended for selecting
the drive, motor and gear combination.
￭ Derating
Surrounding air temperature derating
In the temperature range +45…55 °C (+113…131 °F), the rated output current is derated
by 0.5 percentage points for every added 1 °C (1.8 °F). The output current can be
138 Technical data
calculated by multiplying the current given in the rating table by the derating factor
(k):
1.00
0.95
0.90
+45 °C +55 °C T
+113 °F +131 °F
Coolant temperature derating

See section Temperature limits (page 132).
Antifreeze content derating

See section Temperature limits (page 132).
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.
For a more accurate derating, use the DriveSize PC tool.
Supply voltage derating (frame n×R8i inverter units with diode supply unit)
If the DC supply voltage of the inverter unit (U1) is below 810 V (which corresponds to
a drive supply voltage of 600 V AC when a diode supply unit is used), the rated output
current must be derated by multiplying by U1/810 (represented by k in the diagram).
1.00
709
810
U1 (V DC)
709 810 976
Switching frequency derating

In the switching frequency range 3.0 … 7.5 kHz, the output current is derated by 8
percentage points for each kHz. For example, the derating factor for 5 kHz is 0.84.
Output frequency derating

Below the output frequency of 12 Hz, the output current is derated by 3.5 percentage
points per each Hz. For example, the derating factor for 9 Hz is 0.895.
Above the output frequency of 150 Hz, the output current is derated by 1 percentage
point per each 10 Hz. For example, the derating factor for 175 Hz is 0.975.
Note that this concerns continuous or frequent use in this frequency range. Temporary
use in frequency range below 12 Hz does not cause need for derating.
Technical data 139
Inverter unit frame sizes and modules used

Module(s) used
ACS880-107LC-… Frame size
Qty Type
UN = 500 V
0094A-5 R7i 1 ACS880-104LC-0094A-5(+E205)
0120A-5 R7i 1 ACS880-104LC-0120A-5(+E205)
0140A-5 R7i 1 ACS880-104LC-0140A-5(+E205)
0170A-5 R7i 1 ACS880-104LC-0170A-5(+E205)
0200A-5 R7i 1 ACS880-104LC-0200A-5(+E205)
0240A-5 R7i 1 ACS880-104LC-0240A-5(+E205)
0300A-5 R7i 1 ACS880-104LC-0300A-5(+E205)
0380A-5 R7i 1 ACS880-104LC-0380A-5(+E205)
0460A-5 R7i 1 ACS880-104LC-0460A-5(+E205)
UN = 690 V
0062A-7 R7i 1 ACS880-104LC-0062A-7+E205
0082A-7 R7i 1 ACS880-104LC-0082A-7+E205
0100A-7 R7i 1 ACS880-104LC-0100A-7+E205
0130A-7 R7i 1 ACS880-104LC-0130A-7+E205
0140A-7 R7i 1 ACS880-104LC-0140A-7+E205
0190A-7 R7i 1 ACS880-104LC-0190A-7+E205
0220A-7 R7i 1 ACS880-104LC-0220A-7+E205
0290A-7 R7i 1 ACS880-104LC-0290A-7+E205
0340A-7 R7i 1 ACS880-104LC-0340A-7+E205
0389A-7 R7i 1 ACS880-104LC-0389A-7+E205
0390A-7 R8i 1 ACS880-104LC-0390A-7+E205
0430A-7 R8i 1 ACS880-104LC-0430A-7+E205
0480A-7 R8i 1 ACS880-104LC-0480A-7+E205
0530A-7 R8i 1 ACS880-104LC-0530A-7+E205
0600A-7 R8i 1 ACS880-104LC-0600A-7+E205
0670A-7 R8i 1 ACS880-104LC-0670A-7+E205
0750A-7 R8i 1 ACS880-104LC-0750A-7+E205
0850A-7 R8i 1 ACS880-104LC-0850A-7+E205
1030A-7 2 × R8i 2 ACS880-104LC-0530A-7+E205
1170A-7 2 × R8i 2 ACS880-104LC-0600A-7+E205
1310A-7 2 × R8i 2 ACS880-104LC-0670A-7+E205
1470A-7 2 × R8i 2 ACS880-104LC-0750A-7+E205
1660A-7 2 × R8i 2 ACS880-104LC-0850A-7+E205
1940A-7 3 × R8i 3 ACS880-104LC-0670A-7+E205
2180A-7 3 × R8i 3 ACS880-104LC-0750A-7+E205
2470A-7 3 × R8i 3 ACS880-104LC-0850A-7+E205
2880A-7 4 × R8i 4 ACS880-104LC-0750A-7+E205
3260A-7 4 × R8i 4 ACS880-104LC-0850A-7+E205
140 Technical data
Module(s) used
ACS880-107LC-… Frame size
Qty Type
3580A-7 5 × R8i 5 ACS880-104LC-0750A-7+E205
4050A-7 5 × R8i 5 ACS880-104LC-0850A-7+E205
4840A-7 6 × R8i 6 ACS880-104LC-0850A-7+E205
5650A-7 7 × R8i 7 ACS880-104LC-0850A-7+E205
6460A-7 8 × R8i 8 ACS880-104LC-0850A-7+E205
Technical data 141
Cooling data and noise

