ACS880-M04 Drive: Hardware Manual

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ABB MACHINERY DRIVES
ACS880-M04 drive
Hardware manual
List of related manuals
Drive manuals and guides Code (English)
ACS880-M04 firmware manual 3AXD50000030629
ACS880-M04 hardware manual 3AXD50000028613
ACS880-M04 quick installation guide 3AXD50000032345
Option manuals and guides

ACX-AP-X Assistant control panels user’s manual 3AUA0000085685
ACS-BP-S Basic control panel user’s manual 3AXD50000032527
ACS880-01 drives and ACS880-04 drive modules 3AUA0000127818
Common DC systems Application guide
Drive (IEC 61131-3) application programming manual 3AUA0000127808
FDPI-02 diagnostics and panel interface user’s manual 3AUA0000113618
FSO-12 safety functions module user’s manual 3AXD50000015612
Technical Guide No. 3 – EMC Compliant Installation and 3AFE61348280
Configuration for a Power Drive System
Converter module capacitor reforming instructions 3BFE64059629
Manuals and quick guides for I/O extension modules,
fieldbus adapters, safety options, etc.
Tool and maintenance manuals and guides

Drive composer PC tool user's manual 3AUA0000094606
You can find manuals and other product documents in PDF format on the Internet. See section Document
library on the Internet on the inside of the back cover. For manuals not available in the Document library,
contact your local ABB representative.
Hardware manual
ACS880-M04 machinery drive
Table of contents
1. Safety instructions
5. Mechanical installation
7. Electrical installation
9. Start-up
 2023 ABB Oy. All Rights Reserved. 3AXD50000028613 Rev B

EN
EFFECTIVE: 2024-01-24
Table of contents 5
Table of contents
List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use of warning and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 18
Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. About the manual

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Categorization according to frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Quick installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3. Operation principle and hardware description

ACS880-M04 drive overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Module layout – Frame R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Module layout – Frame R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4. Planning the cabinet installation

Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cabinet frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Disposition of devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6 Table of contents
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Vertically alone or side by side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Horizontally alone or side by side back installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Horizontally alone side installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Preventing recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Cabinets with multiple modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Delivery check and drive module identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Before installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Required tools for installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installing the drive with screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installing drive to a DIN installation rail – Frames R1 and R2 only . . . . . . . . . . . . . . . . . 51
Installing mains choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installing EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installing brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6. Planning the electrical installation

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Requirements in European Union (EU) countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Requirements in non-EU countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Additional guidelines – North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Power cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Grounding requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Additional grounding requirements – IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Additional grounding requirements – UL (NEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Signals run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Drive composer PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
FPBA-01 PROFIBUS DP adapter module connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Cable routing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Table of contents 7
Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . . . 65
Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 66
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Protecting the drive and the input power and motor cables against thermal overload . . . 66
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connecting a motor temperature sensor to the drive trough an option module . . . . . . . . 68
Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Example of a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Changing the motor power supply from the drive to direct-on-line . . . . . . . . . . . . . . . . . . 73
Changing the motor power supply from direct-on-line to the drive . . . . . . . . . . . . . . . . . . 73
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7. Electrical installation
Removing the cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Motor and motor cable insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Break resistor assembly insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Disconnecting the internal EMC filter – all frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Installing the power cable clamp plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Power cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Installing the optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connecting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ZCU-14 layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Control connections to the ZCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DI6 as a PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
AI1 or AI2 as a Pt100 or KTY84 sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DIIL input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Drive-to-drive link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Safe torque off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Safety functions (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Control unit connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Ground isolation diagram (ZCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8 Table of contents
Connecting the control cables – all frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8. Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
9. Start-up
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10. Maintenance
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Replacing fan (Frames R1 and R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Replacing fan (Frames R3 and R4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
11. Technical data

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Nominal ratings with 230 V AC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Low motor noise derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Supply cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
gR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Terminal and lead-through data for power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Screwdrivers for the terminals of main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
ZCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Ground isolation diagram (ZCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
AC input (supply) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Energy efficiency data (ecodesign) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Table of contents 9
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Compliance with the EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
12. The Safe torque off function

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety)
Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Multiple drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Start-up including validation test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Validation test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Validation test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Perfect proof test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Simplified proof test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
TÜV certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Declarations of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
13. Mains chokes

When is a mains choke required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Selecting a mains choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Guidelines for installing the mains choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Connecting the mains choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10 Table of contents
14. EMC filters

EMC standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
EMC filter emission limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
EMC filtering option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Selecting EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Installing EMC filters – JFI-A1/JFI-B1 (Frame R1/R2, category C3) . . . . . . . . . . . . . . . . . . 170
JFI-x1 filter installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
JFI-x1 filter connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Installing the JFI-A1 filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Installing the JFI-B1 filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Installing EMC filter – JFI-0x (Frames R1…R4, category C2) . . . . . . . . . . . . . . . . . . . . . . . 175
JFI-0x filter installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
JFI-0x filter connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
15. du/dt and common mode filtering

When is du/dt or common mode filtering required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Selecting the du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_
179
Additional requirements for the braking applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Installing du/dt and common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
du/dt filters data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
du/dt filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Common mode filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
du/dt filters dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
du/dt filters degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
16. Resistor braking

Selecting brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Brake choppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Brake choppers data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Brake resistors data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Brake resistors degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Brake resistors dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Installing and wiring brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Contactor protection of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Commissioning the braking circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
17. Dimension drawings

Frame size R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Frame size R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Frame size R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Frame size R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Table of contents 11
Mains chokes (type CHK-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Mains choke – CHK-xx dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
EMC filters (type JFI-x1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
JFI-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
JFI-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
EMC filters (type JFI-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
EMC filter – JFI-xx dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Brake resistors (type JBR-xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Brake resistor - JBR-xx dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
12 Table of contents
Safety instructions 13
1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must follow when you install
and operate the drive and do maintenance on the drive. If you ignore the safety
instructions, injury, death or damage can occur.
Use of warning and notes in this manual

• Warnings tell you about conditions which can cause injury or death, or damage to
the equipment. They also tell you how to prevent the danger.
• Notes draw attention to a particular condition or fact, or give information on a
subject.
The manual uses these warning symbols:
Electricity warning tells about hazards from electricity which can cause injury or
death, or damage to the equipment.
General warning tells about conditions, other than those caused by electricity, which
can cause injury or death, or damage to the equipment.
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
Hot surface warning warns you of component surfaces that may become hot
enough to cause burns if touched.
14 Safety instructions
General safety in installation, start-up and maintenance

These instructions are for all personnel that install the drive and do maintenance work
on it.
WARNING! Follow these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
• Handle the drive carefully.
• Use safety shoes with a metal toe cap to avoid foot injury.
• Keep the drive in its package or protect it otherwise from dust and burr from
drilling and grinding until you install it.
• Protect also the installed drive against dust and burr. Electrically conductive
debris inside the drive may cause damage or malfunction.
• Vacuum clean the area below the drive before the start-up to prevent the drive
cooling fan from drawing the dust inside the drive.
• Do not cover the air inlet and outlet when the drive runs.
• Make sure that there is sufficient cooling. For more information, see sections
Checking the installation site on page 49 and on page 128.
• Before you connect voltage to the drive, make sure that the drive covers are on.
Keep the covers on during the operation.
• Before you adjust the drive operation limits, make sure that the motor and all
driven equipment can operate throughout the set operation limits.
• Before you activate automatic fault reset functions of the drive control program,
make sure that no dangerous situations can occur. These functions reset the
drive automatically and continue operation after a fault. If these functions are
activated, the installation must be clearly marked as defined in IEC/EN 61800-5-1,
subclause 6.5.3, for example, "THIS MACHINE STARTS AUTOMATICALLY".
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors. The maximum
number of times the circuit can charge is: 100000 (frames R1-R2) and 50000
(frames R3-R4).
If you have connected safety circuits to the drive (for example, emergency stop and
Safe torque off), validate them at the start up.
Note:
• If you select an external source for start command and it is On, the drive will start
immediately after fault reset, unless you configure the drive for pulse start.
• When the control location is not set to Local, the stop key on the control panel will
not stop the drive.
Drives can be repaired only by an authorized person.
Electrical safety in installation, start-up and maintenance

 Precautions before electrical work
These warnings are for all personnel who do work on the drive, motor cable or motor.

damage to the equipment can occur. If you are not a qualified electrician, do
not do the electrical installation or maintenance work. Go through these steps before
you begin any installation or maintenance work.
1. Clearly identify the work location.
2. Disconnect all possible voltage sources.
• Open the main disconnector at the power supply of the drive.
• Make sure that reconnection is not possible. Lock the disconnector to open
position and attach a warning notice to it.
• Disconnect any external power sources from the control circuits before you do
work on the control cables.
CAUTION - Risk of electric shock. After disconnecting the input power, always
wait for 5 minutes to let the intermediate circuit capacitors discharge before you
start working on the drive, motor or motor cable.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized.
• Use a multimeter with an impedance of at least 1 Mohm.
• Make sure that the voltage between the drive input power terminals (L1, L2,
L3) and the grounding terminal (PE) is close to 0 V.
• Make sure that the voltage between the drive DC terminals (UDC+ and UDC-)
and the grounding terminal (PE) is close to 0 V.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation
work.
 Additional instructions and notes

• If you install the drive on an IT system (an ungrounded power system or a high-
resistance-grounded [over 30 ohms] power system), disconnect the internal EMC
filter; otherwise the system will be connected to ground potential through the EMC
filter capacitors. This can cause danger or damage the drive. See page 78.
Note: Disconnecting the internal EMC filter increases the conducted emission
and reduces the drive EMC compatibility considerably. See section Compliance
with the EN 61800-3:2004 on page 136.
• Use all ELV (extra low voltage) circuits connected to the drive only within a zone
of equipotential bonding, that is, within a zone where all simultaneously
accessible conductive parts are electrically connected to prevent hazardous
voltages appearing between them. You can accomplish this by a proper factory
grounding, that is, make sure that all simultaneously accessible conductive parts
are grounded to the protective earth (PE) bus of the building.
• Do not do insulation or voltage withstand tests on the drive or drive modules.
Note:
• The motor cable terminals of the drive are at a dangerous voltage when the input
power is on, regardless of whether the motor is running or not.
• The DC and brake resistor terminals (UDC+, UDC-, R+ and R-) are at a
dangerous voltage.
• External wiring can supply dangerous voltages to the terminals of relay outputs.
• The Safe torque off function does not remove the voltage from the main and
auxiliary circuits. The function is not effective against deliberate sabotage or
misuse.
WARNING! Use a grounding wrist band when you handle the printed circuit
boards. Do not touch the boards unnecessarily. The components on the boards
are sensitive to electrostatic discharge.
 Grounding
These instructions are for all personnel who are responsible for the electrical
installation, including the grounding of the drive.

equipment malfunction can occur, and electromagnetic interference can
increase.
• If you are not a qualified electrician, do not do grounding work.

• Always ground the drive, the motor and adjoining equipment to the protective
earth (PE) bus of the power supply. This is necessary for the personnel safety.
Proper grounding also reduces electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) bus of the power supply.
• Make sure that the conductivity of the protective earth (PE) conductors is
sufficient. See section Selecting the power cables on page 54. Obey the local
regulations.
• Connect the power cable shields to the protective earth (PE) terminals of the
drive.
• Make a 360° grounding of the power and control cable shields at the cable entries
to suppress electromagnetic disturbances.
Note:
• You can use power cable shields as grounding conductors only when their
conductivity is sufficient.
• Standard IEC/EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch
current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed
protective earth (PE) connection. In addition,
• install a second protective earth conductor of the same cross-sectional area
as the original protective earthing conductor,
or
• install a protective earth conductor with a cross-section of at least 10 mm2 Cu
or 16 mm 2 Al,
or
• install a device which automatically disconnects the supply if the protective
earth conductor breaks.
Additional instructions for permanent magnet motor drives

 Safety in installation, start-up and maintenance
These are additional warnings concerning permanent magnet motor drives. The other
safety instructions in this chapter are also valid.
WARNING! Follow these instructions. If you ignore them, injury or death and
• Do not work on a drive when a rotating permanent magnet motor is connected to

it. A rotating permanent magnet motor energizes the drive including its input
power terminals.
Before installation, start-up and maintenance work on the drive:
• Stop the motor.
• Disconnect the motor from the drive with a safety switch or by other means.
• If you cannot disconnect the motor, make sure that the motor cannot rotate during
work. Make sure that no other system, like hydraulic crawling drives, can rotate
the motor directly or through any mechanical connection like felt, nip, rope, etc.
• Measure that the installation is de-energized.
• Use a multimeter with an impedance of at least 1 Mohm.
• Make sure that the voltage between the drive output terminals (T1/U, T2/V,
T3/W) and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive input power terminals (L1, L2,
L3) and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive DC terminals (UDC+, UDC-) and
the grounding (PE) terminal is close to 0 V.
• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W).
Connect the output terminals together as well as to the PE.
Start-up and operation:
• Make sure that the operator cannot run the motor over the rated speed. Motor
overspeed causes overvoltage that can damage or explode the capacitors in the
intermediate circuit of the drive.
General safety in operation

These instructions are for all personnel that operate the drive.
• Do not control the motor with the disconnector at the drive power supply; instead,
use the control panel start and stop keys or commands through the I/O terminals
of the drive.
• Give a stop command to the drive before you reset a fault. If you have an external
source for the start command and the start is on, the drive will start immediately
after the fault reset, unless you configure the drive for pulse start. See the
firmware manual.
• Before you activate automatic fault reset functions of the drive control program,
make sure that no dangerous situations can occur. These functions reset the
drive automatically and continue operation after a fault. If these functions are
activated, the installation must be clearly marked as defined in IEC/EN 61800-5-1,
subclause 6.5.3, for example, "THIS MACHINE STARTS AUTOMATICALLY".
Note: When the control location is not set to Local, the stop key on the control panel
will not stop the drive.
About the manual 21
2
About the manual
This chapter describes the intended audience and contents of this manual. It contains
a flowchart of steps in checking the delivery, installing and commissioning the drive.
The flowchart refers to chapters/sections in this manual and other manuals.
Applicability
This manual applies to the ACS880-M04 drive module of frame sizes R1 to R4.
Intended audience
This manual is intended for people who plan the installation, install, commission, use
and service the drive. Read the manual before working on the drive. The reader is
expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
This manual is written for readers worldwide. Both SI and imperial units are shown
wherever appropriate.
Categorization according to frame size

The ACS880-M04 drive is manufactured in frame sizes R1 to R4. Some instructions,
technical data and dimensional drawings which concern only certain frame sizes are
marked with the symbol of the frame size (R1, R2, R3, R4). The frame size is marked
on the drive designation label. See also the frame size of each drive type in the
ratings tables in chapter Technical data.
22 About the manual
Categorization according to the + code

The instructions, technical data and dimensional drawings which concern only certain
optional selections are marked with + codes, e.g. +L500. The options included in the
drive can be identified from the + codes visible on the type designation label of the
drive. See the + code selections listed in Type designation label on page 33.
Quick installation and commissioning flowchart
Task Refer to
Identify the frame size of your drive: Type designation label on page 49.
R1, R2, R3, R4.
Plan the installation. Select the cables, etc. Planning the cabinet installation on page 37.
Check the ambient conditions, ratings, Planning the electrical installation on page 53.
required cooling air flow, input power Technical data on page 112.
connection, compatibility of the motor, motor
Option manual (if optional equipment is
connection, and other technical data.
included)
Unpack and check the drive. Contents of the package on page 47.
Check that all necessary optional modules Delivery check and drive module identification
and equipment are present and correct. on page 48.
Only intact units may be started up. If the converter was non-operational for more
than one year, reform the converter DC link
capacitors. For more information, contact your
ABB representative.
Check the installation site. Checking the installation site on page 49.
Install the drive in a cabinet. Installing the drive on page 50.
Route the cables. Routing the cables on page 64.

About the manual 23
Task Refer to
Check the insulation of the supply cable, the Checking the insulation of the assembly on
motor and the motor cable, and the resistor page 77.
cable (if present).
If the drive is about to be connected to an IT Electrical safety in installation, start-up and

(ungrounded) system, disconnect the internal maintenance on page 15.
varistors and EMC filters. Also note that using Checking the compatibility with IT
an EMC filter is not allowed in an IT (ungrounded) systems on page 78.
(ungrounded) system.
Connect the power cables. Connecting the power cables on page 79.
Connect the control and the auxiliary control Connecting the control unit on page 87.
cables. For optional equipment:
Mains chokes on page 163.
EMC filters on page 167.
Resistor braking on page 181.
Manuals for any optional equipment
Check the installation. Installation checklist on page 101.
Commission the drive. Start-up on page 103.

Firmware manual [3AXD50000030629
(English)]
Commission the brake chopper if required. Resistor braking on page 181.
Operate the drive: start, stop, speed control Firmware manual [3AXD50000030629
etc. (English)]
24 About the manual
Terms and abbreviations

Term/Abbreviation Explanation
Brake chopper Conducts the surplus energy from the intermediate circuit of the
drive to the brake resistor when necessary. The chopper
operates when the DC link voltage exceeds a certain maximum
limit. The voltage rise is typically caused by deceleration
(braking) of a high inertia motor.
Brake resistor Dissipates the drive surplus braking energy conducted by the
brake chopper to heat. Essential part of the brake circuit. Refer
to Brake chopper.
Control board Circuit board in which the control program runs.
Capacitor bank Refer to DC link capacitors.
DC link DC circuit between rectifier and drive
DC link capacitors Energy storage which stabilizes the intermediate circuit DC
voltage
Drive Frequency converter for controlling AC motors
EFB Embedded fieldbus
EMC Electromagnetic compatibility
FBA Fieldbus adapter
FCAN-01/-01-M Optional CANopen adapter module
FCNA-01 ControlNet adapter module
FDNA-01 Optional DeviceNet adapter module
FECA-01/-01-M Optional EtherCAT adapter module
FENA-01/-11/-21/-21-M Optional Ethernet adapter module for EtherNet/IP, Modbus TCP
and PROFINET IO protocols
FEPL-02 Ethernet POWERLINK adapter module
FPBA-01/-01-M Optional PROFIBUS DP adapter module
Frame (size) Refers to drive physical size, for example R1 and R2. The type
designation label attached to the drive shows the frame of the
drive, refer to Type designation key on page 34.
FSCA-0x Optional Modbus/RTU adapter module
IGBT Insulated Gate Bipolar Transistor; a voltage-controlled
semiconductor type widely used in drives due to their easy
controllability and high switching frequency.
I/O Input/Output
JBR-xx Series of optional brake resistors
JFI-xx Series of optional EMC filters
JPU/RPU Power unit; see the definition below.
Power unit Contains the power electronics and connections of the drive
module. The ZCU is connected to the power unit.
About the manual 25
Term/Abbreviation Explanation
RFI Radio-frequency interference
ZMU The memory unit attached to the control unit of the drive.
ZCU The control unit of the drive module. The ZCU is installed on top
of the power unit. The external I/O control signals are connected
to the ZCU, or optional I/O extensions mounted on it.
26 About the manual
Operation principle and hardware description 27
3
Operation principle and
hardware description
The chapter describes the operating principle and construction of the drive module.
ACS880-M04 drive overview

The ACS880-M04 is an air-cooled IP20 drive module for controlling asynchronous
induction motors, permanent magnet motors and ABB synchronous reluctance
motors. It must be installed into a cabinet by the customer.
The drive is available in several frame sizes depending on the output power. All frame
sizes use the same control unit of ZCU type.
28 Operation principle and hardware description
Operation principle
 Main circuit
AC supply
CHK-xx mains choke (see

chapter Mains chokes on
page 163)
UDC+ UDC– U1 V1 W1 JFI-xx EMC filter (see chapter
ACS880-M04 EMC filters on page 167)
Rectifier
+ –
Capacitor bank
drive
Brake chopper (see chapter
Resistor braking on page
181)
U2 V2 W2 R– R+
NOCHxxxx-xx du/dt filter JBR-xx brake resistor (see

(see chapter du/dt and chapter Resistor braking on
common mode filtering page 181)
on page 177) Motor output
 Motor control
The motor control is based on direct torque control. Two phase currents and DC link
voltage are measured and used for the control. The third phase current is measured
for earth fault protection.
Layout
 General
The DC input terminals are located at the top of the module and the AC output
terminals are located at the bottom of the module.
The ZCU-14 control unit is mounted onto the module. The control unit contains the
basic I/Os and slots for optional I/O modules. For descriptions of the I/O terminals on
the control unit, see Connecting the control unit on page 87.
Other optional equipments are primarily installed on separate mounting plates.
The modules are fitted with external DC fuses. The frames R1...R4 modules have an
internal capacitor pre-charge circuit.
 Module layout – Frame R1

(Note that frame R2 has a similar layout)
Item Explanation
3
1 DC (input) connection (obscured)
2 Motor (output) connection (obscured)
8 3 Grounding/clamping plates for power
cables
13 4 ZCU-14 control unit
5 Power unit
6 Slots for optional I/O modules
6 7 I/O terminal blocks
8 Grounding/clamping plate for control
cables
9 Memory unit
10 Control panel connector
11 Air temperature sensor
4 12 Cover with recess for control panel
5 (can optionally be left out)
12 13 Varistor board connecting screw (VAR).
6
9
3
10
2
11
 Module layout – Frame R4

(Note that frame R3 has a similar layout.)
Item Explanation
8 1 DC (input) connection (under
1 connector cover)
2 Motor (output) connection (under
connector cover)
6 3 Grounding/clamping plates for
power cables
13
4 ZCU control unit
4
5 Power unit
6 Slots for optional I/O modules
12 6
7 I/O terminal blocks
7 8 Grounding/clamping plate for
5 control cables
9 Memory unit
6 10 Control panel connector
11 Air temperature sensor
12 Cover with panel mounting
platform (can optionally be left
out)
2 13 Varistor board connecting screw
9 (VAR).
10
11
3
Power connections and control interfaces

