—

Encoder Kit Installation Procedure

for ABB ACS880-01 demo drive
Use Baldor (grey) motor
(Kit 3AUA0000234592)

Table of Contents
Purpose ................................................................................................................................................... 2
Additional references ......................................................................................................................... 2
Warnings ................................................................................................................................................ 2
Tools Required ...................................................................................................................................... 2
Unpacking .............................................................................................................................................. 3
Installation Process ............................................................................................................................ 4
Remove power to the demo unit .................................................................................................. 4
Remove the flywheel cover............................................................................................................. 5
Mount the flywheel cover spacer .................................................................................................. 5
Mount the encoder ........................................................................................................................... 6
Mount the flywheel to the motor shaft ....................................................................................... 9
Mount the FEN-01 module............................................................................................................ 10
Power the drive ............................................................................................................................... 12
Program the FEN-01 module .......................................................... Error! Bookmark not defined.
Backup drive parameters ................................................................ Error! Bookmark not defined.

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Purpose
The purpose of this document is to identify how to install the encoder option kit to the
ABB ACS880 U.S. demo drive. This is specifically designed to fit U.S. ACS880 demo drives
that utilize the Baldor (grey) motor. A separate kit and installation document exists for
the new U.S. demo units that utilize an ABB (blue) motor. Neither of these kits work on
ACS880 demos built outside the U.S.

This encoder kit can be used to accurately close the speed loop of the demo drive. The
hardware can also be used to demonstrate the N5700 positioning software. The N5700
software is not included with this kit. Please contact your ABB representative to obtain a
copy of this software.

Additional references
For more information on the ACS880-01 drive used in the ACS880-01 demo, refer to the
hardware manual 3AUA0000078093. The FEN-01 manual is document number
3AFE68784603. Refer to document 3AXD50000206063 for FETA-01 installation
instructions. The encoder data sheet can be found here:
http://encoder.com/core/files/encoder/uploads/files/datasheet-15th.pdf

Warnings
This drive has hazardous voltages present that could cause injury or even death. If you are
not a qualified electrical professional do not perform this work. Only those qualified and
competent on working with higher voltages should install this option kit. Refer to the
ACS880-01 Hardware manual for further information.

Tools Required
The following tools are required to add the encoder kit to your ACS880 demo:
Standard #2 Phillips screwdriver
T10 Torx driver
T20 Torx driver
ABB flat screwdriver (3.5mm)
1.5mm Allen Wrench (provided with encoder)
Small rubber mallet

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Unpacking
This encoder kit is designed to be used on ABB ACS880 demo drives that were built using
a Baldor (grey) motor. If your demo is newer using a blue ABB motor, use kit
3AUA0000234593. This hardware will not fit the blue ABB motors.

Along with these installation instructions, this kit contains:

• 15T-02SF-1024NV1RHV-F02 encoder mounted to bracket (with Allen wrench to
secure to shaft)
• Flywheel cover
• Flywheel cover spacer
• 4-Flywheel cover mounting screws
• 3-Flywheel cover washers
• Degree Wheel label for the flywheel
• FEN-01 encoder module
• FETA-01 termination board for FEN-01

Below is a photo of the components. The FETA-01 is sitting on top of the Fen module
(actually a FEN-31 for the photo). The FETA shown does not have a cover on it. Units you
receive will have a cover as in photos later in this document.

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Installation Process

Remove power to the demo unit

Unplug power to the back of the demo and remove any other remote power source that
may be connected to the demo.

There are dangerous voltages inside the panel and at the drive terminals. Unplug the unit
and wait 10 minutes for capacitances to bleed down before you start installing the
encoder kit. Tip: It might be easier to install the kit with the demo unit on its back. The
power cord on the back of the unit will limit you from doing this.

Remove the drive cover

Using the T20 torx driver (and following the ACS880-01 hardware manual
(3AUA0000078093) if needed, remove the drive cover by loosening the two captive screws
and tilting the cover upward.

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Remove the flywheel cover
Using the Phillips screwdriver remove the 4 screws holding the flywheel cover onto the
motor. The cover and screws are replaced in the kit and will not be reused.

Remove the flywheel

With the flywheel cover removed, grasp the flywheel securely and pull straight off the
motor shaft. Do not damage the flywheel or motor and make sure to pull straight else you
may elongate the bore of the plastic flywheel making it unusable. This flywheel is a press
fit and should not have any screws securing it to the motor.

Mount the flywheel cover spacer

Place the flywheel cover spacer plate on the motor. This plate has no specific orientation.
Align the spacer plate holes with the motor C-face mounting holes. Ensure that the
spacer is flat against the motor with no gaps. The spacer should fit somewhat loose on
the motor face.

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Mount the encoder
Warning
The encoder is robust, as is the spring bracket mounted to its back, however, use caution
not to bend or over-stress the spring bracket or cable connection at the encoder or
damage could occur. Do not put excessive stress on the encoder bearings or damage to
the encoder will occur.

Slip-fit encoder to motor

Carefully grasp the encoder and bracket combination and ensure there is a slip fit
between the encoder and motor shaft. If there is not a slip fit polish the motor shaft with
emery cloth or for large nicks, a fine file, to obtain a slip fit while ensuring no debris/metal
filings go into the motor or demo case. (You may want to set the demo case vertically
when you polish the motor shaft to help prevent debris from entering the motor bearing
or panel.) Do not put excessive stress on the encoder bearings or damage to the encoder
could occur.