Coolant flow Heat dissipa-
Coolant volume Noise
rate tion*
Into air
Modules includ- sur-
ACS880-107LC-… Into
ing heat ex- Cabinet piping US round-
l/min coolant dB(A)
changer gal/min ing cab-
inet
l US qt l US qt W W
UN = 500 V
0094A-5 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 970 20 63
0120A-5 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 1200 20 63
0140A-5 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 1500 20 63
0170A-5 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 1700 30 63
0200A-5 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 2000 30 63
0240A-5 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 2500 40 63
0300A-5 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 3300 50 63
0380A-5 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 4600 60 63
0460A-5 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 6100 80 63
UN = 690 V
0062A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 1150 60 63
0082A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 1420 70 63
0100A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 1680 70 63
0130A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 2100 80 63
0140A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 2400 80 63
0190A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 3200 90 63
0220A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 3700 100 63
0290A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 4500 120 63
0340A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 5500 130 63
0389A-7 0.5** 0.5** 1.9** 2.0** 13*** 3.4*** 6700 140 63
0390A-7 1.9 2.0 2.4 2.5 16 4.2 5100 100 63
0430A-7 1.9 2.0 2.4 2.5 16 4.2 5600 100 63
0480A-7 1.9 2.0 2.4 2.5 16 4.2 6400 100 63
0530A-7 1.9 2.0 2.4 2.5 16 4.2 7200 100 63
0600A-7 1.9 2.0 2.4 2.5 16 4.2 8200 100 63
0670A-7 1.9 2.0 2.4 2.5 16 4.2 9400 100 63
0750A-7 1.9 2.0 2.4 2.5 16 4.2 10800 100 63
0850A-7 1.9 2.0 2.4 2.5 16 4.2 12700 100 63
1030A-7 3.8 4.0 4.0 4.2 32 8.5 14000 300 66
1170A-7 3.8 4.0 4.0 4.2 32 8.5 16000 300 66
1310A-7 3.8 4.0 4.0 4.2 32 8.5 18400 300 66
1470A-7 3.8 4.0 4.0 4.2 32 8.5 21200 300 66
1660A-7 3.8 4.0 4.0 4.2 32 8.5 24800 300 66
1940A-7 5.7 6.0 5.7 6.0 48 12.7 27200 300 68
142 Technical data
Coolant flow Heat dissipa-

Coolant volume Noise
rate tion*
Into air
Modules includ- sur-
ACS880-107LC-… Into
ing heat ex- Cabinet piping US round-
l/min coolant dB(A)
changer gal/min ing cab-
inet
l US qt l US qt W W
2180A-7 5.7 6.0 5.7 6.0 48 12.7 31400 400 68
2470A-7 5.7 6.0 5.7 6.0 48 12.7 36900 400 68
2880A-7 7.6 8.0 8.0 8.5 64 16.9 41500 500 69
3260A-7 7.6 8.0 8.0 8.5 64 16.9 48700 700 69
3580A-7 9.5 10.0 9.7 10.2 80 21.1 51600 700 70
4050A-7 9.5 10.0 9.7 10.2 80 21.1 60500 900 70
4840A-7 11.4 12.0 11 11.6 96 25.4 72300 900 71
5650A-7 13.3 14.1 14 14.8 112 29.6 84400 1000 72
6460A-7 15.2 16.1 15 15.9 128 33.8 96500 1200 72
*These losses are not calculated according to IEC 61800-9-2.
**In single-module cabinet configuration.
***In single-module cabinet configuration (28 l/min or 7.4 US gal/min in two-module cabinet configur-
ation).
Technical data 143
DC fuses
The inverter unit has DC fuses at the input of each inverter module.
Notes:
• Fuses with higher current rating than the recommended ones must not be used.
• Fuses from other manufacturers can be used if they meet the ratings and the
melting curve of the fuse does not exceed the melting curve of the fuse mentioned
in the table.
• The fuses listed are UL Recognized.
DC fuses at inverter module input