Slot 1 / Slot 2 Control unit (ZCU)
Fxx
FIO-01 (Digital I/O extension)
FIO-11 (Analog I/O extension)
FIO-21 (Digital/Analog I/O Slot 1
extension)
FEN-01 (Incremental [TTL]
encoder interface) Fxx
FEN-11 (Absolute encoder
interface)
FEN-21 (Resolver interface)
FEN-31 (Incremental [HTL] Slot 2
encoder interface)
Slot 3 (Fieldbus adapter)
X12
**FCAN-01 (CANopen) Safety option
FDNA-01 (DeviceNet) Control panel or
**FECA-01 (EtherCAT®) control panel and PC
**FENA-11 (Ethernet/IP,
Modbus/TCP, PROFINET IO)
Memory unit
FENA-21 (2-port Ethernet/IP, Slot 3* (see page
Modbus/TCP, PROFINET IO)
FLON-01 (LONWORKS® ) Fxxx
*Relay outputs XRO1…3
FSCA-01 (Modbus/RTU)
(3 pcs) For more information
**FPBA-01 (PROFIBUS DP) External power input XPOW on these connections,
*Analog inputs XAI see page 88. For
*Analog outputs XAO specifications, see
Drive-to-drive link XD2D page 124.
Safe torque off XSTO *Programmable
*Digital inputs XDI
(6 pcs)
*Digital XDIO
input/outputs (2 pcs)
24 V DC output XD24
Power unit (JPU/RPU)

PE PE
3-phase power L1 U1 U2
M
supply Brake V2
L2 V1 chopper 3~
L3 W1 UDC+ W2 AC motor
R– R+ UDC-
t°
Brake resistor (optional)
Note:
*Reserved for fieldbus is included in delivery.
**Also supports M-series fieldbuses.
Type designation label

This is a sample type designation label.
1
5
2
6
No. Description
1 Type designation, see Type designation key below.
2 Degree of protection
3 Frame (size)
4 Nominal ratings, see Ratings on page 112.
5 Valid markings
6 S/N: Serial number in format MYYWWXXXX, where
M: Manufacturer
YY: Year of manufacture: 15, 16, 17, ... for 2015, 2016, 2017, ...
W: Week of manufacture: 01, 02, 03, ... for week 1, week 2, week 3, ...
XXXX: Running item number starting each week from 0001.
Type designation key

The type designation key tells you the specifications and configuration of the drive.
The table shows the primary drive variants.
Sample type code: ACS880-M04-04A8-5+XXXX
• The first digits from left indicate the basic configuration (ACS880-M04-04A8-5).
• The optional selections are given thereafter, preceded by + signs (e.g. +L501).
The main selections are described below.
Note: Not all selections are necessarily available for all types; refer to ACS880-
M04 ordering information, available on request.
Selection Alternatives
Product series ACS880
Type M04 Drive module.
When no options are selected: IP20 (UL Open Type), plain front
cover, no control panel, no mains choke (frames R1 and R2),
internal mains choke (frames R3 and R4), no EMC filter, internal
brake chopper, coated boards, Safe torque off, Primary control
program, Quick installation and start-up Guide.
Current rating 04A8 For example, 04A8 refers to a nominal output current of 4.8 A. See
Ratings on page 112.
Voltage range 2 200…240 V
5 380…500 V
Option codes (plus codes)
Filters E... +E200: EMC filter, C3, 2nd Environment, Unrestricted (Earthed
network) (External with frames R1 and R2, internal with frames R3
and R4)
Control panel and J... +0C168: No drive module front cover, no control panel
front cover +J400: Control panel mounted on drive module front cover
options +J410: Control panel with door mounting platform kit including 3 m
cable
+J414: Control panel mounting platform on drive module (no
control panel included)
Fieldbus K... +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 Modbus/RTU adapter module
+K473: FENA-11 Ethernet/IP™, Modbus/TCP and PROFINET IO
adapter module
+K469: FECA-01 EtherCAT® adapter module
Selection Alternatives
I/O extensions L... +L500: FIO-11 analog I/O extension module
and feedback +L501: FIO-01 digital I/O extension module
interfaces +L502: FEN-31 HTL encoder interface module
+L516: FEN-21 resolver interface module
+L517: FEN-01 TTL encoder interface module
+L518: FEN-11 absolute TTL encoder interface module
+L519: FIO-21 analog/digital I/O extension module
Programs N... +N5050: Crane control program
Note: The following technology library is required with the Crane
control program:
+N3050: Crane technology library
+N5000: Winder control program
+N8200 High-speed control program
Specialties +P904: Extended warranty
Printed hardware R... +R700: English
and firmware +R701: German
manuals in +R702: Italian
specified +R703: Dutch
language +R704: Danish
(The delivered +R705: Swedish
manual set can +R706: Finnish
include manuals +R707: French
in English if the +R708: Spanish
translation is not +R709: Portuguese
available.) +R710: Portuguese spoken in Brazil
+R711: Russian
+R714: Turkish
3AXD10000434191
Planning the cabinet installation 37
4
Planning the cabinet
installation
This chapter guides in planning the installation of a drive module into a user-defined
cabinet. The issues discussed are essential for safe and trouble-free use of the drive
system.
Note: The installation examples in this manual are provided only to help the installer
in designing the installation.
WARNING! Installation must always be designed and made according to

applicable local laws and regulations. ABB does not assume any liability
whatsoever for any installation which breaches the local laws and/or other
regulations.
38 Planning the cabinet installation
Cabinet construction
 Cabinet frame
Make sure... 
The cabinet frame is sturdy enough to carry the weight of the drive components, control
circuitry and other equipment installed in it.
The cabinet protects the drive module against contact and meets the requirements for
dust and humidity. See data for relative humidity and contamination under Ambient
conditions on page 132.
 Disposition of devices
Check that ...
The layout is spacious enough for easy installation and maintenance. There should be
sufficient space for cooling air flow, obligatory clearances, cables and cable support
structures.
See the layout example in Cooling and degrees of protection on page 42.
 Grounding of mounting structures
Make sure ...
Proper grounding of
• all cross-members or shelves on which the drive system components are mounted
• the components through their fastening points to the installation base.
Note: It is recommended to mount the EMC filter (if present) and the drive module on the
same mounting plate.
The connecting surfaces are left unpainted.
Free space requirements

The drive modules can be installed side by side. The alternate ways to install the
modules are illustrated below. See the free space requirements table below.
For dimensions of the drive modules, refer to chapter Dimension drawings on
page 189.
 Vertically alone or side by side

c =0
a a
a
Free space requirement

Above (a) Below (b) On the sides (c)
mm in mm in mm in
200 7.9 300 12 0 0
b b b
Do not install the drive upside down.

 Horizontally alone or side by side back installation

b c a
a c b
 Horizontally alone side installation

This installation is recommended only with the R1 frame. For this kind of installation
with other frames, use additional support.
Note: EMC filters of type JFI-x1 mounted directly above the drive module do not
increase the free space requirements. (For EMC filters of type JFI-0x, see the
dimension drawing of the filters on page 193.)
200 mm [7.9”]
300
300 mm [12”]
Note: The temperature of the cooling air entering the unit must not exceed the
maximum allowed ambient temperature (see Ambient conditions on page 132).
Consider this when installing heat-generating components (such as other drives,
mains chokes and brake resistors) nearby.
Cooling and degrees of protection

Check that... 
The cabinet has enough free space for the components for sufficient cooling. Observe
the minimum clearances given for each component.
The air inlets and outlets are equipped with gratings that guide the airflow, protect
against contact, and prevent water splashes from entering the cabinet.
The drawing below shows two typical cabinet cooling solutions. The air inlet is at the
bottom of the cabinet, while the outlet is at the top, either on the upper part of the door or
on the roof.
Air outlet
Air inlet
The air inlets and outlets are sufficient in size.

Note: In addition to the power loss of the drive module, ventilate the heat dissipated by
cables and other additional equipment.
Cooling of the modules is arranged such that the requirements meet the data in Cooling
on page 130.
Note: The values apply to continuous nominal load. If the load is less than nominal, less
cooling air is required.
Ambient temperature is within the limits specified in Ambient conditions on page 132.
The installation site is sufficiently ventilated.
In IP22 cabinets, the internal cooling fans of the modules are usually sufficient to keep
the component temperatures low enough.
In IP54 cabinets, thick filter mats are used to prevent water splashes from entering the
cabinet. This entails the installation of additional cooling equipment, such as a hot air
exhaust fan.
 Preventing recirculation of hot air

Cabinet (side view)
HOT
AREA
Main airflow out
Air baffle plates
COOL AREA
Main airflow in
Outside the cabinet

Prevent hot air circulation outside the cabinet by leading the outcoming hot air away
from the area where the inlet air to the cabinet is taken. Possible solutions are listed
below:
• gratings that guide airflow at the air inlet and outlet
• air inlet and outlet at different sides of the cabinet
• cool air inlet in the lower part of the front door and an extra exhaust fan on the roof
of the cabinet.
Inside the cabinet

Prevent hot air circulation inside the cabinet with leak-proof air baffle plates. No
gaskets are usually required.
 Cabinets with multiple modules

The hot air from a drive module must not enter another module. In a cabinet with
multiple modules, the practical way is to install a wall to separate the cool area (at the
front part of the cabinet) from the hot area (back part). The wall can be fastened to
two vertical pillars on both left and right.
Since the air outlet at the top of the modules points directly upwards, the air must be
guided to the hot area using separate airflow guides. See the example below.
SIDE VIEW
Airflow out Airflow out
Hot area
Cool area
Drive modules
Airflow guides Opening in the wall

to allow airflow
Wall
Airflow in
 Cabinet heaters
Use a cabinet heater if there is a risk of condensation in the cabinet. Although the
primary function of the heater is to keep the air dry, it may also be required for heating
at low temperatures. When placing the heater, follow the instructions provided by its
manufacturer.
Mechanical installation 47
5
Mechanical installation
The chapter describes the mechanical installation procedure of the drive.
Contents of the package

The drive is delivered in a cardboard box. To open, remove any banding and lift the
top off the box.
48 Mechanical installation
Compartment for
cable clamp plates
EMC/RFI filter and
control panel
mounting kit
(Underneath the
drive module – lift Compartment for
out the module and terminal blocks
open left-hand side and manuals
flap to access)
ACS880-M04
drive module
Check that the box contains... 

ACS880-M04 drive module, with factory-installed options
Three cable clamp plates (two for power cabling, one for control cabling) with screws
Screw-type terminal blocks to be attached to the headers on the ZCU control unit and
the power unit
EMC filter (+E200) if ordered (with frames R1 and R2 only)
Control panel mounting kit (+J410) if ordered
Printed quick guides
Printed manuals if ordered
Delivery check and drive module identification

Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive module to
verify that the unit is of the correct type. See Type designation label on page 33.
Before installing the drive

 Checking the installation site
Before installation, check the installation site according to the requirements below.
For frame details, refer to Dimension drawings on page 189.
Check that... 
The frame details are according to the Dimension drawings from page 189.
The operational conditions of the drive meets the Ambient conditions on page132.
The surface on which the drive is to be mounted on is
• even as possible
• of non-flammable material
• strong enough to carry the weight of the drive.
See sections Dimensions and weights (page 122) and Free space requirements
(page 39).
The installation site is sufficiently ventilated or cooled to transfer away the drive losses.
See section on page 128.
The floor/material below the installation is non-flammable.
There is enough free space above and below the drive to enable cooling air flow, service
and maintenance.
See the required Free space requirements (page 39) for each of the different mounting
alignments and Cooling and degrees of protection (page 42).
 Required tools for installing the drive

To install the drive mechanically, you need the following tools:
• A drill and suitable drill bits
• A screwdriver or wrench with a set of suitable bits (as appropriate for the
installation hardware used)
• A tape measure and spirit level
• Personal protective equipment.
Installing the drive

You can install the drive:
• With screws on to a wall
• To a DIN installation rail with the integrated lock.
See the possible installation directions and free space requirements on page 39.
 Installing the drive with screws

1. Mark the locations for the four holes. The mounting points are shown in
Dimension drawings.
H
2. Fix the screws or bolts to the marked locations.

3. Position the drive onto the screws on the surface.
Note: Lift the drive only by its chassis.
4. Tighten the screws.

 Installing drive to a DIN installation rail – Frames R1 and R2 only

1. Click the drive to the rail. To detach the drive, press the release lever on top of the
drive as shown in the figure.
2. Fasten the lower edge of the drive to the mounting base through the two fastening
points.
1
Installing mains choke

See chapter Mains chokes on page 163.
Installing EMC filter

See chapter EMC filters on page 167.
Installing brake resistor

See chapter Resistor braking on page 181.
Planning the electrical installation 53
6
Planning the electrical
installation
This chapter contains instructions for planning the electrical installation of the drive,
for example, for checking the compatibility of the motor and drive, selecting cables,
protections and cable routing.
WARNING! Installation must be designed and done according to the

whatsoever for any installation which breaches the local laws and/or other
regulations.
If recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.
Checking the compatibility of the motor and drive

Use an asynchronous AC induction motor or a permanent magnet motor with the
drive. Several induction motors can be connected to the drive at a time but only one
permanent magnet motor can be connected to the drive at a time.
Make sure that the motor and the drive are compatible according to the Ratings on
page 112. The ratings table lists the typical motor power for each drive type.
54 Planning the electrical installation
Selecting the supply disconnecting device

According to safety regulations, equip each drive with a supply disconnecting device.
Install a hand-operated input disconnecting device between the AC power source
and the drive.
Note: You must be able to lock the disconnecting device to the open position for
installation and maintenance work.
 Requirements in European Union (EU) countries

To meet the European Union Directives, according to standard EN 60204-1, Safety of
Machinery, the disconnecting device must be one of the following types:
• switch-disconnector of utilization category AC-23B (EN 60947-3)
• disconnector that has an auxiliary contact that in all cases causes switching
devices to break the load circuit before the opening of the main contacts of the
disconnector (EN 60947-3)
• circuit breaker suitable for isolation in accordance with EN 60947-2.
 Requirements in non-EU countries

The disconnecting device must conform to the applicable local safety regulations.
Selecting the power cables

 General guidelines
Select the input power and motor cables according to local regulations:
• Current: Select a cable capable of carrying the maximum load current and
suitable for the prospective short-circuit current provided by the supply network.
The method of installation and ambient temperature affect the cable current
carrying capacity. Obey local regulations and laws.
• Temperature: For an IEC installation, select a cable rated for at least 70 °C (158
°F) maximum permissible temperature of conductor in continuous use. For North
America, select a cable rated for at least 75 °C (167 °F).
Important: For certain product types or option configurations higher temperature
rating may be required. See the technical data for details.
• Voltage: 600 V AC cable is accepted for up to 500 V AC. 750 V AC cable is
accepted for up to 600 V AC. 1000 V AC cable is accepted for up to 690 V AC.
To comply with the EMC requirements of the CE mark, use one of the preferred cable
types. See Preferred power cable types (page 56).
Symmetrical shielded cable reduces electromagnetic emission of the whole drive
system as well as the stress on motor insulation, bearing currents and wear. Metal
conduit reduces electromagnetic emission of the whole drive system.
 Typical power cable sizes

The table below gives typical copper cable types with concentric copper shield for the
drives with nominal current. For terminal and entry data for power cables, see
Terminal and lead-through data for power cables (page 124).
Note: Aluminum cables are not allowed in UL (NEC) installations.
Type Frame size Cable size, Conductor size,
ACS880-M04- Cu (mm2)1) Cu (AWG) 2)
-03A0-2/5 R1 3×1.5 + 1.5 14
-03A6-2/5 R1 3×1.5 + 1.5 14
-04A8-2/5 R1 3×1.5 + 1.5 14
-06A0-2/5 R1 3×1.5 + 1.5 14
-08A0-2/5 R1 3×1.5 + 1.5 14
-010A-2/5 R2 3×2.5 + 2.5 14
-014A-2/5 R2 3×2.5 + 2.5 14
-018A-2/5 R2 3×6 + 6 10
-025A-2/5 R3 3×6 + 6 10
-030A-2/5 R3 3×10 + 10 8
-035A-2/5 R3 3×10 + 10 8
-044A-2/5 R3 3×16 + 16 6
-050A-2/5 R3 3×16 + 16 6
-061A-2/5 R4 3×25 + 16 4
-078A-2/5 R4 3×35 + 16 2
-094A-2/5 R4 3×50 + 25 1
1)
) The cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one
on top of the other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (EN 60204-1 and
IEC 60364-5-52/2001). For other conditions, size the cables according to local safety regulations,
appropriate input voltage and the load current of the drive.
2
The cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40 °C
(104 °F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or earth
(directly buried). For other conditions, size the cables according to local safety regulations, appropriate input
voltage and the load current of the drive.
Temperature: For IEC, select a cable rated for at least 70 °C maximum permissible
temperature of conductor in continuous use. For North America, power cables
must be rated for 75 °C (167 °F) or higher.
Voltage: 600 V AC cable is accepted for up to 500 V AC.
See also Supply cable fuses on page 118.
 Power cable types

Preferred power cable types
This section shows the preferred cable types. Make sure that the selected cable type
also complies with local/state/country electrical codes.
Cable type Use as input power Use as motor or brake
cabling resistor cabling
PE Yes Yes
Symmetrical shielded (or armored)

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

and symmetrically constructed PE
conductor and a shield (or armor)
Yes Yes
PE

and a shield (or armor), and separate
PE conductor/cable1)
1)
A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient
for the PE use.
Alternate power cable types

Cable type Use as input power Use as motor or brake
cabling resistor cabling
Yes with phase conductor Yes with phase conductor
smaller than 10 mm2 (8 smaller than 10 mm2 (8
AWG) Cu. AWG) Cu, or motors up to
30 kW (40 hp).
Note: Shielded or
armored cable, or cabling
in metal conduit is always
Four-conductor cable in plastic jacket
recommended to
(three phase conductors and PE)
minimize radio frequency
interference.
Yes Yes with phase conductor
smaller than 10 mm2 (8
AWG) Cu, or motors up to
30 kW (40 hp)
Four-conductor armored cable (three

phase conductors and PE)
Yes Yes with motors up to 100
kW (135 hp). A potential
equalization between the
frames of motor and
driven equipment is
required.
Shielded (Al/Cu shield or armor)1)
four-conductor cable (three phase
conductors and a PE)
1)Armor may act as an EMC shield, as long as it provides the same performance as a concentric
EMC shield of a shielded cable. To be effective at high frequencies, the shield conductivity must
be at least 1/10 of the phase conductor conductivity. The effectiveness of the shield can be
evaluated based on the shield inductance, which must be low and only slightly dependent on
frequency. The requirements are easily met with a copper or aluminum shield/armor. The cross-
section of a steel shield must be ample and the shield helix must have a low gradient. A
galvanized steel shield has a better high-frequency conductivity than a non-galvanized steel
shield.
Not allowed power cable types

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

with individual shields for
each phase conductor
 Additional guidelines – North America

ABB recommends the use of metallic conduit for power wiring. ABB also
recommends the use of symmetrical shielded VFD cable between drive and motor(s).
This table shows examples of methods for wiring the drive. Refer to NFPA 70 (NEC)
along with state and local codes for the appropriate methods for your application.
Wiring method Notes
Conduit - Metallic 1) 2)
Electrical metallic tubing: Type Prefer symmetrical shielded VFD cable. Use separate conduit
EMT run for each motor. Do not run input power wiring and motor
Rigid metal conduit: Type wiring in the same conduit.
RMC
Liquid-tight flexible metal
electrical conduit: Type LFMC
Conduit - Non-metallic 2) 3)
Liquid-tight flexible non- Prefer symmetrical shielded VFD cable. Use separate conduit
metallic conduit: Type LFNC run for each motor.
Do not run input power wiring and motor wiring in the same
conduit.
Wireways 2)
Metallic Prefer symmetrical shielded VFD cable.
Separate motor wiring from input power wiring and other low
voltage wiring.
Do not run outputs of multiple drives parallel. Bundle each
cable (wiring) together and use separators where possible.
Free air 2)
Enclosures, air handlers, etc. Prefer symmetrical shielded VFD cable. Allowed internally in
enclosures when in accordance with UL.
1)
Metallic conduit may be used as an additional ground path, provided this path is a solid path
capable of handling ground currents.
2)
See NFPA NFPA 70 (NEC), UL, and local codes for your application.
3)
Non-metallic conduit use underground is allowed; however, these installations inherently have
an increased chance for nuisance problems due to the potential for water/moisture in the
conduit. Water/moisture in the conduit increases the likelihood of VFD faults or warnings. Proper
installation is required to make sure there is no intrusion of water/moisture.
Metal conduit
Couple separate parts of a metal conduit together: bridge the joints with a ground
conductor bonded to the conduit on each side of the joint. Also bond the conduits to
the drive enclosure and motor frame. Use separate conduits for input power, motor,
brake resistor, and control wiring. Do not run motor wiring from more than one drive in
the same conduit.
 Power cable shield