Confirm proper alignment with bracket

This step should be preset from the factory. Note the rotational orientation between the
encoder and its bracket in the photo below. The rotational orientation must be
approximately as shown for the flywheel cover cable slot to properly align with the
encoder cable. If this orientation is not correct, loosen the encoder mounting screws and
rotate the encoder CCW w/r to the encoder bracket. Carefully retighten the encoder
bracket screws. Turn the encoder over and ensure that there will be clearance between
the motor shaft and encoder bracket when the encoder is place on the motor shaft.

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Slip the encoder onto the motor shaft
Once you have a slip fit between the encoder and motor shaft, and the orientation
between the encoder and encoder bracket is correct, slide the encoder and bracket onto
the motor shaft until the bracket bottoms out against the motor. Do not put excessive
pressure on the encoder housing while finding this fit as encoder bearing damage could
occur. The encoder must easily slide on the shaft while moving the mounting bracket.
Align the encoder cable to approximately the 5:00 position while facing the motor. Grasp
the encoder bracket and not the encoder housing and hold it securely to the motor face
while tightening the encoder Allen screw. This assures you have a proper fit without
stressing the encoder bearings.

Route the encoder cable

Using the Phillips screwdriver, remove the 8 screws holding the demo panel to the frame.
Carefully lift the panel so that the encoder cable can be routed through the gap between
the panel and motor.

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Route the cable through the motor opening as shown in the photo below and bring it back
through the opening in the bottom of the drive. Feed enough cable though the drive so
that it can be connected to a FEN module in slot 2.

Secure demo panel to the demo frame

While the demo unit is open, check mounting hardware inside for tightness. The demos
take a beating and things can loosen up.

Locate the panel in its original position (confirm cable location between panel and motor)
and secure with 8 screws. Use care when tightening the screws so that you don’t strip
out the holes in the aluminum frame.

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Replace the flywheel decal with a 360 degree decal

You have an option to add a decal to the flywheel that has an arrow at 0 degrees and
markings around the perimeter. This could be used to track the position of two motor
shafts when using positioning software. Remove the existing decal and apply the new
one.

Center the decal as well as you can and starting at one side apply the decal while working
out air bubbles as you move across the flywheel. The decal is slightly larger than the
flywheel. Use a razor blade or other sharp device to trim the perimeter of the decal once it
is installed.

Mount the flywheel to the motor shaft

The flywheel is strictly a press fit onto the motor shaft. To secure the flywheel to the motor shaft,
carefully align the flywheel to the shaft and gently tap the center of the flywheel with a rubber mallet.
(You may want to put a couple layers of masking tape or a small piece of cloth to protect the decal first,
depending upon your mallet.) Rotate the motor shaft while tapping to ensure the flywheel is going on
straight. Keep tapping and rotating until the flywheel bottoms out on the motor shaft (about ¼”). If the
flywheel is not pressed on straight the flywheel bore could become elongated and will no longer fit
tightly to the motor shaft. (You might want to use a smaller mallet. This is all I had.)

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Mount the flywheel cover to the motor

Use the new longer flywheel cover screws and the three washers included in the kit to secure the
flywheel cover to the motor. Place the three washers over the three motor holes (not over the encoder
bracket hole), route the encoder cable through the slot in the flywheel cover, and align with the motor
holes. The washers make up the difference in height for the encoder bracket arm.

Place the four cover screws thru the cover and secure with the Phillips screwdriver while making sure
the encoder cable fits loose in the flywheel cover. This will securely capture the encoder housing and
bracket. Below is a finished view.

Mount the FEN-01 module

If you need to, refer to the FEN-01 manual (3AFE68784603) for additional instructions.
Mount the FEN module in slot 2 or any other desired slot (parameter list below reflects
slot 2 mounting). Secure the module with the push tab and the T10 Torx grounding screw.

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Mount the FETA-01 adapter
Using the installation instructions (3AXD50000206063), secure the FETA-01 adapter card
to the FEN-01 module.

Wire the encoder to the FETA-01 module

The encoder module wiring is defined in the table below. Connect the color codes
correctly to the FETA-01 using the 3.5mm flat screwdriver. Encoder leads are tinned for
your convenience.

Signal A A’ B B’ Z Z’ +V Com Shield

Wire Color Brown Yellow Red Green Orange Blue White Black None
FETA-01 1 2 3 4 5 6 7 8 Black
X41Terminal term
block

Terminal numbers on the FETA-01 are difficult to see. Note that X41 is the terminal wired
and that 1 is on the left with the brown wire.

Mount the drive cover.

Wiring is complete and you can install the cover on the drive.

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Power the drive
Plug the power cable into the back of the demo and turn on power.

Program the FEN-01 module

The following parameters are used to program the FEN-01 module in Slot 2:

Parameter 91.11 91.12 92.1 92.10 92.12

Name Module 1 Module 1 Encoder 1 Pulses per Speed Calculation
Type Location Type Revolution Mode
Value FEN-01 Slot 2 TTL 1024 A&B all

Refresh the drive parameters using parameter 91.10 Encoder Parameter Refresh or cycle
power.

Make sure the motor and encoder electrically are in the same direction
• Run the drive in the positive direction. This should be clockwise as you face the
drive shaft end. If turning the opposite, reverse two motor leads. Be careful to pull
the power on the drive demo and wait 10 minutes for the bus to discharge before
removing the drive cover.
• Observe Parameter 1.04 Encoder 1 speed filtered to see if the encoder speed is
positive. If not either reverse A and B channels on the encoder.
• Restart the drive and confirm the motor and encoder are both in the same
direction.

Close the speed loop on the drive

If at this time you want to close the drive speed loop, set parameter 90.41 to Encoder 1.

Backup drive parameters

Backup the parameters and the installation is complete.

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