ACS880-107LC-…
Qty A V Manufacturer Type
UN = 500 V
0094A-5 2 160 1250 Bussmann 170M4388
0120A-5 2 200 1250 Bussmann 170M4389
0140A-5 2 250 1250 Bussmann 170M4390
0170A-5 2 315 1250 Bussmann 170M4391
0200A-5 2 400 1250 Bussmann 170M4393
0240A-5 2 450 1250 Bussmann 170M6541
0300A-5 2 550 1250 Bussmann 170M6543
0380A-5 2 700 1250 Bussmann 170M6545
0460A-5 2 900 1100 Bussmann 170M6547
UN = 690 V
0062A-7 2 125 1250 Bussmann 170M3392
0082A-7 2 160 1250 Bussmann 170M4388
0100A-7 2 200 1250 Bussmann 170M4389
0130A-7 2 250 1250 Bussmann 170M4390
0140A-7 2 315 1250 Bussmann 170M4391
0190A-7 2 350 1250 Bussmann 170M4392
0220A-7 2 400 1250 Bussmann 170M4393
0290A-7 2 550 1250 Bussmann 170M6543
0340A-7 2 630 1250 Bussmann 170M6544
0389A-7 2 700 1250 Bussmann 170M6545
0390A-7
2 800 1250 Bussmann 170M6546
0430A-7
0480A-7 2 900 1100 Bussmann 170M6547
0530A-7 2 1000 1100 Bussmann 170M6548
0600A-7 2 1100 1000 Bussmann 170M6549
0670A-7 2 1250 1100 Bussmann 170M6500
0750A-7
2 1400 1100 Bussmann 170M6501
0850A-7
1030A-7 4 1000 1100 Bussmann 170M6548
1170A-7 4 1100 1000 Bussmann 170M6549
1310A-7 4 1250 1100 Bussmann 170M6500
144 Technical data
DC fuses at inverter module input

ACS880-107LC-…
Qty A V Manufacturer Type
1470A-7
4 1400 1100 Bussmann 170M6501
1660A-7
1940A-7 6 1250 1100 Bussmann 170M6500
2180A-7 6
2470A-7 6
2880A-7 8
3260A-7 8
3580A-7 10 1400 1100 Bussmann 170M6501
4050A-7 10
4840A-7 12
5650A-7 14
6460A-7 16
Dimensions and weights

See chapter Dimensions (page 155).
Free space requirements

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

mm in. mm in. mm in.
1000 39 0 0 250 9.85
Technical data 145
Typical power cable sizes

The tables below give current carrying capacity (ILmax) for aluminum and copper
PVC/XLPE insulated cables. A correction factor K = 0.70 is used. Time const is the
temperature time constant of the cable.
The cable sizing is based on max. 9 cables laid on the cable trays side by side, three
ladder type trays one on top of the other, ambient temperature 30 °C (EN 60204-1 and
IEC 60364-5-52).
Aluminum cable PVC insulation XLPE insulation