If the cable shield is used as the sole protective earth (PE) conductor, make sure that
its conductivity agrees with the PE conductor requirements.
To effectively suppress radiated and conducted radio-frequency emissions, the cable
shield conductivity must be at least 1/10 of the phase conductor conductivity. The
requirements are easily met with a copper or aluminum shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of a
concentric layer of copper wires with an open helix of copper tape or copper wire. The
better and tighter the shield, the lower the emission level and bearing currents.
3 4 5
1 Insulation jacket
2 Helix of copper tape or copper wire
3 Copper wire shield
4 Inner insulation
5 Cable core
Grounding requirements
This section gives general requirements for grounding the drive. When you plan the
grounding of the drive, obey all the applicable national and local regulations.
The conductivity of the protective earth conductor(s) must be sufficient.
Unless local wiring regulations state otherwise, the cross-sectional area of the
protective earth conductor must agree with the conditions that require automatic
disconnection of the supply required in 411.3.2 of IEC 60364-4-41:2005 and be
capable of withstanding the prospective fault current during the disconnection time of
the protective device. The cross-sectional area of the protective earth conductor must
be selected from the table below or calculated according to 543.1 of IEC 60364-5-54.
This table shows the minimum cross-sectional area of the protective earth conductor
related to the phase conductor size according to IEC/UL 61800-5-1 when the phase
conductor(s) and the protective earth conductor are made of the same metal. If this is
not so, the cross-sectional area of the protective earth 76 Guidelines for planning the
electrical installation conductor must be determined in a manner which produces a
conductance equivalent to that which results from the application of this table.
Cross-sectional area of the phase Minimum cross-sectional area of the

conductors corresponding protective earth
conductor
S (mm2)
Sp (mm 2)
S ≤ 16 S1)
16 < S ≤ 35 16
35 < S S/2
1)
For the minimum conductor size in IEC installations,refer to Additional grounding
requirements – IEC.
If the protective earth conductor is not part of the input power cable or input power
cable enclosure, the minimum permitted cross-sectional area is:
• 2.5 mm 2
if the conductor is mechanically protected,
or
• 4 mm 2 if the conductor is not mechanically protected. If the equipment is cord-
connected, the protective earth conductor must be the last conductor to be
interrupted if there is a failure in the strain relief mechanism.
 Additional grounding requirements – IEC

This sectiongivesgroundingrequirements accordingtostandardIEC/EN 61800-5-1.
Because the normal touch current of the drive is more than 3.5 mA AC or 10 mA DC:
• the minimum size of the protective earth conductor must comply with the local
safety regulations for high protective earth conductor current equipment, and
• you must use one of these connection methods:
1. a fixed connection and:

• a protective earth conductor with a minimum cross-sectional area of 10 mm2
Cu or 16 mm2 Al (as an alternative when aluminum cables are permitted), or
• a second protective earth conductor of the same cross-sectional area as the
original protective earth conductor,
or
• a device that automatically disconnects the supply if the protective earth
conductor is damaged.
2. a connection with an industrial connector according to IEC 60309 and a minimum
protective earth conductor cross-section of 2.5 mm2 as part of a multi-conductor
power cable. Sufficient strain relief must be provided.
If the protective earth conductor is routed through a plug and socket, or similar means
of disconnection, it must not be possible to disconnect it unless power is
simultaneously removed.
Note: You can use power cable shields as grounding conductors only when their
conductivity is sufficient
 Additional grounding requirements – UL (NEC)

This section gives grounding requirements according to standard UL 61800-5-1.
The protective earth conductor must be sized as specified in Article 250.122 and
table 250.122 of the National Electric Code, ANSI/NFPA 70.
For cord-connectedequipment, it must notbepossible todisconnect theprotective
earth conductor before power is removed.
Selecting the control cables

 Shielding
Use only shielded control cables.
Use a double-shielded twisted pair cable (figure a below) for analog signals. Use one
individually shielded pair for each signal. Do not use common return for different
analog signals.
A double-shielded cable (figure a) is the best alternative for low-voltage digital

signals, but a single-shielded twisted pair cable (figure b) is also acceptable.
a b
 Signals in separate cables

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

If their voltage does not exceed 48 V, relay-controlled signals can be run in the same
cables as digital input signals. The relay-controlled signals should be run as twisted
pairs.
 Relay cable
The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL,
Germany) was tested and approved by ABB.
 Control panel cable

In remote use, the cable connecting the control panel to the drive must not exceed
100 m (330 ft). If multiple panels or drives are connected, the total length of the panel
bus must not exceed 100 m (330 ft).
The cable type tested and approved by ABB is used in control panel option kits.
Suitable cables are CAT 5e unshielded or shielded twisted pair cables.
 Drive composer PC tool cable

Connect the Drive composer PC tool to the drive through the USB port of the control
panel. Use a USB type A (PC) - type B (control panel) cable. The maximum length of
the cable is 3 m (9.8 ft).
 FPBA-01 PROFIBUS DP adapter module connectors

Frames R1…R4: The following connector types were tested to fit in the tight space for
option slot 1.
• Phoenix Contact SUBCON-PLUS-PROFIB/PG/SC2, part number 2708245. Lead
the cable through the control cable hole on the right in the lead-through plate (1).
• Siemens, part number 6GK1 500 0EA02. Lead the cable through the middle
control cable hole in the lead-through plate (2). Drive
Routing the cables

 General rules
• Route the motor cable away from other cables. The motor cables of several drives
can be put in parallel next to each other.
• Install the motor cable, input power cable and control cables on separate trays.
• Avoid long parallel runs of motor cables with other cables to decrease
electromagnetic interference caused by the rapid changes in the drive output
voltage.
• Where control cables must cross power cables, make sure they are arranged at
an angle as near to 90 degrees as possible.
• Do not run extra cables through the drive.
• Make sure the cable trays have good electrical bonding to each other and to the
grounding electrodes. Aluminum tray systems can be used to improve local
equalizing of potential.
 Cable routing diagram
min. 300 mm (12 in)
Input power or
brake resistor cable
90° min. 500 mm (20 in)

Control cable Motor cable
min. 200 mm (8 in)
Input power cable

Control cable
 Separate control cable ducts

Put 24 V and 230 V (120 V) control cables in separate ducts unless the 24 V cable is
insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V (120 V).
230 V
(120 V)
24 V
 Continuous motor cable shield or enclosure for equipment on the

motor cable
To minimize the emission level when there are safety switches, contactors,
connection boxes or similar equipments on the motor cable between the drive and the
motor:
• European Union: Install the equipment in a metal enclosure with 360 degree
grounding for the shields of both the incoming and outgoing cable, or connect the
shields of the cables otherwise together.
• US: Install the equipment in a metal enclosure in a way that the conduit or motor
cable shielding runs consistently without breaks from the drive to the motor.
Implementing thermal overload and short-circuit protection

 Protecting the drive and input power cable in short-circuits
Protect the drive and input cable with fuses as follows:
~ M
~ 3~
Size the fuses at the distribution board according to instructions given in chapter
Technical data on page 111. The fuses protect the input cable in short-circuit
situations, restrict drive damage and prevent damage to adjoining equipment in case
of a short-circuit inside the drive.
Note: If you want to use circuit breakers, contact ABB for more information.
 Protecting the motor and motor cable in short-circuits

The drive protects the motor cable and motor in a short-circuit situation when the
motor cable is sized according to the nominal current of the drive. No additional
protection devices are needed.
 Protecting the drive and the input power and motor cables against
thermal overload
The drive protects itself and the input and motor cables against thermal overload
when the cables are sized according to the nominal current of the drive. No additional
thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, use a separate circuit

breaker or fuses for protecting each motor cable and motor against overload.
The drive overload protection is tuned for the total motor load. It may not trip due to
an overload in one motor circuit only
 Protecting the motor against thermal overload

According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive includes a
motor thermal protection function that protects the motor and switches off the current
when necessary. Depending on a drive parameter value, the function either monitors
a calculated temperature value (based on a motor thermal model) or an actual
temperature indication given by motor temperature sensors. The user can tune the
thermal model further by feeding in additional motor and load data.
The most common temperature sensors are:
• motor sizes IEC180…225: thermal switch, eg, Klixon
• motor sizes IEC200…250 and larger: PTC or Pt100.
For more information, see ACS880-M04 firmware manual (3AXD50000030629
[English]).
Protecting the drive against ground faults

The drive is equipped with an internal ground fault protective function to protect the
unit against ground faults in the motor and motor cable. This is not a personnel safety
or a fire protection feature. The ground fault protective function can be reduced with a
parameter 31.20 Earth fault.
For more information, see ACS880-M04 firmware manual (3AXD50000030629
[English]).
 Residual current device compatibility

The drive is suitable to be used with residual current devices of Type B.
Note: The EMC filter of the drive includes capacitors connected between the main
circuit and the frame. These capacitors and long motor cables increase the ground
leakage current and may cause fault current circuit breakers to function.
Implementing a motor temperature sensor connection
WARNING! IEC 61800-5-1 requires double or reinforced insulation between

live parts and accessible parts when:
• the accessible parts are not conductive, or
• the accessible parts are conductive, but not connected to the protective earth.
Obey this requirement when you plan the connection of the motor temperature
sensor to the drive.
You have these implementation alternatives to comply with IEC 61800-5-1:

1. If there is double or reinforced insulation between the sensor and the live parts of
the motor: You can connect the sensor directly to the analog/digital input(s) of the
drive. See the control cable connection instructions. Make sure that the voltage is
not more than the maximum allowed voltage over the sensor.
2. If there is basic insulation between the sensor and the live parts of the motor, or if
the insulation type is not known: You can connect the sensor to the drive via an
option module. The sensor and the module must form a double or reinforced
insulation between the motor live parts and the drive control unit. See Connecting
a motor temperature sensor to the drive trough an option module (page 68). Make
sure that the voltage does not exceed the maximum allowed voltage over the
sensor.
3. If there is basic insulation between the sensor and the live parts of the motor, or if
the insulation type is not known: You can connect a sensor to a digital input of the
drive via an external relay. The sensor and the relay must form a double or
reinforced insulation between the motor's live parts and the digital input of the
drive. Make sure that the voltage does not exceed the maximum allowed voltage
over the sensor.
 Connecting a motor temperature sensor to the drive trough an

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

insulation requirement
Type Insulation/Isolation PTC KTY Pt100,

Pt1000
FIO-11 Galvanic isolation between sen- x x x Reinforced insulation

sor connector and drive control
unit connector. No isolationbe-
tweensensor connector and
other I/O connectors.
FIO-21 Galvanic isolation between sen- x - - Reinforced insulation

sor connector and other connec-
tors (including drive control unit
connector).
FEN-01 Galvanic isolation between sen- x - - Reinforced insulation
tweensensor connector and TTL
encoder emulation output.
FEN-11 Galvanic isolation between sen- x x - Reinforced insulation
FEN-21 Galvanic isolation between sen- x x - Reinforced insulation
FEN-31 Galvanic isolation between sen- x - Reinforced insulation

sor connector and drive
control unit connector. No isola-
tion between sensor connector
and other connectors.
FAIO-01 Basic insulation between sensor x x x Reinforced or basic
connector and drive control unit insulation. With basic
connector. No insulation insulation, the other I/O
between sensor connector and connectors of the option
other I/O connectors. module must be kept
disconnected.
FPTC01/02 Reinforced insulation between x - - No special requirement
1) sensor connector and other con-
nectors (including drive control
unit connector).
1)
Suitable for use in safety functions (SIL2 / PL c classified).
Implementing the Emergency stop function

For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Design the emergency stop according to relevant standards.
Note: Pressing the stop key on the control panel of the drive does not generate
an emergency stop of the motor or separate the drive from dangerous potential.
Implementing the Safe torque off function

See chapter The Safe torque off function on page 141.
Implementing the Power-loss ride-through function

See ACS880-M04 firmware manual (3AXD50000030629 (English]).
Using a safety switch between the drive and the motor

Install a safety switch between the permanent magnet motor and the drive output.
The safety switch isolates the motor from the drive during maintenance work on the
drive.
Using a contactor between the drive and the motor

The control of the output contactor depends on how you use the drive. See also
Implementing a bypass connection on page 71.
When you use the vector control mode and motor ramp stop, open the contactor as
follows:
1. Give a stop command to the drive.
2. Wait until the drive stops the motor.
3. Open the contactor.
When you use the vector control mode and motor coast stop or the scalar control
mode, open the contactor as follows:
1. Give a stop command to the drive.
2. Open the contactor.
WARNING! In vector control mode, do not open the output contactor when the
drive controls the motor. The vector control operates faster than the contactor
opens its contacts.
If the contactor starts to open when the drive controls the motor, the vector control
tries to maintain the load current and increases the drive output voltage to the
maximum. This can cause damage to the contactor.
Implementing a bypass connection

If the drive needs to be bypassed frequently, use mechanically or electrically
interlocked contactors between the motor and the drive and between the motor and
the power line. Make sure with interlocking that the contactors cannot be closed
simultaneously. The installation must be clearly marked as defined in IEC/EN 61800-
5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”.
For more information refer to the example below.
WARNING! Do not connect the drive output to the electrical power network.
This can cause damage to the drive.
 Example of a bypass connection
Q1 Drive main switch S11 Drive main contactor on/off control

Q4 Bypass circuit breaker S40 Motor power supply selection (drive or
direct-on-line)
K1 Drive main contactor S41 Start when motor is connected direct-on-
line
K4 Bypass contactor S42 Stop when motor is connected direct-on-
line
K5 Drive output contactor
 Changing the motor power supply from the drive to direct-on-line

1. Stop the drive and the motor with the drive control panel (drive in local control
mode) or with the external stop signal (drive in remote control mode).
2. Open the main contactor of the drive with S11.
3. Change the motor power supply from the drive to direct-on-line with S40.
4. Wait for 10 seconds to allow the motor magnetization to decrease.
5. Start the motor with S41.
 Changing the motor power supply from direct-on-line to the drive

1. Stop the motor with S42.
2. Change the motor power supply from direct-on-line to the drive with S40.
3. Close the main contactor of the drive with switch S11 (-> turn to position ST for
two seconds and leave in position 1).
4. Start the drive and the motor with the drive control panel (drive in local control
mode) or with the external start signal (drive in remote control mode).
Protecting the contacts of relay outputs

Inductive loads (relays, contactors, motors) cause voltage transients when switched
off. The voltage transients can connect capacitively or inductively to other conductors
and cause a malfunction in the system. To protect the contacts of relay outputs,
• Use a noise attenuating circuit (varistors, RC filters [AC] or diodes [DC]) which
minimizes the EMC emission of inductive loads at switch-off.
• Install the noise attenuating circuit as close as possible to the inductive load.
• Do not install a noise attenuating circuit at the relay output.
Relay outputs
230 V AC
Varistor
230 V AC
RC filter
+ 24 V DC
Diode
Electrical installation 75
7
Electrical installation
The chapter describes the electrical installation procedure of the drive.
WARNING! Only qualified electricians are allowed to do the work described in

this chapter. Follow the Safety instructions on page 13. If you ignore them,
injury or death, or damage to the equipment can occur.
Make sure that the drive is disconnected from the input power during installation. If
the drive is already connected to the input power, wait for 5 minutes after
disconnecting the input power.
WARNING! Installation must always be designed and made according to

whatsoever for any installation that breaches the local laws and/or other regulations.
If recommendations given by ABB are not followed, the drive system may experience
problems that the warranty does not cover.
76 Electrical installation
Removing the cover assembly

Remove the cover assembly from the ZCU control unit, before installing the option
modules or before connecting the control cables. See also the module layout diagram
on page 29.
Checking the insulation of the assembly

 Drives 
Do not make any voltage tolerance 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. There are also, voltage-limiting circuits inside the drive which cuts down the
testing voltage automatically.
 Input power cable
Check the insulation of the input cable according to local regulations before connecting
it to the drive.
 Motor and motor cable insulation
Check that the motor cable is disconnected from the drive output terminals T1/U, T2/V
and T3/W.
Measure the insulation resistance between the phase conductors and 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 exceed 100 Mohm
(reference value at 25 °C or 77 °F). For the insulation resistance of other motors, please
consult the manufacturer’s instructions.
Note: Moisture inside the motor casing will reduce the insulation resistance. If moisture
is suspected, dry the motor and repeat the measurement.
U1
M
V1
3~
ohm W1
PE
 Break resistor assembly insulation

Check that the resistor cable is connected to the resistor, and disconnected from the
drive output terminals R+ and R-.
At the drive end, connect the R+ and R- conductors of the resistor cable together.
Measure the insulation resistance between the combined conductors and the PE
conductor by using a measuring voltage of 1 kV DC. The insulation resistance must be
higher than 1 Mohm..
R+
R-
ohm
PE
Checking the compatibility with IT (ungrounded) systems

The internal EMC filter is not suitable for use on an IT (ungrounded) system.
Disconnect the EMC filter before connecting the drive to the supply network. For
instructions on how to do this, see page 78.
WARNING! Do not install the drive with the internal EMC filter connected on an
IT system (an ungrounded power system or a high-resistance-grounded [over
30 ohms] power system), otherwise the system will be connected to ground potential
through the EMC filter capacitors of the drive. This can cause danger, or damage the
drive.
Note: When the internal EMC filter is disconnected, the drive EMC compatibility is
considerably reduced. See section Compliance with the EN 61800-3:2004 on page
136.
 Disconnecting the internal EMC filter – all frame sizes

To disconnect the internal varistors and EMC filter (option +E200), in an IT
(ungrounded), do as follows:
1. Switch off the power from the drive.
2. Remove the following screws:
• VAR (frames R1 and R2, located close to the supply terminals)
• EMC, VAR1 and VAR2 (frames R3 and R4, located on the front of the power
unit).
Connecting the power cables

 Power cable connection diagram
For alternatives, see Planning L1 L2 L3 (PE) (PE)
the electrical installation:
Selecting the supply 1) 2)
disconnecting device (page 54).
CHK-xx mains choke (optional). See

Mains chokes (page 163).
JFI-xx EMC filter (optional). See

EMC filters (page 167).
The UDC+/UDC– connectors can be

used for common DC configurations.
See page 84.
ACS880-M04
UDC+ UDC– U1 V1 W1
PE
U2 V2 W2 R– R+
du/dt filter(s) 3)
(optional). See
du/dt and
common mode Optional brake
filtering (page resistor (see Resistor
177). braking [page 181])
V1
U1 W1
3~
Motor
PE
Notes:
• If shielded supply (input) cable is used, and the conductivity of the shield is not sufficient (see Power cable
shield on page 59), use a cable with a ground conductor (1) or a separate PE cable (2).
• For motor cabling, use a separate ground cable (3) if the conductivity of the cable shield is not sufficient (see
Power cable shield on page 59) and the cable has no symmetrical ground conductors.
 Power cable connection procedure

See cabling drawing with tightening torques for all frame sizes on page 83.
WARNING! Follow all Safety instructions on page 13. If you ignore them,
injury or death, or damage to the equipment can occur.
1. Frame sizes R3 and R4 only: Remove the two plastic connector covers at the top
and bottom of the drive. Each cover is fastened with two screws.
2. On IT (ungrounded) systems, remove the following screws to disconnect the
internal varistors and EMC filters (option +E200):
• VAR (frames R1 and R2, located close to the supply terminals)
• EMC, VAR1 and VAR2 (frames R3 and R4, located on the front of the power
unit).
WARNING! If a drive whose varistors/filters are not disconnected is installed

on an IT system (an ungrounded power system or a high resistance grounded
[over 30 ohms] power system), the system is connected to ground potential through
the varistors/filters of the drive. This may cause danger or damage to the drive.
3. Fasten the two cable clamp plates included to the drive (see page 82), one at the
top, one at the bottom. The clamp plates are identical. Using the cable clamp
plates as shown below will provide better EMC compliance, as well as act as a
strain relief for the power cables.
4. Strip the power cables so that the shields are bare at the cable clamps.
5. Twist the ends of the cable shield wires into pigtails.
6. Strip the ends of the phase conductors.
7. Connect the following:
• phase conductors of the supply cable to U1, V1 and W1 terminals of the drive.
• phase conductors of the motor cable to U2, V2 and W2 terminals.
• conductors of the resistor cable (if present) to R+ and R– terminals.
With frame size R3 or R4: attach the screw terminal lugs included to the
conductors first. Crimp lugs can be used instead of screw lugs.
8. Tighten the cable clamps onto the bare cable shields.
9. Crimp a cable lug onto each shield pigtail. Fasten the lugs to ground terminals.
Note: Try to work out a compromise between the length of the pigtail and the
length of unshielded phase conductors as both should ideally be as short as
possible.
10. Cover visible bare shield and pigtail with insulating tape.
11. With frame size R3 or R4, cut suitable slots on the edges of the connector covers
to accommodate the supply and motor cables. Install the covers again. (Tighten
the screws to 3 N·m [25 lbf·in]).
12. Secure the cables outside the unit mechanically.
13. Ground the other end of the supply cable shield or PE conductor(s) at the
distribution board. In case a mains choke and/or an EMC filter (option +E200) is
installed, make sure the PE conductor is continuous from the distribution board to
the drive.
Grounding the motor cable shield at the motor end

For minimum radio frequency interference, ground the cable shield 360 degrees at
the lead-through of the motor terminal box
or ground the cable by twisting the shield so that the flattened shield is wider than 1/5
of its length.
b > 1/5 · a
b
a
 Installing the power cable clamp plates

Two identical power cable clamp plates are included with the drive. The picture below
depicts a frame size R1 drive; the installation is similar with other frame sizes.
Note: Support the cables adequately within the installation enclosure, especially if not
using the cable clamps.
Frames R1 and R2: 1.5 N·m (13 lbf·in)

Frames R3 and R4: 3 N·m (25 lbf·in)
1.5 N·m (13 lbf·in)

 Power cable connections

Supply
cable
Cable clamp on bare shield

1.5 N·m (13 lbf·in)
Below cable clamp, cover bare

shield with insulating tape
1.5 N·m (13 lbf·in)
0.5 … 0.6 N·m

(4.4 … 5.3 lbf·in)
0.5 … 0.6 N·m

(4.4 … 5.3 lbf·in)
1.5 N·m (13 lbf·in)
Above cable clamp, cover bare

shield with insulating tape
Cable clamp on bare shield

1.5 N·m (13 lbf·in)
Motor cable Brake resistor cable
See page 128 for terminal wire size capacity.

DC connection
The UDC+ and UDC– terminals are intended for common DC configurations of a
number of ACS880-M04 drives, allowing regenerative energy from one drive to be
utilised by the other drives in motoring mode.
One or more drives are connected to the AC supply depending on the power
requirement. In case two or more R1-R2 frames are connected to the AC supply,
each AC connection must be equipped with a mains choke to ensure even current
distribution between the rectifiers. The diagram below shows two configuration
examples.
AC supply
UDC+
~ UDC+
~ UDC+
~
UDC–
~ UDC–
~ UDC–
~
M M M
3~ 3~ 3~
AC supply
Mains chokes
UDC+
~ UDC+
~ UDC+
~
UDC–
~ UDC–
~ UDC–
~
M M M
3~ 3~ 3~
Each drive has an independent DC capacitor pre-charging circuit.
UDC+ UDC- U1 V1 W1
ACS880-M04 R1-R4
____
_ __
DC chokes*
Pre-charging circuit
____
_ __
R+ R- U2 V2 W2
* only for frames R3 and R4.
See DC connection ratings on page 129.