Conductor temperature 70 °C Conductor temperature 90 °C
Size Ø [mm] ILmax [A] Time const. [s] ILmax [A] Time const. [s]
3 × 35 + 10 Cu 26 67 736 84 669
3 × 50 + 15 Cu 29 82 959 102 874
3 × 70 + 21 Cu 32 105 1182 131 1079
3 × 95 + 29 Cu 38 128 1492 159 1376
3 × 120 + 41 Cu 41 148 1776 184 1637
3 × 150 + 41 Cu 44 171 2042 213 1881
3 × 185 + 57 Cu 49 196 2422 243 2237
3 × 240 + 72 Cu 54 231 2967 286 2740
3 × 300 + 88 Cu 58 267 3478 330 3229
2 × (3 × 70 + 21 Cu) 2 × 32 210 1182 262 1079
2 × (3 × 95 + 29 Cu) 2 × 38 256 1492 318 1376
2 × (3 × 120 + 41 Cu) 2 × 41 297 1776 368 1637
2 × (3 × 150 + 41 Cu) 2 × 44 343 2042 425 1881
2 × (3 × 185 + 57 Cu) 2 × 49 392 2422 486 2237
2 × (3 × 240 + 72 Cu) 2 × 54 462 2967 572 2740
2 × (3 × 300 + 88 Cu) 2 × 58 533 3478 659 3229
3 × (3 × 150 + 41 Cu) 3 × 44 514 2042 638 1881
3 × (3 × 185 + 57 Cu) 3 × 49 588 2422 728 2237
3 × (3 × 240 + 72 Cu) 3 × 54 693 2967 859 2740
3 × (3 × 300 + 88 Cu) 3 × 58 800 3478 989 3229
4 × (3 × 185 + 57 Cu) 4 × 49 784 2422 971 2237
4 × (3 × 240 + 72 Cu) 4 × 54 924 2967 1145 2740
4 × (3 × 300 + 88 Cu) 4 × 58 1067 3478 1319 3229
5 × (3 × 185 + 57 Cu) 5 × 49 980 2422 1214 2237
5 × (3 × 240 + 72 Cu) 5 × 54 1155 2967 1431 2740
5 × (3 × 300 + 88 Cu) 5 × 58 1333 3478 1648 3229
6 × (3 × 240 + 72 Cu) 6 × 54 1386 2967 1718 2740
6 × (3 × 300 + 88 Cu) 6 × 58 1600 3478 1978 3229
7 × (3 × 240 + 72 Cu) 7 × 54 1617 2967 2004 2740
7 × (3 × 300 + 88 Cu) 7 × 58 1867 3478 2308 3229
8 × (3 × 240 + 72 Cu) 8 × 54 1848 2967 2290 2740
8 × (3 × 300 + 88 Cu) 8 × 58 2133 3478 2637 3229
9 × (3 × 240 + 72 Cu) 9 × 54 2079 2967 2577 2740
9 × (3 × 300 + 88 Cu) 9 × 58 2400 3478 2967 3229
10 × (3 × 240 + 72 Cu) 10 × 54 2310 2967 2867 2740
10 × (3 × 300 + 88 Cu) 10 × 58 2667 3478 3297 3229
146 Technical data
Copper cable PVC insulation XLPE insulation

Conductor temperature 70 °C Conductor temperature 90 °C
Size Ø [mm] ILmax [A] Time const. [s] ILmax [A] Time const. [s]
3 × 1.5 + 1.5 13 13 85 16 67
3 × 2.5 + 2.5 14 18 121 23 88
(3 × 4 + 4) 16 24 175 30 133
3×6+6 18 30 251 38 186
3 × 10 + 10 21 42 359 53 268
3 × 16 + 16 23 56 514 70 391
3 × 25 + 16 24 71 791 89 598
3 × 35 + 16 26 88 1000 110 760
3 × 50 + 25 29 107 1308 134 990
3 × 70 + 35 32 137 1613 171 1230
3 × 95 + 50 38 167 2046 209 1551
3 × 120 + 70 41 193 2441 241 1859
3 × 150 + 70 44 223 2820 279 2139
3 × 185 + 95 50 255 3329 319 2525
3 × 240 + 120 55 301 4073 376 3099
3 × 300 + 150 58 348 4779 435 3636
2 × (3 × 70 + 35) 2 × 32 274 1613 342 1230
2 × (3 × 95 + 50) 2 × 38 334 2046 418 1551
2 × (3 × 120 + 70) 2 × 41 386 2441 482 1859
2 × (3 × 150 + 70) 2 × 44 446 2820 558 2139
2 × (3 × 185 + 95) 2 × 50 510 3329 638 2525
2 × (3 × 240 + 120) 2 × 55 602 4073 752 3099
2 × (3 × 300 + 150) 2 × 58 696 4779 869 3636
3 × (3 × 120 + 70) 3 × 41 579 2441 723 1859
3 × (3 × 150 + 70) 3 × 44 669 2820 837 2139
3 × (3 × 185 + 95) 3 × 50 765 3329 957 2525
3 × (3 × 240 + 120) 3 × 55 903 4073 1128 3099
3 × (3 × 300 + 150) 3 × 58 1044 4779 1304 3636
4 × (3 × 150 + 70) 4 × 44 892 2820 1116 2139
4 × (3 × 185 + 95) 4 × 50 1020 3329 1276 2525
4 × (3 × 240 + 120) 4 × 55 1204 4073 1504 3099
4 × (3 × 300 + 150) 4 × 58 1391 4779 1304 3636
5 × (3 × 185 + 95) 5 × 50 1275 3329 1595 2525
5 × (3 × 240 + 120) 5 × 55 1505 4073 1880 3099
5 × (3 × 300 + 150) 5 × 58 1739 4779 2173 3636
6 × (3 × 185 + 95) 6 × 50 1530 3329 1914 2525
6 × (3 × 240 + 120) 6 × 55 1806 4073 2256 3099
6 × (3 × 300 + 150) 6 × 58 2087 4779 2608 3636
7 × (3 × 240 + 120) 7 × 55 2107 4073 2632 3099
7 × (3 × 300 + 150) 7 × 58 2435 4779 3043 3636
8 × (3 × 240 + 120) 8 × 55 2408 4073 3008 3099
8 × (3 × 300 + 150) 8 × 58 2783 4779 3477 3636
Technical data 147
Input power (DC) connection

Voltage (U1) ACS880-107LC-xxxxx-5: 513…707 V DC ±10%. This is indicated
in the type designation label as typical input voltage levels
(566/679/707 V DC).
ACS880-107LC-xxxxx-7: 709…976 V DC ±10%. This is indicated
in the type designation label as typical input voltage levels
(742/849/976 V DC).
Drive AC supply network type TN (grounded) and IT (ungrounded) systems, corner-grounded

systems up to 600 V AC
Input terminals See Terminal and cable entry data for the power
cables (page 147).
Motor (AC) connection

Motor types Asynchronous AC induction motors, permanent magnet syn-
chronous motors and AC induction servomotors, ABB synchron-
ous reluctance (SynRM) motors
Voltage (U2) 0 to AC supply voltage of drive, 3-phase symmetrical, Umax at

field weakening point
Frequency (f2) 0…500 Hz

• For higher operational output frequencies, please contact
your local ABB representative.
• Operation outside the range of 12…150 Hz requires derat-
ing. See section Derating (page 137).
Current See section Ratings.
Switching frequency 3 kHz (typical).

The switching frequency can vary per frame and voltage. For
exact values, contact your local ABB representative.
Maximum motor cable length 500 m (1640 ft)
Note: Longer cables cause a motor voltage decrease which

limits the available motor power. The decrease depends on
the motor cable length and characteristics. Contact ABB for
more information.
Output terminals See Terminal and cable entry data for the power
cables (page 147).
Terminal and cable entry data for the power cables

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

The maximum number of motor cables depends on the cable size, cable material,
number of inverter modules and on the inverter unit cubicle width. Before you select
motor cable sizes, check the inverter unit construction from the project-specific
dimension drawings and use the tables below to determine the connection capability.
148 Technical data
Maximum number of 3-phase motor cables (copper) for each inverter module, n×R8i with cable exit
from bottom
Copper compression cable lugs (DIN 46235)
Cable cross
section 1×R8i 1×R8i 2×R8i 3×R8i Connection method
(mm2) (300 mm (400 mm (500 mm (700 mm
cubicle) cubicle) cubicle) cubicle)
50 4 (6*) 6 5 (6*) 5 (6*)
70 4 (6*) 6 5 (6*) 5 (6*)
95 4 (6*) 6 5 (6*) 5 (6*)
120 4 4 4 4
150 4 4 4 4
185 4 4 4 4
240 4 4 4 4
300 - - - - -
* Requires additional engineering. Standard cable entry plate not suitable.
Maximum number of 3-phase motor cables (aluminum) for each inverter module, n×R8i with cable exit
from bottom
Aluminum compression cable lugs (DIN 46329)
Cable cross
section 1×R8i 1×R8i 2×R8i 3×R8i Connection method
(mm2) (300 mm (400 mm (500 mm (700 mm
cubicle) cubicle) cubicle) cubicle)
50 4 (6*) 6 5 (6*) 5 (6*)
70 4 (6*) 6 5 (6*) 5 (6*)
95 4 (6*) 6 5 (6*) 5 (6*)
120 4 6 5 5
150 4 6 5 5
185 4 6 5 5
240 2 2 2 2
300 2* 2* 2* 2*
* Requires additional engineering. Standard cable entry plate not suitable.