For more information on common DC configurations, see ACS880-01 drives and
ACS880-04 drive modules Common DC systems Application guide
(3AUA0000127818 [English]).
Installing the optional modules

Optional modules such as fieldbus adapters, I/O extensions and encoder interfaces
ordered using option codes (see Type designation key on page 34) are pre-installed
at the factory. Instructions for installing additional modules into the slots on the ZCU
control unit (see page 32 for the available slots) are presented below.
To install the optional modules, proceed as follows:
1. Remove the cover assembly from the ZCU control unit. See Removing the cover
assembly on page 76.
2. Remove the protective cover (if present) from the connector of the slot.
3. Insert the module carefully into its position on the drive.
4. Fasten the screw.
Note: Fix the screws correctly for fulfilling the EMC requirements and for proper
operation of the module.
5. Install the cover assembly again after any specific installation and wiring of the
module is complete.
See Ground isolation diagram (ZCU) on page 96 and the appropriate option
manual for specific installation and wiring instructions.
Connecting the control unit

 ZCU-14 layout and connections
Connec- Description
tions
X202
XRO1 XPOW External power input
XAI Analog inputs
XRO2 XAO Analog outputs

XD2D Drive to drive link
XRO1 Relay output RO1
XRO3
XPOW
XD24 Start interlock connection (DIIL)
J1, J2 and +24 V output
XDIO Digital input/outputs
XAI XDI Digital inputs
X203
XSTO Safe torque off connection
X12 Connector for FSO-xx safety
XAO functions module (optional)
X12 X13 Control panel connection
J3
X202 Option slot 1
XD2D X203 Option slot 2
X204 Option slot 3
X205 Memory unit connection (memory
XSTO unit inserted in the drawing)
J1, J2 Voltage/Current selection jumpers
(J1, J2) for analog inputs
XDI J3 Drive-to-drive link termination
X204
jumper (J3)
J6 Common digital input ground
XDIO selection jumper (J6). See the
J6 Ground isolation diagram (ZCU)
(page 96).
XD24
X13 X205
 Control connections to the ZCU control unit

Relay outputs XRO1…XRO3
Ready NO 13
250 V AC / 30 V DC COM 12
2A NC 11
Running NO 23
250 V AC / 30 V DC COM 22
2A NC 21
Faulted(-1) NO 33
250 V AC / 30 V DC COM 32 Fault
2A NC 31
External power input XPOW
GND 2
24 V DC, 2 A min. (without optional modules)
+24VI 1
Reference voltage and analog inputs J1, J2, XAI
AI1: U AI2: U
AI1/AI2 current/voltage selection
AI1: I AI2: I
By default not in use. AI2- 7
0(4)…20 mA, Rin = 100 ohm 1) AI2+ 6
Speed reference AI1- 5
0(2)…10 V, R in > 200 kohm 2) AI1+ 4
Ground AGND 3
-10 V DC, RL 1…10 kohm -VREF 2
10 V DC, RL 1…10 kohm +VREF 1
Analog outputs XAO
AGND 4
Motor current 0…20 mA, RL < 500 ohm
AO2 3
AGND 2
Motor speed rpm 0…20 mA, RL < 500 ohm
AO1 1
Drive-to-drive link XD2D
Shield 4
BGND 3
Drive-to-drive link 3)
A 2
B 1
Drive-to-drive link termination 3) J3
Safe torque off XSTO
IN2 4
Safe torque off. Both circuits must be closed for the IN1 3
drive to start. 4) SGND 2
OUT 1
Digital inputs XDI
By default not in use. DI6 6
Constant speed 1 select (1 = on) 5) DI5 5
Acceleration & deceleration select 6) DI4 4
Reset DI3 3
Forward (0) / Reverse (1) DI2 2
Stop (0) / Start (1) DI1 1
Digital input/outputs XDIO
Output: Running DIO2 2
Output: Ready DIO1 1
Ground selection 7) J6
Auxiliary voltage output, digital interlock 8) XD24
Digital input/output ground DIOGND 5
+24 V DC 200 mA 9) +24VD 4
Digital input ground DICOM 3
+24 V DC 200 mA 9) +24VD 2
Run enable 8) DIIL 1
Safety functions module connection X12
Control panel connection X13
Memory unit connection X205
Note: The wire size accepted by all screw terminals (for both stranded and solid wire) is
0.5 … 2.5 mm2 (24…12 AWG). The torque is 0.5 N·m (5 lbf·in).
1)
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected by jumper
J2.
Note: Changing the setting requires reboot of control unit.
2)
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected by jumper
J1.
Note: Changing the setting requires reboot of control unit
3) See section Drive-to-drive link (page 92).
4)
See chapter The Safe torque off function (page 141).
5)
Constant speed 1 is defined by parameter 22.26.
6) 0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use.
1 = Acceleration/deceleration ramps defined by parameters 23.14/23.15 in use.
7) Jumper/switch J6. Determines whether DICOM is separated from DIOGND (ie. common reference for
digital inputs floats; in practice, selects whether the digital inputs are used in current sinking or sourcing
mode). See Ground isolation diagram (ZCU) (page 96).
8) See section DIIL input (page 92)
9)
Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and
DIO2.
 External power supply for the control unit (XPOW)

By default, the ZCU control unit is powered from the power module. An external
24 V DC, 2 A power supply for the control unit can be connected to terminal block
XPOW.
It is recommended to use an external supply if
• the control board needs to be kept operational during input power breaks, for
example, because of uninterrupted fieldbus communication, or
• immediate restart is needed after power breaks (that is, no control board power
up delay is allowed).
See also description of parameter 95.04 Control board supply in the firmware
manual.
 DI6 as a PTC sensor input

To comply with the drive safety standard IEC 61800-5-1:

You can connect PTC sensor to digital input DI6 of the drive only if there is double or
reinforced insulation between the sensor and motor winding.
• Make sure that the voltage over the sensor is not more than the maximum value
allowed for the sensor.
• Do not connect both ends of the cable shield directly to ground. If a capacitor
cannot be used at one end, leave that end of the shield unconnected.
• See the firmware manual for the parameter settings.
+24VD
T
1 DI6
2
3.3 nF
3
> 630 V AC
1 PTC sensor
2 Double insulation
3 Motor winding
For the connection alternatives, refer to Implementing a motor temperature sensor

connection on page 68.
 AI1 or AI2 as a Pt100 or KTY84 sensor input

To comply with the drive safety standard IEC 61800-5-1:

You can connect Pt100 or KTY84 sensors between an analog input and output of the
drive only if there is double or reinforced insulation between the sensor and the motor
winding. It is possible to use one to three Pt100 sensors in series or one KTY84
sensor.
• Make sure that the voltage over the sensor is not more than the maximum value
allowed for the sensor.
• Do not connect both ends of the cable shield directly to ground. If a capacitor
cannot be used at one end, leave that end of the shield unconnected.
• See the firmware manual for the parameter settings.
1…3 × Pt100 or 1 × KTY84 XAI

AIn+ a)
AIn-
XAO
AOn b)
AGND
1
T T T
2 3.3 nF
3 > 630 V AC
1 Sensor(s)
2 Double insulation
3 Motor winding
a) For AI1, set input type to voltage with switch/jumper J1 (ZCU) or switch AI1 (BCU).
For AI2, set input type with J2 (ZCU) or AI2 (BCU). Set the appropriate analog input
unit to V (volt) in parameter group 12 Standard AI.
b) Select the excitation mode in parameter group 13 Standard AO.
For the connection alternatives, refer to Implementing a motor temperature sensor

connection on page 68.
 DIIL input
The DIIL input can used for the connection of safety circuits. By default, the input is
parametrized to stop the unit when the input signal is lost.
 Drive-to-drive link
The drive-to-drive link is a daisy-chained RS-485 transmission line that allows basic
master/follower communication with one master drive and multiple followers. Enable
bus termination on the drives at the ends of the drive-to-drive link. On intermediate
drives, disable bus termination.
The settings for each type of control unit are:
Control unit type Switch/jumper Settings
designation
ZCU-14 J3 Termination enabled
(frame sizes R1…R4) Termination disabled
Use 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) for
the wiring. For best immunity, ABB recommends high quality cable. Keep the cable as
short as possible. However, the minimum cable length is 1 m. Avoid unnecessary
loops and parallel runs near power cables such as motor cables.
Example wiring diagram of drive-to-drive link

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

For the drive to start, both connections (OUT1 to IN1 and IN2) must be closed. By
default, the terminal block has jumpers to close the circuit. Remove the jumpers
before connecting an external Safe torque off circuit to the drive.
For information on the implementation of Safe torque off function, see chapter The
Safe torque off function (page 141).
 Safety functions (X12)

See the connections to the safety functions module on page 87 and FSO-12 user’s
manual (3AXD50000015612 [English])
 Control unit connector data
Power supply Connector pitch 5 mm, wire size 2.5 mm2

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

DIO1 and DIO2 As inputs:
(XDIO:1 and XDIO:2) 24 V logic levels: “0” < 5 V, “1” > 15 V
Input/output mode Rin: 2.0 kohm
selection by parameters. Filtering: 0.25 ms (ZCU)
DIO1 can be configured as As outputs:
a frequency input (0…16 Total output current from +24VD is limited to 200 mA
kHz with hardware filtering
of 4 microseconds) for 24 +24VD
V level square wave signal
(sinusoidal or other wave
form cannot be used).
DIO2 can be configured as
a 24 V level square wave DIOx
frequency output. See the
firmware manual, RL
parameter group 11.
DIOGND
Reference voltage for Connector pitch 5 mm, wire size 2.5 mm2
analog inputs +VREF 10 V ±1% and –10 V ±1%, Rload 1…10 kohm
and -VREF
(XAI:1 and XAI:2)
Analog inputs AI1 and Connector pitch 5 mm, wire size 2.5 mm2
AI2 (XAI:4 … XAI:7) Current input: –20…20 mA, Rin = 100 ohm
Current/voltage input Voltage input: –10…10 V, Rin > 200 kohm
mode selection by Differential inputs, common mode range ±30 V
jumpers/switches. 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 Connector pitch 5 mm, wire size 2.5 mm2
AO2 (XAO) 0…20 mA, Rload < 500 ohm
Frequency range: 0…300 Hz (ZCU)
Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm2
(XD2D) Physical layer: RS-485
Termination by switch or jumper
Safe torque off Connector pitch 5 mm, wire size 2.5 mm2
connection Input voltage range: -3…30 V DC
(XSTO) Logic levels: “0” < 5 V, “1” > 17 V
For the drive to start, both connections must be “1”
Current consumption: 66 mA (continuous) per STO channel per
drive module
EMC (immunity) according to IEC 61326-3-1
Control panel Connector: RJ-45

connection (X13) Cable length < 3 m
The terminals of the control unit fulfil the Protective Extra Low Voltage (PELV) requirements.
The PELV requirements of a relay output are not fulfilled if a voltage higher than 48 V is
connected to the relay output.
 Ground isolation diagram (ZCU)

XPOW
+24VI 1
GND 2
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5 Common mode voltage between
AI2+ 6 channels +30 V
AI2- 7
XAO
AO1 1
AGND 2
AO2 3
AGND 4
XD2D
B 1
A 2
BGND 3
XRO1, XRO2, XRO3
NC 1
COM 2
NO 3
NC 1
COM 2
NO 3
NC 1
COM 2
NO 3
XD24
DIIL 1
+24VD 2
DICOM 3
+24VD 4
DIOGND 5
XDIO
DIO1 1
DIO2 2
XDI
DI1 1 *
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
XSTO
OUT1 1
GND 2
IN1 3
IN2 4
Ground
*Ground selector (J6) settings
All digital inputs share a common ground (DICOM connected to DIOGND). This is the default
setting.
Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from DIO signal ground
(DIOGND). Isolation voltage 50 V.
Connecting the control cables – all frame sizes

For technical data and default I/O connections of the drive control unit, refer to
Control connections to the ZCU control unit (page 88).
1. In the cabinet, remove shrouding wherever necessary to allow access to the
cable entries and any trunking inside the cubicle.
2. Run the control cables into the cubicle. If possible, arrange for a 360° grounding
of the cable shield at the cable entry.
If the outer surface of the shield is non-conductive, turn the shield inside out as
shown below and wrap copper foil around the cable to keep the shielding
continuous. Do not cut the grounding wire (if present).
Stripped cable Conductive surface of Stripped part covered
the shield exposed with copper foil
Copper foil
Cable shield Shielded twisted pair
Grounding wire
3. Run the cables to the control unit of the drive (or other connection point) using
cable trunking wherever possible.
4. (Only when running the cable to the drive module) The drive control units have a
clamp plate attached. Remove the outer sheathing of the cable at one of the
clamps on the plate. Tighten the clamp onto the bare cable shield.
5. Cut the cables to suitable length.
6. Strip the cable ends and conductors. When connecting to the drive I/O, also
remove the shield along with the outer sheathing, and use electrical tape or shrink
tubing to contain the strands. Elsewhere, twist the outer shield strands into a
bundle, crimp a lug onto it and connect it to the nearest chassis grounding point.
Keep as short as
possible
SHIELD*
4
3
2
1
*If no dedicated “shield”

connector is provided,
ground the inner cable
shields to the chassis.
At the other end of the Where grounding clamps are

cable, leave the shield not available, twist the shield
unconnected, or connect strands into a bundle, crimp a
it to ground via a lug terminal onto it and fasten
capacitor with a value of the lug to the chassis. Secure
a few nanofarads. the cable into place with eg.
cable ties.
7. Connect the conductors to appropriate terminals (refer to chapter Control

connections to the ZCU control unit).
8. Refit any shrouds removed earlier.
Installation checklist 101
8
Installation checklist

This chapter contains a list for checking the mechanical and electrical installation of
the drive module.
Checklist
Check the mechanical and electrical installation of the drive module before start-up.
Go through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
Check that... 
MECHANICAL INSTALLATION
The ambient operating conditions are allowable. (See Mechanical installation, Technical
data: Ratings, Ambient conditions.)
The unit is fastened properly to the cabinet. (See Planning the cabinet installation and
Mechanical installation.)
The cooling air will flow freely.
The motor and the driven equipment are ready for start. (See Planning the electrical
installation, Technical data: Motor connection.)
ELECTRICAL INSTALLATION (See Planning the electrical installation, Electrical installation.)
The VAR (frames R1 and R2) and EMC/VAR1/VAR2 (frames R3 and R4) screws are
removed if the drive is connected to an IT (ungrounded) supply network.
The capacitors are reformed if stored over one year (contact local ABB representative for
more information).
The drive is grounded properly.
The supply (input power) voltage matches the drive nominal input voltage.
102 Installation checklist
Check that... 
The supply (input power) is connected to U1/V1/W1 (UDC+/UDC- in case of a DC
supply) and the terminals are tightened to specified torque.
Appropriate supply (input power) fuses and disconnector are installed.
The motor is connected to U2/V2/W2, and the terminals are tightened to the specified
torque.
The brake resistor (if present) is connected to R+/R-, and the terminals are tightened to
specified torque.
The motor cable (and brake resistor cable, if present) is routed away from other cables.
There are no power factor compensation capacitors in the motor cable.
The external control connections to the ZCU control unit are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
The supply (input power) voltage cannot be applied to the output of the drive through a
bypass connection.
Motor connection box and other covers are in place.
Start-up 103
9
Start-up
This chapter refers to the start-up instructions of the cabinet-installed drive.
Start-up procedure
1. Make sure the installation of the drive is according to the Installation checklist on
page 101.
2. Check that the motor and driven equipment are ready for start.
3. Perform the start-up tasks instructed by the cabinet-installer of the drive module.
4. Switch On the power.
5. Set-up the drive control program according to the start-up instructions in the
Firmware manual.
6. Validate the Safe torque off function according to the Validation test procedure on
page 148.
104 Start-up
Maintenance 105
10
Maintenance
This chapter contains preventive maintenance instructions.
Safety
WARNING! Read the Safety instructions on the first pages of this manual
before performing any maintenance on the equipment.
Ignoring the safety instructions can cause injury or death.
Maintenance intervals
The table below show the maintenance tasks which can be done by the end user.
For the complete maintenance schedule contact the ABB service
(https://new.abb.com/drives/services).
Maintenance task/object Interval Instruction
DC capacitor reforming Every year of storage See Reforming the capacitors
on page 109.
Heatsink temperature check Every 6 to 12 months See Heatsink on page 106.
and cleaning depending on the dustiness of
the environment
Inspection of tightness of Every year See page Power cable
power connections connection procedure on
page 80.
Visual inspection of cooling See Cooling fan on page 107.
fan
106 Maintenance
Maintenance task/object Interval Instruction

Cooling fan replacement Every 3 years if used in clean See Cooling fan on page 107.
operating environment.
Yearly inspection is highly
recommended if used in dusty,
corroded or ambient
temperature is higher than
40 °C (104 °F).
DC capacitor replacement Every 6 years if the ambient Contact your local ABB
temperature is higher than Service representative.
40 °C (104 °F) or if the drive is
subjected to cyclic heavy load
or continuous nominal load.
Otherwise, every 9 years.
Control panel battery Every 3 years The battery is housed on the
replacement rear of the control panel.
Replace with a new CR 2032
battery.
Control unit battery for real- Every 3 years
time clock
Heatsink
The heatsink fins pick up dust from the cooling air. If the heatsink is not clean, the
drive runs into overtemperature warnings and faults. In a normal environment, the
heatsink should be checked annually and in a dusty environment it should it be
checked more often.
Clean the heatsink as follows (when necessary):
1. Remove the cooling fan (see section Cooling fan).
2. Blow clean compressed air (not humid) from bottom to top and simultaneously
use a vacuum cleaner at the air outlet to trap the dust.
Note: If there is a risk of dust entering the adjoining equipment, perform the
cleaning in another room.
3. Refit the cooling fan.
Maintenance 107
Cooling fan
The actual lifespan of the cooling fan depends on the drive usage and ambient
temperature. Fan failure can be predicted by the increasing noise from fan bearings
and the gradual rise in the heatsink temperature in spite of heatsink cleaning.
If the drive is operated in a critical part of a process, it is recommended to replace the
immediately after these symptoms start appearing.
Note: Replacement fans are available from ABB. Do not use spare parts other than
ABB-specified spare parts.
 Replacing fan (Frames R1 and R2)

To replace the fan in frames R1 and R2, follow these steps:
1. Detach the power cable clamp plate and terminal blocks.
2. Release the retaining clips (arrowed) carefully using a screwdriver.
3. Pull the fan holder out.
4. Disconnect the fan cable.
5. Carefully bend the clips on the fan holder to free the fan.
6. Install the new fan in the reverse order.
Note: The airflow direction is bottom-to-top. Install the fan so that the airflow arrow
points up.
Airflow directio
n
108 Maintenance
 Replacing fan (Frames R3 and R4)

To repalce the fan in frames R3 and R4, follow these steps:
1. Remove the fan by releasing the retaining clip (arrowed) carefully using a
screwdriver.
2. Pull the fan holder out.
3. Disconnect the fan cable.
4. Carefully bend the clips on the fan holder to free the fan.
5. Install the new fan in the reverse order.
Note: The airflow direction is bottom-to-top. Install the fan so that the airflow arrow
points up.
Airflow directi
on
Maintenance 109
Reforming the capacitors

The capacitors must be reformed if the drive has been stored for a year or more. See
manufacturing date on the Type designation label (see page 33).
For information on reforming the capacitors, see Converter module capacitor
reforming instructions (3BFE64059629 [English]).
Memory unit
After replacing an inverter control unit, the existing parameter settings can be
retained by transferring the memory unit from the defective unit to the new unit.
WARNING! Do not remove or insert the memory unit when the control unit is
powered.
To remove the memory unit,

1. Undo the fastening screw.
2. Pull out the memory unit.
ZCU-14
After power-up, the drive scans the memory unit. If a different control program or
different parameter settings are detected, they are copied to the drive. This takes
about 10 to 30 seconds.
Note: Drive does not respond while copying is in progress.
110 Maintenance
Technical data 111
11
Technical data
This chapter contains the technical specifications of the drive.
112 Technical data
Ratings
 Nominal ratings with 230 V AC supply
Drive type Frame Input Output ratings
ACS880-M04 size ratings Nominal No-overload Light-overload Heavy-duty use
use use
I1N *I1N I2N IMax PN ILd PLd PLd IHd PHd PHd
A A A A kW hp A kW hp A kW hp
-03A0-2 R1 2.1 3.5 3.0 4.4 0.37 0.5 2.8 0.37 0.5 2.5 0.37 0.5
-03A6-2 R1 2.9 5.2 3.6 5.3 0.55 0.75 3.4 0.55 0.75 3.0 0.37 0.5
-04A8-2 R1 3.7 6.3 4.8 7.0 0.75 1 4.5 0.75 1 4.0 0.55 0.75
-06A0-2 R1 5.2 8.9 6.0 8.8 1.1 1.5 5.5 1.1 1.5 5.0 0.75 1
-08A0-2 R1 6.3 10.7 8.0 10.5 1.5 2 7.6 1.5 2 6.0 1.1 1.5
-010A-2 R2 8.3 13 10.5 13.5 2.2 3 9.7 2.2 3 9.0 1.5 2
-014A-2 R2 11 17 14 16.5 3 3 13.0 3 3 11.0 2.2 3
-018A-2 R2 15 21 18 21 4 5 16.8 4 5 14.0 3 3
-025A-2 R3 19 – 25 33 5.5 7.5 23 5.5 7.5 19.0 4 5
-030A-2 R3 26 – 30 36 7.5 10 28 7.5 10 24 5.5 7.5
-035A-2 R3 30 – 35 44 7.5 10 32 7.5 10 29 7.5 10
-044A-2 R3 35 – 44 53 11 15 41 11 15 35 7.5 10
-050A-2 R3 42 – 50 66 11 15 46 11 15 44 11 15
-061A-2 R4 54 – 61 78 15 20 57 15 20 52 11 15
-078A-2 R4 64 – 78 100 18.5 25 74 18.5 25 69 15 20
-094A-2 R4 81 – 94 124 22 30 90 22 30 75 18.5 25
3AXD10000434191
See symbol definitions on page 114.