Technical data 149
Output terminal dimensions, n×R8i

Distance between adja- Distance between adja- Maximum distance Maximum cable lug dia-
cent holes, horizontal cent holes, vertical between terminal sur- meter (including pos-
(A) (B) faces sible shrink hose)
(C)
mm in mm in mm in mm in
30.5* 1.2* 44.5 1.75 67 2.63 29 1.14
Side view Front view

A
C C
* The maximum cable lug width for the leftmost hole is 42 mm (1.65 in).
Terminal data for the inverter control unit

See chapter Control units of the drive (page 93).
Efficiency
98.5 … 98.7% at nominal power level depending on drive type.
The efficiency is not calculated according to IEC 61800-9-2.
Energy efficiency data (ecodesign)

Energy efficiency data is not provided for the drive/unit. Multidrives and multidrive
modules are not in the scope of the EU ecodesign requirements (Regulation
EU/2019/1781) or the UK ecodesign requirements (Regulation SI 2021 No. 745).
Protection classes
Degrees of protection IP42 (standard), IP54 (option +B055)
(IEC/EN 60529)
Enclosure types (UL50) UL Type 1 (standard), UL Type 12 (option +B055). For indoor use only.
Arcing class B – ASSEMBLY providing personnel and ASSEMBLY protection under arcing
(IEC TR 61641) conditions.
Tested at the following voltage with an arcing current of 65 kA for 300 milli-
seconds:
• 400 V units (indicated by "-3" in drive type): 420 V
Overvoltage category III, except for auxiliary power connections (fan, control, heating, lighting,
(IEC/EN 60664-1) cooling unit pump etc) which are category II.
Protective class I
(IEC/EN 61800-5-1)
150 Technical data
Optical components
The specifications of the optic cable are as follows:
• Storage temperature: -55 … +85 °C (-67 … +185 °F)
• Installation temperature: -20 … +70 °C (-4 … +158 °F)
• Maximum short-term tensile force: 50 N (11.2 lbf)
• Minimum short-term bend radius: 25 mm (1.0 in)
• Minimum long-term bend radius: 35 mm (1.4 in)
• Maximum long-term tensile load: 1 N (3.6 ozf)
• Flexing: Max. 1000 cycles
ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components
from Avago Technologies’ Versatile Link range. Note that the optical component type
is not directly related to the actual communication speed.
Note: The optical components (transmitter and receiver) on a fiber optic link must be
of the same type.
Plastic optical fiber (POF) cables can be used with both 5 MBd and 10 MBd optical
components. 10 MBd components also enable the use of Hard Clad Silica (HCS®) cables,
which allow longer connection distances thanks to their lower attenuation. HCS®
cables cannot be used with 5 MBd optical components.
The maximum lengths of fiber optic links for POF and HCS® cables are 20 and 200
meters (65.6 ft and 656 ft) respectively.
Technical data 151
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.
Operation Storage Transportation