ACS880-M04 size ratings Nominal No- Light-overload Heavy-duty
overload use use
use
I1N *I1N I2N IMax PN ILd PLd IHd PHd
A A A A kW A kW A kW
-03A0-5 R1 2.3 3.8 3.0 4.4 1.1 2.8 1.1 2.5 0.75
-03A6-5 R1 3.1 5.6 3.6 5.3 1.5 3.4 1.5 3.0 1.1
-04A8-5 R1 4.0 6.8 4.8 7.0 2.2 4.5 1.5 4.0 1.5
-06A0-5 R1 5.5 9.4 6.0 8.8 2.2 5.5 2.2 5.0 2.2
-08A0-5 R1 6.6 11.2 8.0 10.5 3.0 7.6 3.0 6.0 2.2
-010A-5 R2 8.7 13 10.5 13.5 4.0 9.7 4.0 9.0 4.0
-014A-5 R2 12 18 14 16.5 5.5 13.0 5.5 11.0 5.5
-018A-5 R2 16 23 18 21 7.5 16.8 7.5 14.0 7.5
-025A-5 R3 20 – 25 33 11.0 23 11 19.0 7.5
-030A-5 R3 26 – 30 36 15.0 28 15 24 11.0
-035A-5 R3 30 – 35 44 18.5 32 15 29 15.0
-044A-5 R3 36 – 44 53 22 41 22 35 18.5
Technical data 113

overload use use
use
-050A-5 R3 42 – 50 66 22 46 22 44 22
-061A-5 R4 55 – 61 78 30 57 30 52 22
-078A-5 R4 65 – 78 104 37 74 37 66 37
-094A-5 R4 82 – 94 124 45 90 45 75 37
3AXD10000434191

ACS880-M04 size ratings Nominal No-overload Light- Heavy-
use overload use duty use
A A A A hp A hp A hp
-03A0-5 R1 2.3 3.8 3.0 4.4 1.5 2.8 1.0 2.5 1.0
-03A6-5 R1 3.1 5.6 3.6 5.3 2.0 3.4 2.0 3.0 1.5
-04A8-5 R1 4.0 6.8 4.8 7.0 3.0 4.5 2.0 4.0 2.0
-06A0-5 R1 5.5 9.4 6.0 8.8 3.0 5.5 3.0 5.0 3.0
-08A0-5 R1 6.6 11.2 8.0 10.5 5.0 7.6 5.0 6.0 3.0
-010A-5 R2 8.7 13 10.5 13.5 5.0 9.7 5.0 9.0 5.0
-014A-5 R2 12 18 14 16.5 7.5 13.0 7.5 11.0 7.5
-018A-5 R2 16 23 18 21 10 16.8 10 14.0 10
-025A-5 R3 20 – 25 33 15 23 15 19.0 10
-030A-5 R3 26 – 30 36 20 28 20 24 15
-035A-5 R3 30 – 35 44 25 32 20 29 20
-044A-5 R3 36 – 44 53 30 41 30 35 25
-050A-5 R3 42 – 50 66 30 46 30 44 30
-061A-5 R4 55 – 61 78 40 57 40 52 40
-078A-5 R4 65 – 78 104 50 74 50 66 50
-094A-5 R4 82 – 94 124 60 90 60 75 50
3AXD10000434191
114 Technical data

ACS880-M04 size ratings Nominal No-overload Light- Heavy-
use overload use duty use
-03A0-5 R1 2.3 3.8 3.0 4.4 1.5 2.8 1.1 2.5 1.1
-03A6-5 R1 3.1 5.6 3.6 5.3 1.5 3.4 1.5 3.0 1.5
-04A8-5 R1 4.0 6.8 4.8 7.0 2.2 4.5 2.2 4.0 2.2
-06A0-5 R1 5.5 9.4 6.0 8.8 3.0 5.5 3.0 5.0 2.2
-08A0-5 R1 6.6 11.2 8.0 10.5 4.0 7.6 4.0 6.0 3.0
-010A-5 R2 8.7 13 10.5 13.5 5.5 9.7 5.5 9.0 4.0
-014A-5 R2 12 18 14 16.5 7.5 13.0 7.5 11.0 5.5
-018A-5 R2 16 23 18 21 11.0 16.8 7.5 14.0 7.5
-025A-5 R3 20 – 25 33 15.0 23 11.0 19.0 11.0
-030A-5 R3 26 – 30 36 18.5 28 15.0 24 15.0
-035A-5 R3 30 – 35 44 22 32 18.5 29 18.5
-044A-5 R3 36 – 44 53 30 41 22 35 22
-050A-5 R3 42 – 50 66 30 46 30 44 30
-061A-5 R4 55 – 61 78 37 57 37 52 30
-078A-5 R4 65 – 78 104 45 74 45 66 45
-094A-5 R4 82 – 94 124 55 90 55 75 45
3AXD10000434191
See symbol definitions below.
 Definitions
I1N Nominal input current (rms) at 40 °C (104 °F).

*Without mains choke.
I2N Nominal output current.
IMax Maximum output current. Available for at least 10 seconds at start, otherwise as long
as allowed by drive temperature.
PN Typical motor power for no-overload use.
ILd Continuous rms output current. 10% overload is allowed for 1 minute every 5 minutes.
P Ld Typical motor power for light-overload use.
IHd Continuous rms output current. 50% overload is allowed for 1 minute every 5 minutes.
P Hd Typical motor power for heavy-duty use.
Note: To achieve the rated motor power given in the table, the rated current of the drive must
be higher than or equal to the rated motor current.
The DriveSize dimensioning tool available from ABB is recommended for selecting the drive,
motor and gear combination.
The maximum allowed motor shaft power is limited to 1.5 · P Hd, 1.1 · PN or Pcont.max
(whichever value is the greatest). If the limit is exceeded, motor torque and current are
automatically restricted. The function protects the input bridge of the drive against overload.
Technical data 115
Derating
The continuous output currents stated above must be derated if any of the following
conditions apply:
• ambient temperature exceeds 40 °C (+104°F)
• drive is installed higher than 1000 m above sea level
• parameter-adjustable motor noise level is set as low.
Note: The final derating factor is a multiplication of all applicable derating factors.
 Ambient temperature derating

In the temperature range 40…55 °C (+104…131 °F), the rated output current is
derated by 1% for every added 1 °C (1.8 °F) as follows:
Derating factor
1.00
0.85
Ambient temperature
+40 °C +55 °C
+104 °F +131 °F
 Altitude derating
At altitudes from 1000 to 2000 m (3300 to 6562 ft) above sea level, the derating is 1%
for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool.
 Low motor noise derating

Low motor noise is activated with a drive parameter (see the firmware manual). With
low motor noise, drive loadability is reduced and derating must be applied if a certain
constant output current is needed. See the derated values in the below tables.
For definitions of symbols used in the below tables, see Definitions on page 114.
116 Technical data
Deratings with 230 V AC supply in low motor noise mode

overload use use
use
I1N *I1N I2N IMax PN ILd PLd PLd IHd PHd PHd
A A A A kW hp A kW hp A kW hp
-03A0-2 R1 1.7 2.9 2.5 4.4 0.37 0.5 2.3 0.25 0.5 1.8 0.25 0.25
-03A6-2 R1 2.4 4.4 3 5.3 0.37 0.5 2.8 0.37 0.5 2.2 0.25 0.5
-04A8-2 R1 3.1 5.3 4 7.0 0.55 0.75 3.8 0.55 0.75 3.0 0.37 0.5
-06A0-2 R1 4.4 7.4 5 8.8 0.75 1 4.8 0.75 1 3.8 0.55 0.75
-08A0-2 R1 4.5 7.6 5.7 10.5 1.1 1 5.2 0.75 1 4.2 0.75 1
-010A-2 R2 7.5 11.5 9.5 13.5 1.5 2 9.0 1.5 2 6.8 1.1 2
-014A-2 R2 9.4 14 12 16.5 2.2 3 11.4 2.2 3 8.8 1.5 2
-018A-2 R2 11 15 13 21 3 3 12.2 2.2 3 9.9 2.2 3
-025A-2 R3 12 – 16 33 3 5 15.2 3 5 12 2.2 3
-030A-2 R3 17 – 20 36 4 5 19 4 5 14 3 3
-035A-2 R3 20 – 23 44 5.5 7.5 22 4 7.5 17 4 5
-044A-2 R3 23 – 29 53 5.5 10 27 5.5 7.5 22 5.5 7.5
-050A-2 R3 28 – 33 66 7.5 10 31 7.5 10 26 5.5 7.5
-061A-2 R4 37 – 42 78 7.5 15 37 7.5 10 31 7.5 10
-078A-2 R4 42 – 51 100 11 15 48 11 15 41 7.5 15
-094A-2 R4 53 – 61 124 15 20 58 15 20 45 11 15
3AXD10000434191

ACS880-M04 size ratings Nominal No-overload Light- Heavy-duty
use overload use use
-03A0-5 R1 1.9 3.2 2.5 4.4 0.75 2.3 0.75 1.8 0.55
-03A6-5 R1 2.6 4.7 3 5.3 1.1 2.8 1.1 2.2 0.75
-04A8-5 R1 3.3 5.7 4 7.0 1.5 3.8 1.5 3 1.1
-06A0-5 R1 4.6 7.8 5 8.8 2.2 4.8 1.5 3.8 1.5
-08A0-5 R1 4.6 7.7 5.5 10.5 2.2 5.2 2.2 4.2 1.5
-010A-5 R2 7.9 12 9.5 13.5 4 9 4 6.8 3
-014A-5 R2 10 15 12 16.5 5.5 11.4 5.5 8.8 4
-018A-5 R2 11 16 13 21 5.5 12.2 5.5 9.4 4
-025A-5 R3 13 – 16 33 7.5 15 5.5 12 5.5
-030A-5 R3 17 – 20 36 7.5 19 7.5 14 5.5
-035A-5 R3 20 – 23 44 11 22 7.5 17 7.5
-044A-5 R3 24 – 29 53 11 27 11 21 7.5
-050A-5 R3 28 – 33 66 15 31 15 26 11
-061A-5 R4 36 – 40 78 18.5 37 18.5 31 15
-078A-5 R4 43 – 51 100 22 48 22 41 18.5
-094A-5 R4 53 – 61 124 30 58 30 44 22
3AXD10000434191
Technical data 117

A A A A hp A hp A hp
-03A0-5 R1 1.6 2.7 2.1 4.4 1 1.9 0.75 1.5 0.5
-03A6-5 R1 2.3 4.1 2.6 5.3 1 2.4 1 1.9 0.75
-04A8-5 R1 2.8 4.8 3.4 7.0 2 3.2 1.5 2.6 1
-06A0-5 R1 4.0 6.7 4.3 8.8 2 4.1 2 3.3 1.5
-08A0-5 R1 4.0 6.7 4.8 10.5 3 4.4 2 3.6 2
-010A-5 R2 6.7 10 8 13.5 5 7.7 5 5.8 3
-014A-5 R2 9 13 10 16.5 5 9.7 5 7.6 5
-018A-5 R2 10 14 12 21 7.5 11 7.5 8 5
-025A-5 R3 11 – 14 33 10 13 7.5 11 7.5
-030A-5 R3 15 – 17 36 10 16 10 12 7.5
-035A-5 R3 18 – 21 44 15 20 10 15 10
-044A-5 R3 20 – 25 53 15 23 15 18 10
-050A-5 R3 24 – 29 66 20 27 20 22 15
-061A-5 R4 31 – 34 78 25 31 20 27 20
-078A-5 R4 36 – 43 100 30 41 30 34 25
-094A-5 R4 45 – 52 124 40 49 30 38 25
3AXD10000434191

-03A0-5 R1 1.6 2.7 2.1 4.4 0.75 1.9 0.75 1.5 0.55
-03A6-5 R1 2.3 4.1 2.6 5.3 1.1 2.4 1.1 1.9 0.75
-04A8-5 R1 2.8 4.8 3.4 7.0 1.5 3.2 1.5 2.6 1.1
-06A0-5 R1 4.0 6.7 4.3 8.8 2.2 4.1 1.5 3.3 1.5
-08A0-5 R1 4.0 6.7 4.8 10.5 2.2 4.4 2.2 3.6 1.5
-010A-5 R2 6.7 10 8 13.5 4 7.7 4 5.8 3
-014A-5 R2 9 13 10 16.5 5.5 9.7 4 7.6 4
-018A-5 R2 10 14 12 21 5.5 11 5.5 8 4
-025A-5 R3 11 – 14 33 7.5 13 5.5 11 5.5
-030A-5 R3 15 – 17 36 7.5 16 7.5 12 5.5
-035A-5 R3 18 – 21 44 11 20 11 15 7.5
-044A-5 R3 20 – 25 53 11 23 11 18 7.5
-050A-5 R3 24 – 29 66 15 27 15 22 11
-061A-5 R4 31 – 34 78 18.5 31 18.5 27 15
-078A-5 R4 36 – 43 100 22 41 22 34 18.5
-094A-5 R4 45 – 52 124 30 49 30 38 22
3AXD10000434191
118 Technical data
Supply cable fuses

Fuses for short circuit protection of the supply cable are listed below. The fuses also
protect the adjoining equipment of the drive in case of a short circuit.
Check that the operating time of the fuse is below 0.5 seconds. The operating time
depends on the supply network impedance and the cross-sectional area and length
of the supply cable. See also chapter Planning the electrical installation on page 53.
Note: Fuses with a higher current rating must not be used.
Drive type Input IEC fuse UL fuse Cross-sectional

ACS880-M04 current area of cable
(A) Rated Volt- Class Rated Volt- UL mm2 AWG
current age current age class
(A) (V) (A) (V)
-03A0-2, -03A0-5 4.0* 6 500 gG 6 600 T 1.5…4 16…12
-03A6-2, -03A6-5 6.0* 6 500 gG 6 600 T 1.5…4 16…12
-04A8-2, -04A8-5 7.0* 10 500 gG 10 600 T 1.5…4 16…12
-06A0-2, -06A0-5 9.0* 10 500 gG 10 600 T 1.5…4 16…12
-08A0-2, -08A0-5 11* 16 500 gG 15 600 T 1.5…4 16…12
-010A-2, -010A-5 13* 16 500 gG 15 600 T 1.5…10 16…8
-014A-2, -014A-5 18* 20 500 gG 20 600 T 1.5… 0 16…8
-018A-2, -018A-5 23* 25 500 gG 25 600 T 1.5…10 16…8
-025A-2, -025A-5 20 25 500 gG 25 600 T 6…35 9…2
-030A-2, -030A-5 26 32 500 gG 35 600 T 6…35 9…2
-035A-2, -035A-5 30 40 500 gG 35 600 T 6…35 9…2
-044A-2, -044A-5 36 50 500 gG 45 600 T 6…35 9…2
-050A-2, -050A-5 42 50 500 gG 50 600 T 10…70 6…2/0
-061A-2, -061A-5 55 63 500 gG 70 600 T 10…70 6…2/0
-078A-2, -078A-5 65 80 500 gG 80 600 T 10…70 6…2/0
-094A-2, -094A-5 82 100 500 gG 100 600 T 10…70 6…2/0
*Without mains choke
AWG cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire
insulation at 40 °C (104 °F) surrounding air temperature. Not more than three current-carrying
conductors in raceway or cable or earth (directly burried). For other conditions, dimension the
cables according to local safety regulations, appropriate input voltage and the load current of
the drive.
Technical data 119
 gG fuses
Drive type *A A2 s V Manufacturer Type Fuse size
ACS880-M04 (@500V) DIN
UN = 230 V
-03A0-2 6 110 500 ABB OFAF000H6 000
-03A6-2 6 110 500 ABB OFAF000H6 000
-04A8-2 10 360 500 ABB OFAF000H10 000
-06A0-2 10 360 500 ABB OFAF000H10 000
-08A0-2 16 750 500 ABB OFAF000H16 000
-010A-2 16 750 500 ABB OFAF000H16 000
-014A-2 20 1500 500 ABB OFAF000H20 000
-018A-2 25 2550 500 ABB OFAF000H25 000
-025A-2 25 2550 500 ABB OFAF000H25 000
-030A-2 32 4500 500 ABB OFAF000H35 000
-035A-2 40 7800 500 ABB OFAF000H40 000
-044A-2 50 16000 500 ABB OFAF000H50 000
-050A-2 50 16000 500 ABB OFAF000H50 000
-061A-2 63 20000 500 ABB OFAF000H63 000
-078A-2 80 37000 500 ABB OFAF000H80 000
-094A-2 100 65000 500 ABB OFAF000H100 000
UN = 400 V
-03A0-5 6 110 500 ABB OFAF000H6 000
-03A6-5 6 110 500 ABB OFAF000H6 000
-04A8-5 10 360 500 ABB OFAF000H10 000
-06A0-5 10 360 500 ABB OFAF000H10 000
-08A0-5 16 750 500 ABB OFAF000H16 000
-010A-5 16 750 500 ABB OFAF000H16 000
-014A-5 20 1500 500 ABB OFAF000H20 000
-018A-5 25 2550 500 ABB OFAF000H25 000
-025A-5 25 2550 500 ABB OFAF000H25 000
-030A-5 32 4500 500 ABB OFAF000H35 000
-035A-5 40 7800 500 ABB OFAF000H40 000
-044A-5 50 16000 500 ABB OFAF000H50 000
-050A-5 50 16000 500 ABB OFAF000H50 000
-061A-5 63 20000 500 ABB OFAF000H63 000
-078A-5 80 37000 500 ABB OFAF000H80 000
-094A-5 100 65000 500 ABB OFAF000H100 000
120 Technical data
 gR fuses
Drive type *A A2s V Manufacturer Type Fuse size
ACS880-M04 (@500V) DIN
UN = 230 V
-03A0-2 20 70 690 Bussmann 170M2693 00
-03A6-2 20 70 690 Bussmann 170M2693 00
-04A8-2 20 70 690 Bussmann 170M2693 00
-06A0-2 20 70 690 Bussmann 170M2693 00
-08A0-2 20 70 690 Bussmann 170M2693 00
-010A-2 20 70 690 Bussmann 170M2693 00
-014A-2 25 125 690 Bussmann 170M2694 00
-018A-2 32 275 690 Bussmann 170M2695 00
-025A-2 32 275 690 Bussmann 170M2695 00
-030A-2 32 275 690 Bussmann 170M2695 00
-035A-2 50 1000 690 Bussmann 170M2697 00
-044A-2 50 1000 690 Bussmann 170M2697 00
-050A-2 63 1800 690 Bussmann 170M2698 00
-061A-2 80 3600 690 Bussmann 170M2699 00
-078A-2 100 6650 690 Bussmann 170M2700 00
-094A-2 125 12000 690 Bussmann 170M2701 00
UN = 400 V
-03A0-5 25 125 690 Bussmann 170M2694 00
-03A6-5 25 125 690 Bussmann 170M2694 00
-04A8-5 25 125 690 Bussmann 170M2694 00
-06A0-5 25 125 690 Bussmann 170M2694 00
-08A0-5 25 125 690 Bussmann 170M2694 00
-010A-5 25 125 690 Bussmann 170M2694 00
-014A-5 40 490 690 Bussmann 170M2696 00
-018A-5 40 490 690 Bussmann 170M2696 00
-025A-5 40 490 690 Bussmann 170M2696 00
-030A-5 40 490 690 Bussmann 170M2696 00
-035A-5 63 1800 690 Bussmann 170M2698 00
-044A-5 63 1800 690 Bussmann 170M2698 00
-050A-5 63 1800 690 Bussmann 170M2698 00
-061A-5 80 3600 690 Bussmann 170M2699 00
-078A-5 100 6650 690 Bussmann 170M2700 00
-094A-5 125 12000 690 Bussmann 170M2701 00
Technical data 121
 aR fuses
Drive type *A A2 s V Manufacturer Type Fuse size
ACS880-M04 (@500V) DIN
UN = 230 V
-03A0-2 25 130 690 Bussmann 170M1561 000
-03A6-2 25 130 690 Bussmann 170M1561 000
-04A8-2 25 130 690 Bussmann 170M1561 000
-06A0-2 25 130 690 Bussmann 170M1561 000
-08A0-2 25 130 690 Bussmann 170M1561 000
-010A-2 25 130 690 Bussmann 170M1561 000
-014A-2 40 270 690 Bussmann 170M1563 000
-018A-2 40 270 690 Bussmann 170M1563 000
-025A-2 40 270 690 Bussmann 170M1563 000
-030A-2 40 270 690 Bussmann 170M1563 000
-035A-2 63 1450 690 Bussmann 170M1565 000
-044A-2 63 1450 690 Bussmann 170M1565 000
-050A-2 80 2550 690 Bussmann 170M1566 000
-061A-2 100 4650 690 Bussmann 170M1567 000
-078A-2 125 8500 690 Bussmann 170M1568 000
-094A-2 160 16000 690 Bussmann 170M1569 000
UN = 400 V
-03A0-5 25 130 690 Bussmann 170M1561 000
-03A6-5 25 130 690 Bussmann 170M1561 000
-04A8-5 25 130 690 Bussmann 170M1561 000
-06A0-5 25 130 690 Bussmann 170M1561 000
-08A0-5 25 130 690 Bussmann 170M1561 000
-010A-5 25 130 690 Bussmann 170M1561 000
-014A-5 40 270 690 Bussmann 170M1563 000
-018A-5 40 270 690 Bussmann 170M1563 000
-025A-5 40 270 690 Bussmann 170M1563 000
-030A-5 40 270 690 Bussmann 170M1563 000
-035A-5 63 1450 690 Bussmann 170M1565 000
-044A-5 63 1450 690 Bussmann 170M1565 000
-050A-5 80 2550 690 Bussmann 170M1566 000
-061A-5 100 4650 690 Bussmann 170M1567 000
-078A-5 125 8500 690 Bussmann 170M1568 000
-094A-5 160 16000 690 Bussmann 170M1569 000
122 Technical data
Dimensions and weights