installed for stationary in the protective pack- in the protective pack-
use age age
Installation site altitude 0…2000 m (0…6562 ft) - -
above sea level. For alti-
tudes over 2000 m, con-
tact ABB.
Output derated above
1000 m (3281 ft).
Air temperature 0 … +45 °C -40 … +70 °C -40 … +70 °C
(+32 … +113 °F), no con- (-40 … +158 °F) (-40 … +158 °F)
densation allowed. Out-
put derated in the range
+45 … +55 °C
(+113 … +131 °F).
For UL and CSA compli-
ant installations, the
maximum surrounding
air temperature is 40 °C
(104 °F).
Relative humidity Max. 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the
presence of corrosive gases.
Contamination IEC/EN 60721-3-3:2002 IEC 60721-3-1:1997 IEC 60721-3-2:1997
Chemical gases: Class Chemical gases: Class Chemical gases: Class
3C2 1C2 2C2
Solid particles: Class 3S2. Solid particles: Class 1S3 Solid particles: Class 2S2
No conductive dust al- (packing must support
lowed. this, otherwise 1S2)
Pollution degree 2
IEC/EN 60664-1
Vibration IEC/EN 60721-3-3:2002 IEC/EN 60721-3-1:1997 IEC/EN 60721-3-2:1997
IEC/EN 61800-5-1 10…57 Hz: max. 10…57 Hz: max. 2…9 Hz: max. 3.5 mm
IEC 60068-2-6:2007, 0.075 mm amplitude 0.075 mm amplitude amplitude
EN 60068-2-6:2008 57…150 Hz: 1 g 57…150 Hz: 1 g 9…200 Hz: 10 m/s2
Units with marine con- (32.8 ft/s2)
struction (option +C121):
Max. 1 mm (0.04 in)
(5 … 13.2 Hz), max. 0.7 g
(13.2 … 100 Hz) sinusoid-
al
Shock Not allowed With packing max. With packing max.
IEC 60068-2-27:2008, EN 100 m/s2 (328 ft/s2) 100 m/s2 (328 ft/s2)
60068-2-27:2009 11 ms 11 ms
Colors
RAL 7035, RAL 9017.
152 Technical data
Materials
￭ Drive
Refer to Recycling instructions and environmental information for ACS880
cabinet-installed drives and multidrive modules (3AXD50000153909 [English]).
￭ Packaging of drive
• Plywood 1)
• Wood
• PET (strapping)
• PE (VCI film)
• Metal (fixing clamps, screws)
• VCI emitter capsules
• Clay desiccant.
1) Seaworthy package only
￭ Packaging of options
• Cardboard
• Kraft paper
• PP (straps)
• PE (film, bubble wrap)
• Plywood, wood (only for heavy components).
Materials vary according to the item type, size and shape. Typical package consists
of a cardboard box with paper filling or bubble wrap. ESD-safe packing materials are
used for printed circuit boards and similar items.
￭ Manuals
Printed product manuals are made of recyclable paper. Product manuals are available
on the Internet.
Disposal
The main parts of the drive can be recycled to preserve natural resources and energy.
Product parts and materials should be dismantled and separated.
Generally all metals, such as steel, aluminum, copper and its alloys, and precious metals
can be recycled as material. Plastics, rubber, cardboard and other packaging material
can be used in energy recovery.
Printed circuit boards and DC capacitors need selective treatment according to IEC
62635 guidelines.
To aid recycling, most plastic parts are marked with an appropriate identification
code. In addition, components containing substances of very high concern (SVHCs)
are listed in European Chemicals Agency's SCIP database. SCIP is the database for
information on Substances of Concern In articles as such or in complex objects
(Products) established under the Waste Framework Directive (2008/98/EC). For further
information, contact your local ABB distributor or consult European Chemicals Agency's
Technical data 153
SCIP database to find out which SVHCs are used in the drive, and to find out where
those components are located.
Contact your local ABB distributor for further information on environmental aspects.
End of life treatment must follow international and national regulations.
For more information on ABB end of life services, see
new.abb.com/service/end-of-lifeservices.
Applicable standards
See ACS880 liquid-cooled multidrive cabinets and modules electrical planning
(3AXD50000048634 [English]).
Markings
See ACS880 liquid-cooled multidrive cabinets and modules electrical planning
(3AXD50000048634 [English]).
Tightening torques
Unless a tightening torque is specified in the text, the following torques can be used.
￭ Electrical connections
Size Torque Strength class

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

M5 6 N·m (53 lbf·in) 8.8
M6 10 N·m (7.4 lbf·ft) 8.8
M8 24 N·m (17.7 lbf·ft) 8.8
￭ Insulation supports

M6 5 N·m (44 lbf·in) 8.8
M8 9 N·m (6.6 lbf·ft) 8.8
M10 18 N·m (13.3 lbf·ft) 8.8
M12 31 N·m (23 lbf·ft) 8.8
154 Technical data
￭ Cable lugs

M8 15 N·m (11 lbf·ft) 8.8 (A2-70 or A4-70)
M10 32 N·m (23.5 lbf·ft) 8.8
M12 50 N·m (37 lbf·ft) 8.8
Disclaimers
￭ Generic disclaimer
The manufacturer shall have no obligation with respect to any product which (i) has
been improperly repaired or altered; (ii) has been subjected to misuse, negligence or
accident; (iii) has been used in a manner contrary to the manufacturer’s instructions;
or (iv) has failed as a result of ordinary wear and tear.
￭ Cyber security 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
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.
Dimensions 155
11
Dimensions
Cabinet line-up dimensions

The drive consists of cubicles built into a cabinet line-up. The table below shows the
nominal width and weight of each inverter type. The dimensions are in millimeters
(for inches, divide by 25.4).
Notes:
• The side panels at the left and right ends of the line-up increase the nominal line-up
width by 30 millimeters (1.2”).
• The standard depth of the cabinet line-up is 644 mm (25.35”) excluding protruding
equipment such as handles.
• UL Listed (+C129) units are top cable entry/exit by default.
• Top cable exit increases the height (and free top space requirement) of the cabinet
line-up by 50 mm (2"). Depending on the configuration, top cable exit will also
increase either the width or depth of the cabinet line-up.
• The control electronics of the inverter unit may have to be housed outside the
inverter module cubicles.
The table is followed by selected dimension drawing examples.
156 Dimensions
￭ Dimensions and weights
Cubicle widths Total unit width Total unit weight