See the Dimension drawings on page 189.
Frame Height Height Width1) Depth2) Depth
size (without cable (with cable (without (+J400 / with
clamp plates) clamp plates) options, cover and
cover and control
control panel) panel)
H1 H2 W D1 D2
mm in mm in mm in mm in mm in
R1 364 14.33 474 18.66 90 3.54 157 6.18 237 9.33
R2 380 14.96 476 18.74 100 3.94 234 9.21 315 12.40
R3 567 22.32 658 25.91 165 6.50 235 9.25 316 12.44
R4 567 22.32 744 29.29 220 8.66 235 9.25 316 12.44
1) With
option +J400 (with cover and control panel) the width is increased by 5 mm (0.20 in)
2)
Depth is increased with options (Fieldbus communication, I/O extension, encoder interface
and their cabling
Frame Weight
size
kg lbs
R1 3.4 7.50
R2 5.6 12.35
R3 15.8 34.83
R4 21.5 47.40
Technical data 123
Losses, cooling data and noise

Drive type Power loss1) Airflow Noise
ACS880- W (BTU/h) m3/h dB(A)
M04 (ft3/min)
Load
0% 25% 50% 75% 100%
-03A0-2 66 (226) 71 (244) 77 (264) 84 (287) 91 (312) 24 (14) 47
-03A6-2 66 (226) 73 (247) 80 (272) 88 (300) 97 (332) 24 (14) 47
-04A8-2 72 (245) 80 (273) 90 (307) 101 (346) 114 (390) 24 (14) 47
-06A0-2 72 (245) 83 (284) 97 (332) 114 (390) 134 (457) 24 (14) 47
-08A0-2 72 (245) 87 (298) 106 (363) 129 (439) 154 (526) 24 (14) 47
-010A-2 72 (245) 91 (311) 116 (395) 147 (500) 183 (626) 48 (28) 39
-014A-2 76 (259) 100 (342) 132 (449) 170 (579) 215 (733) 48 (28) 39
-018A-2 76 (259) 109 (371) 152 (520) 208 (709) 274 (936) 48 (28) 39
-025A-2 92 (314) 137 (469) 191 (653) 254 (867) 325 (1109) 142 (84) 71
-030A-2 92 (314) 152 (520) 227 (776) 317 (1082) 421 (1438) 142 (84) 71
-035A-2 95 (323) 160 (545) 239 (816) 333 (1137) 442 (1507) 142 (84) 71
-044A-2 97 (332) 167 (570) 251 (856) 349 (1192) 462 (1576) 200 (118) 71
-050A-2 97 (332) 182 (620) 286 (975) 410 (1400) 555 (1894) 200 (118) 71
-061A-2 115 (393) 224 (763) 362 (1236) 531 (1812) 730 (2492) 290 (171) 70
-078A-2 115 (393) 249 (851) 423 (1444) 636 (2172) 889 (3034) 290 (171) 70
-094A-2 115 (393) 272 (929) 481 (1641) 741 (2530) 1054 (3597) 290 (171) 70
-03A0-5 68 (233) 75 (256) 83 (282) 91 (310) 100 (340) 24 (14) 47

-03A6-5 68 (233) 76 (261) 86 (292) 96 (326) 106 (363) 24 (14) 47
-04A8-5 74 (252) 84 (288) 97 (330) 110 (376) 126 (430) 24 (14) 47
-06A0-5 74 (252) 88 (302) 106 (361) 126 (429) 148 (504) 24 (14) 47
-08A0-5 74 (252) 93 (319) 116 (397) 142 (486) 172 (586) 24 (14) 47
-010A-5 77 (261) 101 (345) 132 (450) 169 (576) 212 (722) 48 (28) 39
-014A-5 80 (273) 112 (382) 151 (515) 197 (672) 250 (852) 48 (28) 39
-018A-5 80 (273) 122 (418) 176 (601) 241 (823) 318 (1084) 48 (28) 39
-025A-5 98 (333) 154 (525) 219 (747) 293 (1000) 375 (1282) 142 (84) 63
-030A-5 98 (333) 172 (588) 262 (893) 366 (1249) 485 (1654) 142 (84) 63
-035A-5 100 (342) 181 (619) 277 (947) 388 (1323) 513 (1750) 142 (84) 63
-044A-5 103 (351) 191 (651) 293 (1000) 410 (1398) 541 (1846) 200 (118) 71
-050A-5 103 (351) 209 (712) 335 (1142) 481 (1641) 646 (2205) 200 (118) 71
-061A-5 126 (430) 259 (884) 422 (1441) 616 (2101) 840 (2867) 290 (171) 70
-078A-5 126 (430) 290 (990) 494 (1685) 737 (2514) 1020 (3481) 290 (171) 70
-094A-5 126 (430) 317 (1081) 560 (1910) 854 (2915) 1200 (4096) 290 (171) 70
1)
The losses are not calculated according to the ecodesign standard IEC 61800-9-2.
124 Technical data
Terminal and lead-through data for power cables

Input, motor, resistor and DC cable, maximum wire sizes (per phase) and terminal
screw sizes and tightening torques (T) are given below.
Frame size U1/2, V1/2, W1/2, UDC+/-, R+/- Grounding terminals
Max wire size T T
mm2 N·m N·m
R1 4 0.5 ... 0.6 1.5
R2 10 1.2 ... 1.5 1.5
R3 70 15 3
R4 70 15 18
Screwdrivers for the terminals of main circuit

Frame size Screwdrivers
R1 4 mm slot
R2 5 mm slot
R3 4 mm Allen key (hexagonal socket)
R4 4 mm Allen key (hexagonal socket)
3AXD00000586715.xls F
ZCU control unit

Power supply Connector pitch 5 mm, wire size 2.5 mm2
(XPOW) 24 V (±10%) DC, 2 A
External power input. Two supplies can be
connected to BCU for redundancy.
Relay outputs RO1…RO3 (XRO1… Connector pitch 5 mm, wire size 2.5 mm2
XRO3) 250 V AC / 30 V DC, 2 A
Protected by varistors
+24 V output Connector pitch 5 mm, wire size 2.5 mm2
(XD24:2 and XD24:4) Total load capacity of these outputs is 4.8 W
(200 mA / 24 V) minus the power taken by DIO1
and DIO2.
Technical data 125
Digital inputs DI1…DI6 Connector pitch 5 mm, wire size 2.5 mm2
(XDI:1…XDI:6) 24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP (DI1…DI5), NPN (DI6)
Hardware filtering: 0.04 ms, digital filtering up to
8 ms
DI6 (XDI:6) can alternatively be used as an input
for a PTC thermistor.
“0” > 4 kohm, “1” < 1.5 kohm
Imax : 15 mA (DI1…DI5), 5 mA (DI6)
Start interlock input DIIL Connector pitch 5 mm, wire size 2.5 mm2
(XD24:1 [ZCU]) 24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP
Hardware filtering: 0.04 ms, digital filtering up to
8 ms
Digital inputs/outputs DIO1 and DIO2 Connector pitch 5 mm, wire size 2.5 mm2
(XDIO:1 and XDIO:2) As inputs:
Input/output mode selection by 24 V logic levels: “0” < 5 V, “1” > 15 V
parameters. Rin: 2.0 kohm
DIO1 can be configured as a frequency Filtering: 0.25 ms (ZCU), 1 ms (BCU)
input (0…16 kHz with hardware filtering of As outputs:
4 microseconds) for 24 V level square Total output current from +24VD is limited to
wave signal (sinusoidal or other wave form 200 mA
cannot be used). DIO2 can be configured
as a 24 V level square wave frequency +24VD
output. See the firmware manual,
parameter group 11.
DIOx
RL
DIOGND
Reference voltage for analog inputs Connector pitch 5 mm, wire size 2.5 mm2
+VREF and -VREF 10 V ±1% and –10 V ±1%, Rload 1…10 kohm
(XAI:1 and XAI:2)
126 Technical data
Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 2.5 mm2
(XAI:4 … XAI:7) Current input: –20…20 mA, Rin = 100 ohm
Current/voltage input mode selection by Voltage input: –10…10 V, Rin > 200 kohm
jumpers/switches. 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
Analog outputs AO1 and AO2 Connector pitch 5 mm, wire size 2.5 mm2
(XAO) 0…20 mA, Rload < 500 ohm
Frequency range: 0…300 Hz (ZCU), 0…500 Hz
(BCU)
Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm2
(XD2D) Physical layer: RS-485
Termination by switch or jumper
Safe torque off connection Connector pitch 5 mm, wire size 2.5 mm2
(XSTO) Input voltage range: -3…30 V DC
Logic levels: “0” < 5 V, “1” > 17 V
For the drive to start, both connections must be
“1”
Current consumption: 66 mA (continuous) per
STO channel per drive module
EMC (immunity) according to IEC 61326-3-1
Control panel connection (X13) Connector: RJ-45
Cable length < 3 m
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.
Technical data 127
Ground isolation diagram (ZCU)
XPOW
+24VI 1
GND 2
XAI
+VREF 1
-VREF 2
AGND 3
AI1+ 4
AI1- 5 Common mode voltage between
AI2+ 6 channels +30 V
AI2- 7
XAO
AO1 1
AGND 2
AO2 3
AGND 4
XD2D
B 1
A 2
BGND 3
XRO1, XRO2, XRO3
NC 1
COM 2
NO 3
NC 1
COM 2
NO 3
NC 1
COM 2
NO 3
XD24
DIIL 1
+24VD 2
DICOM 3
+24VD 4
DIOGND 5
XDIO
DIO1 1
DIO2 2
XDI
DI1 1 *
DI2 2
DI3 3
DI4 4
DI5 5
DI6 6
XSTO
OUT1 1
GND 2
IN1 3
IN2 4
Ground
128 Technical data
*Ground selector (J6) settings

All digital inputs share a common ground (DICOM connected to DIOGND).
This is the default setting.
Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from DIO
signal ground (DIOGND). Isolation voltage is 50 V.
AC input (supply) connection

Voltage (U1) 200…240 V AC +/-10%, 3-phase
380…500 V AC +10%/-15%, 3-phase
Network type Symmetrically grounded TN-S system, IT (ungrounded)
Short-circuit 100 kA when protected by fuses given in the on page 128.
withstand Frames R1 and R2: Thermal dimensioning of the DC capacitors is based
strength on max. 5 kA short-circuit current. An input choke should be used to
(IEC 60439-1 achieve 100 kA.
Short-circuit US and Canada: The drive is suitable for use on a circuit capable of
current delivering not more than 100 kA symmetrical amperes (rms) at 500 V
protection maximum when protected by fuses given in the on page 128.
(UL 61800-5-1,
CSA C22.2 No.
274-13)
Frequency 50…60 Hz ±5%
Imbalance Max. ±3% of nominal phase to phase input voltage
Fundamental 0.98 (at nominal load)
power factor
(cos phi1)
Terminals Frame R1: Detachable screw terminal block for 0.25…4 mm2 wire.
Frame R2: Detachable screw terminal block for 0.5…6 mm2 wire.
Frames R3 and R4: Screw lugs for 6…70 mm2 wire included. Suitable
crimp lugs can be used instead.
Technical data 129
DC connection
Voltage 243…356 V DC (ACS880-M04-xxxx-2 drives)
436…743 V DC (ACS880-M04-xxxx-5 drives)
Ratings, fuse
Drive IdcN C IEC fuse UL fuse
recommenda-
type (A) (µF) Rated Voltage Class Rated Voltage Class
tions
ACS880- current (V) current (V)
M04 (A) (A)
-xxxx-2/5
-03A0 3.3 120 16 690 aR 12 690 URC
-03A6 3.9 120 16 690 aR 12 690 URC
-04A8 4.8 240 16 690 aR 12 690 URC
-06A0 6.5 240 16 690 aR 12 690 URC
-08A0 8.7 240 16 690 aR 12 690 URC
-010A 12 370 20 690 aR 16 690 URC
-014A 15 740 32 690 aR 32 690 URD
-018A 20 740 32 690 aR 32 690 URD
-025A 29 670 63 690 aR 63 690 URQ
-030A 38 670 63 690 aR 63 690 URQ
-035A 44 1000 100 690 aR 100 690 URQ
-044A 54 1000 100 690 aR 100 690 URQ
-050A 54 1000 100 690 aR 100 690 URQ
-061A 73 1340 160 690 aR 160 690 URQ
-078A 85 2000 160 690 aR 160 690 URQ
-094A 98 2000 160 690 aR 160 690 URQ
Idc Average DC input current requirement when running a typical

N induction motor at PN at a DC link voltage of 540 V (which
corresponds to an AC input voltage of 400 V).
C Capacitance of DC link.
130 Technical data
Motor connection
Motor types Asynchronous induction motors, permanent magnet motors, ABB
synchronous reluctance motors
Frequency 0…500 Hz
Current See section Ratings.
Switching 3 kHz (default)
frequency
Maximum motor Frames R1 and R2: 150 m (492 ft)*
cable length Frames R3 and R4: 300 m (984 ft)*
*100 m with EN 61800-3 Category C3 filter
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. Note that a sine filter
(optional) at the drive output also causes a voltage decrease.
Efficiency
Approximately 98% at nominal power level
The efficiency is not calculated according to the ecodesign standard
IEC61800-9-2.
Energy efficiency data (ecodesign)
Energy efficiency data according to IEC-61800-9-2 is available from the
ecodesign tool (https://ecodesign.drivesmotors.abb.com).
Cooling
Method Internal fan, flow from bottom to top. Air-cooled heatsink. See Cooling and
degrees of protection on page 42.
Free space See Free space requirements on page 39.
around the unit
Technical data 131
Protection classes
Environmental limits for the drive are given below. The drive must be used
in a heated, indoor, controlled environment.
Degree of IP20 / UL open type. See Cooling and degrees of protection on page 42.
protection
(IEC/EN 60529)
Overv. cat. III
(IEC 60664-1)
Pollution degr. 2
(IEC 60664-1)
132 Technical data
Ambient conditions
Environmental limits for the drive are given below. The drive must be used
in a heated, indoor, controlled environment.
Operation Storage Transportation
installed for stationary in the protective in the protective
use package package
Installation site 0 to 2000 m (6561 ft) - -
altitude above sea level.
Above 1000 m
(3281 ft), see section
Altitude derating on
page 115.
Air temperature -10 to +55°C -40 to +70°C -40 to +70°C
(14 to 131°F). No frost (-40 to +158°F) (-40 to +158°F)
allowed. See section
Derating on page 115.
Relative 0 to 95% Max. 95% Max. 95%
humidity No condensation allowed. Maximum allowed relative humidity is 60% in the
presence of corrosive gases.
Contamination No conductive dust allowed.
levels According to IEC According to IEC According to IEC
(IEC 60721-3-3, 60721-3-3: 60721-3-1: 60721-3-2:
IEC 60721-3-2,
Chemical gases: Class Chemical cases: Class Chemical cases: Class
IEC 60721-3-1)
3C2 1C2 2C2
Solid particles: Class Solid particles: Class Solid particles: Class
3S2 1S2 2S2
The drive must be
installed in clean air
according to enclosure
classification. Cooling
air must be clean, free
from corrosive
materials and
electrically conductive
dust.
Technical data 133
Sinusoidal Tested according to – –

vibration IEC 60721-3-3,
(IEC 60721-3-3) mechanical conditions:
Class 3M4
2…9 Hz: 3.0 mm
(0.12”)
9…200 Hz: 10 m/s2
(33 ft/s2)
Shock – According to ISTA 1A. According to ISTA 1A.
(IEC 60068-2-27, Max. 100 m/s2 Max. 100 m/s2
ISTA 1A) (330 ft/s2), 11 ms (330 ft/s2), 11 ms
Free fall Not allowed 76 cm (30”) 76 cm (30”)
Materials
Drive enclosure • PC/ABS, colour NCS 1502-Y (RAL 9002 / PMS 420 C)
• hot-dip zinc coated steel sheet
• extruded aluminium AlSi.
Packaging Corrugated cardboard, PP bands.
Disposal The main parts of the drive can be recycled to preserve natural resources
and energy. Product parts and materials should be dismantled and
separated.
Generally all metals, such as steel, aluminum, copper and its alloys, and
precious metals can be recycled as material. Plastics, rubber, cardboard
and other packaging material can be used in energy recovery. Printed
circuit boards and large electrolytic capacitors need selective treatment
according to IEC 62635 guidelines. To aid recycling, plastic parts are
marked with an appropriate identification code.
Contact your local ABB distributor for further information on environmental
aspects and recycling instructions for professional recyclers. End of life
treatment must follow international and local regulations.
134 Technical data
Applicable standards
The drive complies with the following standards. The compliance with the European Low
Voltage Directive is verified according to standard EN 61800-5-1.
EN 61800-5-1:2016 Adjustable speed electrical power drive systems.
Part 5-1: Safety requirements – electrical, thermal
and energy.
EN 61800-3:2004 + A1:2012 Adjustable speed electrical power drive systems.
Part 3: EMC requirements and specific test
methods.
EN 60204-1:2006 + A1:2009 + AC:2010 Safety of machinery. Electrical equipment of
machines.
Part 1: General requirements. Provisions for
compliance: The final assembler of the machine
is responsible for installing
• emergency-stop device
• supply disconnecting device
• the drive module into a cabinet
EN 61800-5-1:2007+A1:2017+A11:2021 Adjustable speed electrical power drive systems -
Part 5-1: Safety requirements - Electrical, thermal
and energy
EN 61800-3:2004+A1:2012 Adjustable speed electrical power drive systems -
Part 3: EMC requirements and specific test
methods
EN IEC 63000:2018 Technical documentation for the assessment of
electrical and electronic products with respect to
the restriction of hazardous substances
EN 61800-9-2:2017 Adjustable speed electrical power drive systems -
Part 9-2: Ecodesign for power drive systems,
motor starters, power electronics and their driven
applications - Energy efficiency indicators for
power drive systems and motor starters
EN 60529:1991 + A1:2000 + A2:2013 Degrees of protection provided by enclosures (IP
code)
UL 61800-5-1:2012 UL Standard for Safety. Adjustable speed
Electrical Power Drive Systems – Part 5-1: Safety
Requirement – Electrical, Thermal and Energy.
CSA C22.2 No. 274-13 Adjustable speed drives
Technical data 135
Markings
CE mark
Product complies with the applicable European Union legislation. For fulfilling the
EMC requirements, see the additional information concerning the drive EMC
compliance (IEC/EN 61800-3).
TÜV Safety Approved mark (functional safety)
Product contains Safe torque off and possibly other (optional) safety functions
which are certified by TÜV according to the relevant functional safety standards.
UKCA (UK Conformity Assessed) mark
Product complies with the applicable United Kingdom’s legislation (Statutory
Instruments). Marking is required for products being placed on the market in
Great Britain (England, Wales and Scotland).
UL Listed mark for USA and Canada
Product has been tested and evaluated against the relevant North American
standards by the Underwriters Laboratories.
EAC (Eurasian Conformity) mark
Product complies with the technical regulations of the Eurasian Customs Union.
EAC mark is required in Russia, Belarus and Kazakhstan.
Electronic Information Products (EIP) symbol including an Environment Friendly
Use Period (EFUP).
Product is compliant with the People’s Republic of China Electronic Industry
Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is
20 years.China RoHS II Declaration of Conformity is available from
https://library.abb.com.
WEEE mark
At the end of life the product should enter the recycling system at an appropriate
collection point and not placed in the normal waste stream.
136 Technical data
Compliance with the EN 61800-3:2004

 Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic
equipment to operate without problems within an electromagnetic environment.
Likewise, the equipment must not disturb or interfere with any other product or
system within its locality.
Environment/ Description
Category
First environment Includes establishments connected to a low-voltage network which
supplies buildings used for domestic purposes.
Second environment Includes establishments connected to a network not supplying
domestic premises.
Drive of category C2 Drive of rated voltage less than 1000 V and intended to be installed and
started up only by a professional when used in the first environment.
Note: A professional is a person or organization having necessary
skills in installing and/or starting up power drive systems, including their
EMC aspects.
Drive of category C3 Drive of rated voltage less than 1000 V, intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4 Drive of rated voltage equal to or above 1000 V, or rated current equal
to or above 400 A, or intended for use in complex systems in the
second environment.
 Category C2
The drive complies with the standard with the following provisions:
1. The drive is equipped with external EMC filter JFI-0x (optional accessory to be
ordered separately, see EMC filters on page 167).
2. The motor and control cables are selected as specified in this manual.
3. The drive is installed according to the instructions given in this manual.
4. The maximum motor cable length does not exceed 100 meters (328 ft).
WARNING! The drive may cause radio interference if used in residential or

domestic environment. The user is required to take measures to prevent
interference, in association to the requirements for the CE compliance listed above, if
necessary.
Note: Do not install a drive with the internal or external EMC filter (+E200) on IT
(ungrounded) systems. The supply network connects to the ground potential through
the internal EMC filter capacitors which may cause danger or damage to the drive.
For disconnecting the EMC filter, see instructions on page 78.
Technical data 137
 Category C3
The drive complies with the standard with the following provisions:
1. The drive is equipped with filtering option +E200.
3. Motor cable length does not exceed 100 metres (328 ft).
WARNING! A drive of category C3 is not intended to be used on a low-voltage public

network which supplies domestic premises. Radio frequency interference is expected
if the drive is used on such a network.
 Category C4
If the provisions under Category C3 cannot be met, the requirements of the standard
can be met as follows:
1. It is ensured that no excessive emission is propagated to neighboring low-voltage
networks. In some cases, the inherent suppression in transformers and cables is
sufficient. If in doubt, the supply transformer with static screening between the
primary and secondary windings can be used.
Medium voltage network

Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage

Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A

template is available from the local ABB representative.
138 Technical data
WARNING! A drive of category C4 is not intended to be used on a low-

voltage public network which supplies domestic premises. Radio frequency
interference is expected if the drive is used on such a network.
An RCM mark is attached on each drive to verify its compliance with the EMC product
standard (EN 61800-3:2004), required under the Trans-Tasman Electromagnetic
Compatibility Scheme for levels 1, 2 and 3 in Australia and New Zealand.
For fulfilling the requirements of the standard, see section Compliance with the EN
61800-3:2004 on page 136.
Technical data 139
UL checklist
WARNING! Operation of this drive requires detailed installation and operation

instructions provided in the hardware and software manuals. The manuals are
provided in electronic format in the drive package or on the Internet. Keep the
manuals with the drive at all times. Hard copies of the manuals can be ordered
through the manufacturer.
• Make sure that the drive type designation label includes the applicable marking.
• DANGER - Risk of electric shock. After disconnecting the input power, always
wait for 5 minutes to let the intermediate circuit capacitors discharge before you
start working on the drive, motor or motor cable.
• The drive is to be used in a heated, indoor controlled environment. The drive must
be installed in clean air according to the enclosure classification. Cooling air must
be clean, free from corrosive materials and electrically conductive dust.
• The maximum surrounding air temperature is 40 °C at rated output current. The
output current is derated for 40…55 °C.
• The drive is suitable for use in a circuit capable of delivering not more than 100 kA
rms symmetrical amperes, 500 V (or 240V) maximum when protected by the UL
fuses given elsewhere in this chapter.
• The cables located within the motor circuit must be rated for at least 75 °C in UL-
compliant installations.
• The input cable must be protected with fuses or circuit breakers. These protective
devices provide branch circuit protection in accordance with the national
regulations (National Electrical Code (NEC) or Canadian Electrical Code). Obey
also any other applicable local or provincial codes.
WARNING! The opening of the branch-circuit protective device may be an

indication that a fault current has been interrupted. To reduce the risk of fire or
electric shock, current-carrying parts and other components of the device should be
examined and replaced if damaged.
• The drive provides motor overload protection. The protection is not enabled when
the drive leaves the ABB factory. For enabling the protection, see the firmware
manual.
• The drive overvoltage category according to IEC 60664-1 is III.
140 Technical data
Disclaimers
 Generic disclaimer
The manufacturer shall have no obligation hereunder 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 is designed to be connected to and to communicate information and
data via a network interface. It is Customer's sole responsibility to provide and
continuously ensure a secure connection between the product and Customer network
or any other network (as the case may be). Customer shall establish and maintain
any appropriate measures (such as but not limited to the installation of firewalls,
application of authentication measures, encryption of data, installation of anti-virus
programs, etc) to protect the product, the network, its system and the interface
against any kind of security breaches, unauthorized access, interference, intrusion,
leakage and/or theft of data or information. ABB and its affiliates are not liable for
damages and/or losses related to such security breaches, any unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
The Safe torque off function 141
12
The Safe torque off function
This chapter describes the Safe torque off (STO) function of the drive modules and
gives instructions for its use.
Description
WARNING!
In case of parallel-connected drives or dual-winding motors, the STO must be
activated on each drive to remove the torque from the motor.
The Safe torque off function can be used, for example, as the final actuator device of
safety circuits (such as an emergency stop circuit) that stop the drive in case of
danger. Another typical application is a prevention of unexpected start-up function
that enables short-time maintenance operations like cleaning or work on non-
electrical parts of the machinery without switching off the power supply to the drive.
When activated, the Safe torque off function disables the control voltage for the
power semiconductors of the drive output stage, thus preventing the drive from
generating the torque required to rotate the motor. If the motor is running when Safe
torque off is activated, it coasts to a stop.
The Safe torque off function has a redundant architecture, that is, both channels must
be used in the safety function implementation. The safety data given in this manual is
calculated for redundant use, and does not apply if both channels are not used.
The Safe torque off function complies with these standards:
142 The Safe torque off function
Standard Name
IEC 60204-1:2021 Safety of machinery – Electrical equipment of machines – Part
EN 60204-1:2018 1: 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-related 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/electronic/ programmable electronic safety-related
systems
IEC 61511-1:2017 Functional safety – Safety instrumented systems for the
process industry sector
IEC 61800-5-2:2016 Adjustable speed electrical power drive systems – Part 5-2:
EN 61800-5-2:2007 Safety requirements – Functional
EN IEC 62061:2021 Safety of machinery – Functional safety of safety-related
control systems
EN ISO 13849-1:2015 Safety of machinery – Safety-related parts of control systems –
Part 1: General principles for design
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of control systems –
Part 2: Validation
The function also corresponds to Prevention of unexpected start-up as specified by

EN ISO 14118:2018 (ISO 14118:2017), and Uncontrolled stop (stop category 0) as
specified in EN/IEC 60204-1.
 Compliance with the European Machinery Directive and the UK

Supply of Machinery (Safety) Regulations
The Declarations of conformity are shown at the end of this chapter.’
Wiring
For the electrical specifications of the STO connection, see the technical data of the
control unit.
 Activation switch
In the wiring diagrams, the activation switch has the designation [K]. This represents
a component such as a manually operated switch, an emergency stop push button
switch, or the contacts of a safety relay or safety PLC.
• In case a manually operated activation switch is used, the switch must be of a
type that can be locked out to the open position.
• The contacts of the switch or relay must open/close within 200 ms of each other.
• An FSO safety functions module, an FSPS safety functions module or an FPTC
thermistor protection module can also be used. For more information, see the
module documentation.
 Cable types and lengths

• ABB recommends double-shielded twisted-pair cable.
• Maximum cable lengths:
• • 300 m (1000 ft) between activation switch [K] and drive control unit
• • 60 m (200 ft) between multiple drives
• • 60 m (200 ft) between external power supply and first control unit
Note: A short-circuit in the wiring between the switch and an STO terminal causes a
dangerous fault. Therefore, it is recommended to use a safety relay (including wiring
diagnostics) or a wiring method (shield grounding, channel separation) which reduces
or eliminates the risk caused by the short-circuit.
Note: The voltage at the STO input terminals of the control unit must be at least 17 V
DC to be interpreted as “1”.
The pulse tolerance of the input channels is 1 ms.
 Grounding of protective shields

• Ground the shield in the cabling between the activation switch and the control unit
at the control unit only.
• Ground the shield in the cabling between two control units at one control unit only.
 Single drive (internal power supply)

Dual-channel connection
2 +24 V OUT1
SGND K
IN1
IN2
1 Drive
2 Control unit
K Activation switch
Single-channel connection
1
K
2 +24 V OUT1
SGND
IN1
IN2
Note:
• Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no
SIL/PL classification is given.
• Pay special attention to avoiding any potential failure modes for the wiring. For example,
use shielded cable. For measures for fault exclusion of wiring, see eg. EN ISO 13849-
2:2012, table D.4.
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 OUT1
SGND K
IN1
2 IN2
XSTO
OUT1
SGND
IN1
2 IN2
XSTO
OUT1
SGND
IN1
2 IN2
1 Drive
2 Control unit
K Activation switch
External power supply
24 V DC
– +
XSTO
+24 V OUT1
SGND
IN1
2 IN2
XSTO
OUT1
SGND
IN1
2 IN2
XSTO
OUT1
SGND
IN1
2 IN2
1 Drive
2 Control unit
K Activation switch
Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay
contacts open).
2. The STO inputs on the drive control unit de-energize.
3. The control unit cuts off the control voltage from the drive 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 +Q972, +Q973 or +Q982, also do the
procedure shown in the FSO module documentation.

If an FSPS-21 module is installed, refer to its documentation.
Action 
WARNING!
Obey the safety instructions. If you ignore them, injury or death, or damage to
the equipment 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.
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.
Action 
Test the operation of the failure detection of the drive. The motor can be stopped or
running.
• Open the 1st input channel of the STO circuit. If the motor was running, it should coast
to a stop. The drive generates an FA81 fault indication (see the firmware manual).
• Open the STO circuit (both channels).
• Give a reset command.
• Close the STO circuit (both channels).
• Open the 2nd input channel of the STO circuit. If the motor was running, it should coast
Document and sign the acceptance 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 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 producean
alignment torque which maximally rotates the motor shaft by 180/p degrees (with
permanent magnet motors) or 180/2p degrees (with synchronousreluctance [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 285).
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 279).
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!
Test the operation of the STO function. If the motor is running, it will stop during the test.
standstill.
• 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
• Reset any active faults.
• Open the 2nd input channel of the STO circuit. If the motor was running, it should
coast to a stop. The drive generates an FA82 fault indication (see the firmware
manual).
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!
Test the operation of the STO function. If the motor is running, it will stop during the test.
standstill.
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.
Frame size SIL SC PL PFH PFDavg MTTFD DC SFF Cat. HFT CCF TM PFHdiag λDiag_s λDiag_d
(1/h) Perfect proof test Simplified proof test (a) (%) (%) (a) (1/h) (FIT) (FIT)
T1=5a T1=10a T1= 5 or 10a
R1 3 3 e 3.23E-09 9.66E-06 1.93E-05 3.85E-05 24293 ≥90 98,80 3 1 80 20 1.20E-11 82.44 1.20
R2 3 3 e 3.23E-09 9.45E-06 1.89E-05 3.77E-05 24293 ≥90 98,80 3 1 80 20 1.20E-11 82.44 1.20
R3 3 3 e 3.23E-09 9.45E-06 1.89E-05 3.77E-05 24293 ≥90 98,80 3 1 80 20 1.20E-11 82.44 1.20
R4 3 3 e 3.23E-09 9.45E-06 1.89E-05 3.77E-05 24293 ≥90 98,80 3 1 80 20 1.20E-11 82.44 1.20
3AXD10001616871 A
• The STO is a type A 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), 5 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 of 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: (The total number of life
units) / (the number of dangerous, undetected failures)
during a particular measurement interval under stated
conditions
PFD avg 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
PFH diag 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 Periodic test performed to detect failures in a safety-
62061 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)
SILCL IEC/EN 62061 Maximum SIL (level 1…3) that can be claimed for a safety
function or subsystem
STO IEC/EN 61800-5-2 Safe torque off
T1 IEC 61508-6 Proof test interval. T1 is a parameter used to define the
probabilistic failure rate (PFH or PFD) for the safety
function or subsystem. Performing a proof test at a
maximum interval of T1 is required to keep the SIL
capability valid. The same interval must be followed to
keep the PL capability (EN ISO 13849) valid
Term of Reference Description

abbreviation
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.
 Declarations of conformity

EU Declaration of Conformity
Machinery Directive 2006/42/EC
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxx
We
Manufacturer: ABB Oy
Address: Hiomotie 13, 00380 Helsinki, Finland.
Phone: +358 10 22 11
declare under our sole responsibility that the following products:
Frequency converters
ACS880-01/-11/-31
ACS880-04/-04F/-M04/-14/-34
with regard to the safety functions
- Safe Torque Off

- Safe stop 1, Safe stop emergency, Safely-limited speed, Safe maximum speed, Safe brake control, Prevention of unexpected start-up
(with FSO-12 option module, +Q973, encoderless)
- Safe stop 1, Safe stop emergency, Safely-limited speed, Safe maximum speed, Safe brake control, Safe speed monitor, Safe direction,
Prevention of unexpected start-up (with FSO-21 and FSE-31 option modules, +Q972 and +L521, encoder supported)
- Safe motor temperature (with FPTC-01 thermistor protection module, +L536)
- Safe stop 1 (SS1-t, with FSPS-21 PROFIsafe module, +Q986)
are in conformity with all the relevant safety component requirements of EU Machinery Directive 2006/42/EC, when the listed safety functions are
used for safety component functionality.
The following harmonized standards have been applied:

EN 61800-5-2:2007 Adjustable speed electrical power drive systems – Part 5-2: Safety requirements -
Functional
EN IEC 62061:2021 Safety of machinery – Functional safety of safety-related control systems
EN ISO 13849-1:2015 Safety of machinery – Safety-related parts of control systems. Part 1: General
requirements
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of the control systems. Part 2:
Validation
EN 60204-1:2018 Safety of machinery – Electrical equipment of machines – Part 1: General
requirements
The following other standards have been applied:
IEC 61508:2010, parts 1-2 Functional safety of electrical / electronic / programmable electronic safety-
related systems
IEC 61800-5-2:2016 Adjustable speed electrical power drive systems – Part 5-2: Safety requirements -
Functional
The product(s) referred in this Declaration of conformity fulfil(s) the relevant provisions of other European Union Directives which are notified in
Single EU Declaration of conformity 3AXD10000497831.
Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland.
Helsinki, August 31, 2022

Signed for and on behalf of:
Mika Vartiainen Aaron D. Wade

Local Division Product Unit Manager
Manager ABB Oy
ABB Oy
Document number 3AXD10000099646
Page 1 of 1

Declaration of Conformity
Supply of Machinery (Safety) Regulations 2008
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxx
We
Manufacturer: ABB Oy
Address: Hiomotie 13, 00380 Helsinki, Finland.
Phone: +358 10 22 11
declare under our sole responsibility that the following products:
Frequency converters
ACS880-01/-11/-31
ACS880-04/-04F/-M04/-14/-34
with regard to the safety functions
- Safe Torque Off

- Safe stop 1, Safe stop emergency, Safely-limited speed, Safe maximum speed, Safe brake control, Prevention of unexpected start-up
(with FSO-12 option module, +Q973, encoderless)
- Safe stop 1, Safe stop emergency, Safely-limited speed, Safe maximum speed, Safe brake control, Safe speed monitor, Safe direction,
Prevention of unexpected start-up (with FSO-21 and FSE-31 option modules, +Q972 and +L521, encoder supported)
- Safe motor temperature (with FPTC-01 thermistor protection module, +L536)
- Safe stop 1 (SS1-t, with FSPS-21 PROFIsafe module, +Q986)
are in conformity with all the relevant safety component requirements of the Supply of Machinery (Safety) Regulations 2008, when the listed
safety functions are used for safety component functionality.
The following designated standards have been applied:

Functional
EN IEC 62061:2021 Safety of machinery – Functional safety of safety-related control systems
EN ISO 13849-1:2015 Safety of machinery – Safety-related parts of control systems. Part 1: General
requirements
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of the control systems. Part 2:
Validation
EN 60204-1:2018 Safety of machinery – Electrical equipment of machines – Part 1: General
requirements
The following other standards have been applied:
EN 61508:2010, parts 1-2 Functional safety of electrical / electronic / programmable electronic safety-
related systems
Functional
The product(s) referred in this declaration of conformity fulfil(s) the relevant provisions of other UK statutory requirements, which are notified in
a single declaration of conformity 3AXD10001326405.
Authorized to compile the technical file: ABB Limited, Daresbury Park, Cheshire, United Kingdom, WA4 4BT.
Helsinki, August 31, 2022

Signed for and on behalf of:
Mika
Mik Vartiainen
V ti i Aaron D. Wade
Local Division Product Unit Manager
Manager ABB Oy
ABB Oy
Document number 3AXD10001329538
Page 1 of 1
Mains chokes 163
13
Mains chokes
This chapter describes how to select and install mains chokes for the drive module.
The chapter also contains the relevant technical data.
When is a mains choke required?

With frames R1 and R2, the need for an external choke should be determined on a
case-by-case basis. With frames R3 and R4, the drive modules have an internal
mains choke.
The main choke typically
• reduces harmonics in the input current
• reduces the r.m.s. input current
• reduces supply disturbance and low-frequency interference
• increases the allowed DC bus continuous power
• ensures even current distribution in common DC configurations (see page 84).
164 Mains chokes
Selecting a mains choke

Drive type Type Inductance
ACS880-M04 µH
-03A0-2, -03A0-5 CHK-01 6370
-03A6-2, -03A6-5
-04A8-2, -04A8-5 CHK-02 4610
-06A0-2, -06A0-5
-08A0-2, -08A0-5
-010A-2, -010A-5 CHK-03 2700
-014A-2, -014A-5
-018A-2, -018A-5 CHK-04 1475
-025A-2, -025A-5
-030A-2, -030A-5
-035A2, -035A-5
-044A-2, -044A-5 (Internal choke as standard)
-050A-2, -050A-5
-061A-2, -061A-5
-078A-2, -078A-5
-094A-2, -094A-5
3AXD10000434191
The mains chokes are protected to IP20. For dimensions, wire sizes and tightening
torques, refer Mains choke – CHK-xx dimensions on page 200.
Mains chokes 165
Guidelines for installing the mains choke

• If an EMC filter is also installed, the mains choke is connected between the supply
and the EMC filter. See the connection diagram below.
• For optimal operation of the choke, the drive and the choke must be mounted on
the same conductive surface.
• Ensure the choke does not block the airflow through the drive module, and that
the air rising from the choke is deflected away from the air inlet of the drive
module
• Keep the cable between the drive and the choke as short as possible.
WARNING! The surface of the mains choke becomes hot when in use.
Connecting the mains choke

AC supply
L1 L2 L3 PE
U V W PE
DC supply CHK-xx mains choke

+ –
X Y Z
JFI-xx EMC filter (if present)
ACS880-M04
U1 V1 W1
UDC+ UDC-
~
~
166 Mains chokes
EMC filters 167
14
EMC filters
This chapter describes how to select and install EMC filters for the drive module. The
chapter also contains the relevant technical data.
EMC standards
The EMC product standard (EN 61800-3:2004) covers the specific EMC
requirements stated for drives (tested with motor and cable) within the EU.
Standard Description
EN 55011 or These EMC standards
EN 61000-6-3/4 • apply to industrial and household equipments and systems including
drive components inside.
• neither specify cable length nor require a motor to be connected as a
load.
EN 61800-3 Drive units complying with this standard are always compliant with
comparable categories in EN 55011 and EN 61000-6-3/4, but not
necessarily vice versa.
168 EMC filters
EMC filter emission limits

The emission limits are comparable according to the following general EMC
standards.
EN 61800-3:2004, EN 55011, product family standard for industrial, scientific
product standard and medical (ISM) equipment
Category C1 Group 1 Class B
Category C2 Group 1 Class A
Category C3 Group 2 Class A
Category C4 Not applicable
EMC filtering option

Filtering option +E200 is required to meet the category C3 level with the drive module
installation, including a motor with a max. 100 m cable. This level corresponds to the
A limits for Group 2 equipment according to EN 55011.
With frame sizes R1 and R2, option +E200 is an external filter of type JFI-A1 or
JFI-B1.
With frame sizes R3 and R4, the EMC filter is internal.
An external EMC filter of the type JFI-0x is required in order to meet the category C2
level with the drive module installation, including a motor with a max. 100 m cable.
This level corresponds to the A limits for Group 1 equipment according to EN 55011.
WARNING! An EMC filter must not be installed if the drive is connected to an

IT power system (i.e. an ungrounded, or a high resistance grounded [over 30
ohm] power system).
EMC filters 169
Selecting EMC filters

Drive type Filter type
ACS880-M04 EN 61800-3:2004 Category C3 EN 61800-3: 2004 Category C2
-03A0-2, -03A0-5 Option code +E200 (external filter JFI-02*
-03A6-2, -03A6-5 JFI-A1)
-04A8-2, -04A8-5
-06A0-2, -06A0-5
-08A0-2, -08A0-5
-010A-2, -010A-5 Option code +E200 (external filter JFI-03*
-014A-2, -014A-5 JFI-B1)
-018A-2, -018A-5
-025A-2, -025A-5 Option code: +E200 (internal filter) JFI-05*
-030A-2, -030A-5
-035A2, -035A-5
-044A-2, -044A-5
-050A-2, -050A-5
-061A-2, -061A-5 JFI-07*
-078A-2, -078A-5
-094A-2, -094A-5
*External filter; to be ordered separately
All EMC filters are protected to IP20. See dimension drawings of EMC filters (type
JFI-x1) (page 191) and EMC filters (type JFI-0x) (page 193). For details of
dimensions, wire sizes and tightening torques see EMC filter – JFI-xx dimensions on
page 194.
170 EMC filters
Installing EMC filters – JFI-A1/JFI-B1 (Frame R1/R2,

category C3)
 JFI-x1 filter installation guidelines
• Connect the filter directly to the drive input connectors.
• For optimal operation of the filter, mount the drive and the filter on the same
conductive surface.
 JFI-x1 filter connection diagram

AC supply
L1 L2 L3 PE
DC supply CHK-xx mains choke (if present)

+ –
JFI-x1 EMC filter
ACS880-M04
U1 V1 W1
UDC+ UDC-
~
~
EMC filters 171
 Installing the JFI-A1 filter

To install the JFI-A1 EMC filter,
1. Remove the UDC+/- and U1/V1/W1 terminal blocks (1), and the upper power
cable clamp plate (2) from the drive.
2. Fasten the mounting bracket (3) to the drive module base with two screws (4).
Tighten to 1.5 N·m (13 lbf·in).
3. Push the filter into place through the mounting bracket.
4. Fasten the filter to the mounting bracket with two screws (5). Tighten to 1.5 N·m
(13 lbf·in).
5. Fasten the top edge of the filter to the mounting base with two screws (6).
6. Fasten the power cable clamp plate at the top of the filter. Tighten to
1.5 N·m (13 lbf·in).
172 EMC filters
7. Attach the terminal blocks to the filter.
4
5
3
EMC filters 173
 Installing the JFI-B1 filter

To install the JFI-B1 EMC filter,
1. Remove the UDC+/- and U1/V1/W1 terminal blocks (1), and the upper power
cable clamp plate (2) from the drive.
2. Push the filter into the connectors.
3. Fasten the filter to the drive module base with two screws (3). Tighten to 1.5 N·m
(13 lbf·in).
4. Fasten the top edge of the filter to the mounting base with two screws (4).
5. Fasten the power cable clamp plate at the top of the filter. Tighten to 1.5 N·m
(13 lbf·in).
174 EMC filters
6. Attach the terminal blocks to the filter.
2
1
3
EMC filters 175
Installing EMC filter – JFI-0x (Frames R1…R4, category C2)

 JFI-0x filter installation guidelines
• If a mains choke is also installed, the EMC filter is connected between the mains
choke and the drive module. See the connection diagram below.
• For optimal operation of the filter, the drive and the filter must be mounted on the
same conductive surface.
• Ensure the filter does not block the airflow through the drive module.
• Keep the cable between the drive and the filter as short as possible.
 JFI-0x filter connection diagram

AC supply
L1 L2 L3 PE
CHK-xx mains choke (if present)
L1 L2 L3
JFI-0x EMC filter
L1’ L2’ L3’
U1 V1 W1 PE
ACS880-M04
~
~
176 EMC filters
du/dt and common mode filtering 177
15
du/dt and common mode
filtering
This chapter describes how to select du/dt and common mode filtering for the drive
module. The chapter also contains the relevant technical data.
When is du/dt or common mode filtering required?