ACS880-107LC-…
mm mm kg lbs
UN = 690 V
0062A-7
0082A-7
0100A-7
0130A-7
0140A-7 300 (1 module) 300 (1 module) 245 (1 module) 540 (1 module)
0190A-7 400 (2 modules) 400 (2 modules) 335 (2 modules) 740 (2 modules)
0220A-7
0290A-7
0340A-7
0389A-7
0390A-7
0430A-7
0480A-7
0530A-7
300 300 300 660
0600A-7
0670A-7
0750A-7
0850A-7
1030A-7
1170A-7
1310A-7 500 500 430 950
1470A-7
1660A-7
1940A-7
2180A-7 700 700 600 1320
2470A-7
2880A-7
500 + 500 1000 860 1900
3260A-7
3580A-7
700 + 500 1200 1030 2270
4050A-7
4840A-7 700 + 700 1400 1200 2650
5650A-7 700 + 500 + 500 1700 1460 3220
6460A-7 700 + 700 + 500 1900 1720 3790
Dimensions 157
￭ Dimension drawing examples

Cabinet height and depth
Side view, bottom cable exit Side view, marine construction (option +C121), bottom
cable exit
158 Dimensions
Side view, top cable exit with common motor Side view, top cable exit without common motor
terminal cubicle terminal cubicle
Dimensions 159
Frame R7i
Inverter module cubicle with one R7i module

160 Dimensions
Inverter module cubicle with two R7i modules

Dimensions 161
Location and size of output terminals

￭ Units without common motor terminal cubicle
Inverter module cubicle with one R7i module, bottom cable exit
162 Dimensions
Inverter module cubicle with two R7i modules, bottom cable exit
Dimensions 163
Inverter module cubicle with one R8i module, bottom cable exit
164 Dimensions
Inverter module cubicle with two R8i modules, bottom cable exit
Dimensions 165
Inverter module cubicle with three R8i modules, bottom cable exit
166 Dimensions
￭ Units with common motor terminal cubicle (+H359)

Cubicle width 300 mm, bottom cable exit
Dimensions 167
Cubicle width 300 mm, top cable exit

168 Dimensions

Dimensions 169

170 Dimensions

Dimensions 171

172
—
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.
a7 (frozen)
PDF-A4
Created 2023-07-04, 07:03:52
www.abb.com/drives
3AXD50000196111D
3AXD50000196111 Rev D (EN) 2023-06-30
© Copyright 2023 ABB. All rights reserved.

Specifications subject to change without notice.

ACS880-107LC Inverter Units: Hardware Manual

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—

ABB INDUSTRIAL DRIVES

ACS880-107LC inverter units

1 Introduction to the manual

2 Operation principle and hardware description

7 Control units of the drive

8 The Safe torque off function

9 Internal cooling circuit

Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Contents of this chapter

Categorization by frame size and option code

Use of component designations

Manuals for ACS880 multidrives cabinets

Terms and abbreviations

Contents of this chapter

Overview diagram of the drive system

Inverter unit hardware

Inverter module hardware

Connectors X50, X52 and X53; Auxiliary voltage selector X59

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

Incoming STO signals from BCU control unit

Auxiliary voltage: 230 V AC

Auxiliary voltage: 115 V AC

Fiber optic connectors

LED Color Indication

FAULT Continuous red There is an active fault in the module.

ENABLE / STO Continuous green The module is ready for use.

ENABLE / STO Continuous yellow XSTO connectors are de-energized.

￭ Frame R8i and multiples

Note: With an inverter unit consisting of parallel-connected R8i modules, it is strongly

Auxiliary voltage: 230 V AC

Auxiliary voltage: 115 V AC

Fiber optic connectors

BSFC V50← Name Description

V60→ BSFC Reserved.

BCU V10← BCU Control unit connection. Must be con-

1 Analog and digital I/O extension modules and 7 Control panel.

￭ The control panel

Type designation labels

￭ Inverter module type designation label

Inverter unit type designation key

Contents of this chapter

Electrical safety precautions

1. Clearly identify the work location and equipment.

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

• Handle the fiber optic cables with care.

Checking the insulation of the assembly

￭ Measuring the insulation resistance of the motor and motor cable

Connecting the control cables

￭ Control cable connection procedure

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

B Conductive surface of the shield exposed

C Stripped part covered with copper foil

Routing the control cables inside the cabinet

Connecting control cabling

Frame R7i – Connecting the motor cables

1) 360° grounding at cable lead-through

￭ Motor cable connection procedure

Removing the shrouding