The output of the drive comprises – regardless of output frequency – pulses of
approximately 1.35 times the equivalent supply voltage with a very short rise time.
This is the case with all drives employing modern IGBT drive technology. The motor
and motor cable insulation may undergo the following situation:
• The voltage of the pulses can be almost double at the motor terminals, depending
on the attenuation and reflection properties of the motor cable and the terminals.
This in turn can cause additional stress on the motor and motor cable insulation.
• Modern variable speed drives with their fast-rising voltage pulses and high
switching frequencies can generate current pulses that flow through the motor
bearings, which can gradually erode the bearing races and rolling elements.
Use the,
• optional ABB du/dt filters to avoid stress on motor insulation
• common mode filters to reduce bearing currents.
Note: To avoid damage to the motor bearings, select and install the cables according
to the instructions given in Electrical installation on page 75.
178 du/dt and common mode filtering
Selecting the du/dt filters
Warning! Use the du/dt filtering, common mode filtering, and insulated N-end
bearings according to the following table.
If you ignore these requirements, the motor life can shorten or damage to the motor
bearings can occur, and the warranty is not applicable.
du/dt filters are optional accessories and to be ordered separately. For more
information on common mode filtering, contact your local ABB representative.
Contact the motor manufacturer for information on the motor construction.
Motor type Nominal AC Requirement for
supply Motor ABB du/dt and common mode filters,
voltage insulation insulated N-end motor bearings
system P < 100 kW and frame size < IEC 315
N
PN < 134 hp and frame size < NEMA 500
ABB motors
Random-wound UN < 500 V Standard -
M2_, M3_ and M4_
Form-wound HX_ UN < 500 V Standard -
and AM_
Old* form-wound UN < 500 V Check with + N + CMF
HX_ and modular the motor
manufacture
r.
Random-wound 0 V < UN < Enamelled + N + CMF
HX_ and AM_ ** 500 V wire with
fiber glass
taping
Non-ABB motors
Random-wound UN < 420 V Standard: -
and form-wound ÛLL =
1300 V
420 V < UN Standard: + du/dt
< 500 V ÛLL = 1300
V
or
Reinforced: -
ÛLL = 1600
V, 0.2
microsecond
rise time
*manufactured before 1.1.1998
**For motors manufactured before 1.1.1998, check for additional instructions with the motor
manufacturer.
du/dt and common mode filtering 179
The abbreviations used in the table are defined below.

Abbreviation Definition
UN Nominal AC line voltage
ÛLL Peak line-to-line voltage at motor terminals which the motor insulation must
withstand
PN Motor nominal power
du/dt du/dt filter at the output of the drive
CMF Common mode filter
N N-end bearing: insulated motor non-drive end bearing
 Additional requirements for ABB motors of types other than M2_,

M3_, M4_, HX_ and AM_
Use the selection criteria given for non-ABB motors.
 Additional requirements for the braking applications

When the motor brakes the machinery, the intermediate circuit DC voltage of the
drive increases as well as the motor supply voltage by up to 20 percent. Consider this
voltage increase when you specify the motor insulation requirements if the motor will
be braking a large part of its operation time.
Example: Select the motor insulation system for a 400 V AC line voltage application
as if the drive were supplied with 480 V.
Installing du/dt and common mode filters

Follow the instructions provided with the filters.
180 du/dt and common mode filtering
du/dt filters data

 du/dt filter types
Drive type Filter type
ACS880-M04
-03A0-2, -03A0-5 NOCH0016-60 (3-phase)
-03A6-2, -03A6-5
-04A8-2, -04A8-5
-06A0-2, -06A0-5
-08A0-2, -08A0-5
-010A-2, -010A-5
-014A-2, -014A-5
-018A-2, -018A-5
-025A-2, -025A-5 NOCH0030-60 (3-phase)
-030A-2, -030A-5
-035A2, -035A-5
-044A-2, -044A-5 NOCH0070-60 (3-phase)
-050A-2, -050A-5
-061A-2, -061A-5
-078A-2, -078A-5
-094A-2, -094A-5 NOCH0120-60 (1-phase; three filters included in kit)
3AXD10000434191
 Common mode filter types

Contact your local ABB representative.
 du/dt filters dimensions and weights

Filter type Height Width Depth Weight
mm (inches) mm (inches) mm (inches) kg (lbs)
NOCH0016-60 195 (7.68) 140 (5.51) 115 (4.53) 2.4 (5.3)
NOCH0030-60 215 (8.46) 165 (6.50) 130 (5.12) 4.7 (10.4)
NOCH0070-60 261 (10.28) 180 (7.09) 150 (5.91) 9.5 (20.9)
NOCH0120-60* 200 (7.87) 154 (6.06) 106 (4.17) 7.0 (15.4)
*Dimensions given are per phase
 du/dt filters degree of protection

IP00
Resistor braking 181
16
Resistor braking
This chapter describes how to select, protect and wire brake choppers and resistors.
The chapter also contains the technical data.
Selecting brake choppers and resistors

 Brake choppers
The ACS880-M04 (frames R1…R4) drives have a built-in brake chopper as standard
equipment to handle the energy generated by a decelerating motor.
When the brake chopper is enabled and a resistor is connected, the chopper starts
conducting when the DC link voltage of the drive reaches UDC_BR - 30 V.
The maximum braking power is achieved at UDC_BR + 30 V. Pre-selected resistors
UDC = 1.35 × Used AC supply voltage
UDC_BR = 1.25 × UDC
See the available ABB brake choppers shown in the Brake choppers data table on
page 183.
182 Resistor braking
 Brake resistors
To select a brake resistor, calculate the following:
1. maximum power generated by the motor during braking
2. continuous power based on the braking duty cycle
3. braking energy during the duty cycle.
Pre-selected resistors are available from ABB as shown in the Brake resistors data
table on page 185. If the listed resistor is not sufficient for the application, a custom
resistor can be selected within the limits imposed by the internal brake chopper of the
ACS880-M04. The following rules apply:
• The resistance of the custom resistor must be at least Rmin. The braking power
capacity with different resistance values can be calculated from the following
formula:
2
(U DC_BR + 30 V)
Pmax <
R
WARNING! Never use a brake resistor with a resistance below the value
specified for the particular drive type. The drive and the chopper are not able to
handle the overcurrent caused by the low resistance.
• The maximum braking power must not exceed Pbrmax at any point
• The average braking power must not exceed Pbrcont
• The braking energy must not exceed the energy dissipation capacity of the
selected resistor
• The resistor must be protected from thermal overload; see section Contactor
protection of drive on page 186.
Brake choppers data table

The ratings apply at an ambient temperature of 40 °C (104 °F).
Drive type Internal brake chopper
ACS880-M04 Pbr5 Pbr5 Pbr10 Pbr10 Pbrcont Pbrcont Pbrmax Rmin
(kW) (kW) (kW) (kW) (kW) (kW) (kW) (ohm)
L L L
-03A0-2 0.5 0.2 0.5 0.2 0.45 0.15 2.75 120
-03A6-2 0.75 0.3 0.7 0.25 0.65 0.2
-04A8-2 1.0 0.3 1.0 0.3 0.9 0.25
-06A0-2 1.5 0.8 1.4 0.75 1.3 0.35
-08A0-2
-010A-2 2.8 1.0 2.7 0.9 2.25 0.75 4.0 80
-014A-2 4.1 1.3 3.9 1.2 3.3 1.1 7.3 40
-018A-2 5.3 1.7 5.1 1.6 4.25 1.4
-025A-2 6.8 3.8 6.5 3.4 5.25 2.7 15.4 20
-030A-2 7.8 4.4 7.4 4.0 6 3.1
-035A-2
-044A-2 11.4 6.4 10.8 5.7 8.75 4.5 22.0 13
-050A-2
-061A-2 20.2 14.0 20.0 11.8 18 8
-078A-2
-094A-2
-03A0-5 1.0 0.4 1.0 0.4 0.9 0.3 5.5 120
-03A6-5 1.5 0.5 1.4 0.5 1.3 0.4
-04A8-5 2.0 0.6 1.9 0.6 1.8 0.5
-06A0-5 3.0 1.6 2.8 1.5 2.6 0.7
-08A0-5
-010A-5 5.5 1.9 5.3 1.8 4.5 1.5 7.9 80
-014A-5 8.2 2.6 7.8 2.4 6.6 2.1 14.6 40
-018A-5 10.5 3.4 10.1 3.2 8.5 2.7
-025A-5 13.6 7.6 12.9 6.8 10.5 5.4 30.7 20
-030A-5 15.5 8.8 14.7 7.9 12 6.2
-035A-5
-044A-5 22.7 12.7 21.5 11.4 17.5 9 43.9 13
-050A-5
-061A-5 40.4 28.0 40.0 23.6 36 16
-078A-5
-094A-5
3AXD10000434191
L = Low motor noise mode. See section Low motor noise derating on page 115.
Pbr5 = The drive (drive and chopper) withstands this braking power for 5 seconds per minute.
Pbr10 = The drive (drive and chopper) withstands this braking power for 10 seconds per minute.
Pbrcont = The drive (drive and chopper) withstands this continuous braking power. Braking is
considered continuous if braking time exceeds 30 seconds.
Pbrmax = Maximum braking power of the drive (drive and chopper). The drive (drive and
chopper) withstands this braking power for 1 second within every 10 seconds.
Note: The listed resistors withstand this braking power for 1 second within every 120 seconds.
Rmin = The minimum allowed resistance of the brake resistor.
Brake resistors data table

The ratings apply at an ambient temperature of 40°C (104°F).
Drive type Example brake resistor Example brake resistor
ACS880-M04 JBR-xx SACExxxxx
Type R Pn Epulse Type R PRcont ER
(ohm) (W) (kJ) (ohm) (kW) (kJ)
-03A0-2, -03A0-5 JBR-01 120 105 22 - - - -
-03A6-2, -03A6-5
-04A8-2, -04A8-5
-06A0-2, -06A0-5
-08A0-2, -08A0-5
-010A-2, -010A-5 JBR-03 80 135 40 - - - -
-014A-2, -014A-5 JBR-04 40 360 73 SACE08RE44 44 1 210
-018A-2, -018A-5
-025A-2, -025A-5 JBR-05 20 570 77 SACE15RE22 22 2 420
-030A-2, -030A-5
-035A-2, -035A-5
-044A-2, -044A-5 JBR-06 13 790 132 SACE15RE13 13 2 435
-050A-2, -050A-5
-061A-2, -061A-5
-078A-2, -078A-5
-094A-2, -094A-5
3AXD10000434191
R = Resistance of the listed resistor.

Pn = Continuous power (heat) dissipation of the listed resistor when cooled naturally in a vertical
position.
Epulse = Energy pulse the listed resistor will withstand.
PRcont = Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER
dissipates in 400 seconds.
ER= Short energy pulse that the resistor assembly withstands every 400 seconds. This energy
will heat the resistor element from 40°C (104°F) to the maximum allowable temperature.
Note: All brake resistors must be installed outside the drive module.
 Brake resistors degree of protection

Resistor type Degree of protection
JBR-xx IP20
SACE IP21
Note: The SACE resistors are not UL listed.

 Brake resistors dimensions

See dimensions drawings of Brake resistors (type JBR-xx) on page 195. For details
of dimensions, wire sizes and tightening torques, see Brake resistor - JBR-xx
dimensions on page 196.
Installing and wiring brake resistors

All resistors must be installed outside the drive module in a place where they are
cooled sufficiently, do not block the airflow to other equipment, or dissipate hot air into
the air inlets of other equipment.
WARNING! The materials near the brake resistor must be non-flammable.

The surface temperature of the resistor may rise above 200 °C (400 °F), and
the temperature of the air flowing from the resistor is hundreds of degrees
Celsius. Protect the resistor against contact.
The maximum length of the resistor cable(s) is 20 m (65 ft). For the connections, see
Cable routing diagram on page 64.
 Contactor protection of drive

The drive must be equipped with a main contactor for safety reasons. Wire the
contactor so that it opens in case the resistor overheats. This is essential for safety
since the drive will not otherwise be able to interrupt the main supply if the chopper
remains conductive in a fault situation.
Below is a simple example wiring diagram.
L1 L2 L3
1
OFF
Fuses 2
1 3 5 13 3
ON
2 4 6 14 4
U1 V1 W1
 Resistor thermal switch
ACS880-M04
K1
Main contactor
Commissioning the braking circuit

For more information, see the firmware manual.
1. Enable the brake chopper function. Please note that a brake resistor must be
connected when the chopper is enabled from group 43 Brake chopper.
2. Switch Off the overvoltage control of the drive with parameter 30.30 Overvoltage
control.
3. Adjust any other relevant parameters in group 43 Brake chopper.
WARNING! If the drive is equipped with a brake chopper but the chopper is not
enabled by the parameter setting, the internal thermal protection of the drive
against resistor overheating is not in use. In this case, the brake resistor must be
disconnected.
Note: Some brake resistors are coated with oil film for protection. At the start-up, the
coating burns off and produces a little bit of smoke. Ensure proper ventilation at the
start-up.
Dimension drawings 189
17
Dimension drawings
The dimension drawings of the ACS880-M04 drive (frame sizes R1, R2, R3 and R4)
and the related accessories are show below. The dimensions are given in millimetres
and inches.
190 Dimension drawings
Frame size R1
D
DMS:3AXD10000466877
DMS:3AXD10000466877
D


DMS:3AXD10000466877
Frame size R2
DMS:3AXD10000468576
DMS:3AXD10000468576
DMS:3AXD10000468576
Frame size R3
DMS: 3AXD10000471184
DMS: 3AXD10000471184
Frame size R4
DMS: 3AXD10000471266
DMS: 3AXD10000471266
Mains chokes (type CHK-0x)
68906903
 Mains choke – CHK-xx dimensions

Parameter Choke type
CHK-01 CHK-02 CHK-03 CHK-04
dim A mm (in.) 120 (4.72) 150 (5.91) 150 (5.91) 150 (5.91)
dim B mm (in.) 146 (5.75) 175 (6.89) 175 (6.89) 175 (6.89)
dim C mm (in.) 79 (3.11) 86 (3.39) 100 (3.94) 100 (3.94)
dim D mm (in.) 77 (3.03) 105 (4.13) 105 (4.13) 105 (4.13)
dim E mm (in.) 114 (4.49) 148 (5.83) 148 (5.83) 148 (5.83)
F screw size M5 M5 M5 M5
Weight kg (lbs) 1.8 (4.0) 3.8 (8.4) 5.4 (11.9) 5.2 (11.5)
Wire size – Main terminals 0.5 … 10 0.5 … 10 0.5 … 10 0.5 … 10
mm2 (AWG) (20…6) (20…6) (20…6) (20…6)
Tightening torque – Main 1.5 (13) 1.5 (13) 1.5 (13) 1.5 (13)
terminals N·m (lbf·in)
PE/Chassis terminals M4 M5 M5 M5
Tightening torque – PE/Chassis 3 (26) 4 (35) 4 (35) 4 (35)
terminals N·m (lbf·in)
EMC filters (type JFI-x1)

 JFI-A1
 JFI-B
EMC filters (type JFI-0x)

 EMC filter – JFI-xx dimensions

Parameter Filter type
JFI-02 JFI-03 JFI-05 JFI-07
Dim. A mm (in.) 250 (9.84) 250 (9.84) 250 (9.84) 270 (10.63)
Dim. B mm (in.) 45 (1.77) 50 (1.97) 85 (3.35) 90 (3.54)
Dim. C mm (in.) 70 (2.76) 85 (3.35) 90 (3.54) 150 (5.91)
Dim. D mm (in.) 220 (8.66) 240 (9.45) 220 (8.66) 240 (9.45)
Dim. E mm (in.) 235 (9.25) 255 (10.04) 235 (9.25) 255 (10.04)
Dim. F mm (in.) 25 (0.98) 30 (1.18) 60 (2.36) 65 (2.56)
Dim. G mm (in.) 5.4 (0.21) 5.4 (0.21) 5.4 (0.21) 6.5 (0.26)
Dim. H mm (in.) 1 (0.04) 1 (0.04) 1 (0.04) 1.5 (0.06)
Dim. I mm (in.) 22 (0.87) 25 (0.98) 39 (1.54) 45 (1.77)
Dim. J M5 M5 M6 M10
Dim. K mm (in.) 22.5 (0.89) 25 (0.98) 42.5 (1.67) 45 (1.77)
Dim. L mm (in.) 29.5 (1.16) 39.5 (1.56) 26.5 (1.04) 64 (2.52)
Weight kg (lbs) 0.8 (1.75) 1.1 (2.4) 1.8 (4.0) 3.9 (8.5)
Wire size (solid) 0.2 … 10 0.5 … 16 6…35 16…50
mm2 (AWG) (AWG24…8) (AWG20…6) (AWG8…2) (AWG4…1/0)
Wire size (stranded) 0.2 … 6 0.5 … 10 10…25 16…50
mm2 (AWG) (AWG24…10) (AWG20…8) (AWG6…4) (AWG4…1/0)
Tightening torque of 1.5 … 1.8 1.5 … 1.8 4.0 … 4.5 7…8
terminals N·m (lbf·in) (13.3 … 15.9) (13.3 … 15.9) (35 … 40) (60…70)
Brake resistors (type JBR-xx)

 Brake resistor - JBR-xx dimensions

Parameter Resistor type
JBR-01 JBR-03 JBR-04 JBR-05 JBR-06
Dim. A mm (in.) 295 340 – – –
(11.61) (13.39)
Dim. B mm (in.) 155 (6.10) 200 (7.87) – – –
Dim. C mm (in.) 125 (4.92) 170 (6.69) – – –
Dim. D mm (in.) – – 345 465 (18.31) 595 (23.43)
(13.58)
Dim. E mm (in.) – – 210 (8.27) 330 (12.99) 460 (18.11)
Dim. F mm (in.) – – 110 (4.33) 230 (9.06) 360 (14.17)
Weight kg (lbs) 0.75 (1.7) 0.8 (1.8) 1.8 (4.0) 3.0 (6.6) 3.9 (8.6)
Max. wire size – 10 mm2 (AWG6)
Main terminals
Tightening torque – 1.5 … 1.8 N·m (13 … 16 lbf·in)
Main terminals
Max. wire size – Thermal 4 mm2 (AWG12)
switch terminals
Tightening torque – 0.6 … 0.8 N·m (5.3 … 7.1 lbf·in)
Thermal switch terminals
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 Drives 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.
Contact us
www.abb.com/drives
www.abb.com/drivespartners
3AXD50000028613 Rev B (EN) 2024-01-24

ACS880-M04 Drive: Hardware Manual

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—

ABB MACHINERY DRIVES

Option manuals and guides

Tool and maintenance manuals and guides

 2023 ABB Oy. All Rights Reserved. 3AXD50000028613 Rev B

2. About the manual

3. Operation principle and hardware description

4. Planning the cabinet installation

Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6. Planning the electrical installation

Connecting the control cables – all frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

11. Technical data

12. The Safe torque off function

13. Mains chokes

14. EMC filters

15. du/dt and common mode filtering

16. Resistor braking

17. Dimension drawings

Mains chokes (type CHK-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Use of warning and notes in this manual

General safety in installation, start-up and maintenance

Electrical safety in installation, start-up and maintenance

WARNING! Follow these instructions. If you ignore them, injury or death, or

 Additional instructions and notes

WARNING! Follow these instructions. If you ignore them, injury or death, or

WARNING! Follow these instructions. If you ignore them, injury or death, or

• If you are not a qualified electrician, do not do grounding work.

Additional instructions for permanent magnet motor drives

• Do not work on a drive when a rotating permanent magnet motor is connected to

General safety in operation

Categorization according to frame size

Categorization according to the + code

Quick installation and commissioning flowchart

Install the drive in a cabinet. Installing the drive on page 50.

Route the cables. Routing the cables on page 64.

If the drive is about to be connected to an IT Electrical safety in installation, start-up and

Check the installation. Installation checklist on page 101.

Commission the drive. Start-up on page 103.

Commission the brake chopper if required. Resistor braking on page 181.

Terms and abbreviations

ACS880-M04 drive overview

CHK-xx mains choke (see

NOCHxxxx-xx du/dt filter JBR-xx brake resistor (see

 Module layout – Frame R1

 Module layout – Frame R4

Power connections and control interfaces

Power unit (JPU/RPU)

Type designation label

Type designation key

WARNING! Installation must always be designed and made according to

Free space requirements

 Vertically alone or side by side

Free space requirement

Do not install the drive upside down.

 Horizontally alone or side by side back installation

 Horizontally alone side installation

Cooling and degrees of protection

The air inlets and outlets are sufficient in size.

 Preventing recirculation of hot air