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ACQ80-04 Series
ABB ACQ80-04 Series User Manual
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Drive
1
Control
board
2
Control
logic
3
T
o
motor
4
Activation
switch
K
￭
Wiring
examples
(R0…R2)
Wiring
with
internal
power
supply
24
14
23
13
Y1
A2
Y2
A1
31
32
OUT
GND
IN1
OUT
1
IN2
SG
ND
K
1
2
Drive
1
Safety
PLC
2
Safety
relay
K
Wiring
with
external
power
supply
24
14
23
13
Y1
A2
Y2
A1
31
32
OUT
GND
IN1
OUT
1
ÍN2
SG
ND
K
-
+
1
2
24
V
DC
Drive
1
Safety
PLC
2
Safety
relay
K
150
The
Safe
torque
off
function
149
151
Table of Contents
Default Chapter
5
Table of Contents
5
1 Safety Instructions
11
Contents of this Chapter
11
Use of Warnings and Notes
11
General Safety in Installation, Start-Up and Maintenance
12
Electrical Safety in Installation, Start-Up and Maintenance
14
Electrical Safety Precautions
14
Additional Instructions and Notes
14
Optical Components
15
Printed Circuit Boards
15
Grounding
15
Additional Instructions for Permanent Magnet Motor Drives
17
Safety in Installation, Start-Up, Maintenance
17
Safety in Operation
17
2 Introduction to the Manual
19
Contents of this Chapter
19
Applicability
19
Target Audience
19
Purpose of the Manual
19
Categorization by Frame (Size)
19
Quick Installation and Commissioning Flowchart
20
Terms and Abbreviations
21
Related Documents
22
3 Operation Principle and Hardware Description
25
Contents of this Chapter
25
Operation Principle
25
Layout
26
Frames R0
26
Frame Size R3
28
Frame R4
29
Overview of Power and Control Connections
29
External Control Connecting Terminal, Frame Size R0
30
External Control Connecting Terminal, Frame Size R3
31
External Control Connection Terminals, Frames R6
32
Control Panel
33
Type Designation Label
34
Locations of the Labels on the Drive
35
Type Designation Key
36
4 Mechanical Installation
39
Contents of this Chapter
39
Safety
39
Checking the Installation Site
40
Required Tools
41
Moving the Drive
41
Unpacking and Examining Delivery, Frames R0
42
Unpacking and Examining Delivery, Frames R3
42
Unpacking and Examining Delivery, Frames R5
43
Unpacking and Examining Delivery, Frames R6
44
Installing the Drive
46
Installing the Drive Vertically, Frames Size R0
46
Installing the Drive Vertically, Frame Size R3
47
Installing the Drive Vertically, Frames Size R5
48
Installing the Drive Vertically Side by Side
49
Installing the Drive Horizontally Side by Side
49
5 Planning the Electrical Installation
51
Contents of this Chapter
51
Selecting the Supply Disconnecting Device
51
European Union
51
Other Regions
52
Checking the Compatibility of the Motor and Drive
52
Selecting the Power Cables
52
General Rules
52
Typical Power Cable Sizes
52
Alternative Power Cable Types
53
Recommended Power Cable Types
54
Power Cable Types for Limited Use
54
Not Allowed Power Cable Types
54
Motor Cable Shield
54
Conduit
55
Armored Cable / Shielded Power Cable
55
Selecting the Control Cables
55
Shielding
55
Signals in Separate Cables
56
Signals Allowed to be Run in the same Cable
56
Relay Cable
56
Control Panel Cable
56
Drive Composer PC Tool Cable
56
Routing the Cables
57
General Guidelines, IEC
57
General Guidelines, North America
58
Continuous Motor Cable Shield or Enclosure for Equipment on the Motor Cable
59
Separate Control Cable Ducts
59
Implementing Thermal Overload and Short-Circuit Protection
59
Protecting the Input Cabling and the Drive Upon a Short-Circuit
59
Protecting the Motor and Motor Cable in Short-Circuits
59
Protecting the Drive and the Power Cables against Thermal Overload
59
Protecting the Motor against Thermal Overload
60
Protecting the Drive against Ground Faults
60
Residual Current Device Compatibility
60
Implementing the Emergency Stop Function
60
Implementing the Safe Torque off Function
60
Implementing the Undervoltage Control (Power-Loss Ride-Through)
60
Using a Contactor between the Drive and the Motor
61
Implementing a Bypass Connection
61
Example Bypass Connection
61
Switching the Motor Power Supply from Drive to Direct-On-Line
62
Switching the Motor Power Supply from Direct-On-Line to Drive
63
Protecting the Contacts of Relay Outputs
63
6 Electrical Installation
65
Contents of this Chapter
65
Warnings
65
Required Tools
65
Checking the Insulation of the Assembly
65
Drive
65
Input Power Cable
66
Checking the Insulation of the Motor and Motor Cable
66
Checking the Compatibility with IT (Ungrounded) and Corner-Grounded TN Systems
66
EMC Filter
66
Ground-To-Phase Varistor
67
Frames R0
67
Frames R4
68
Connecting the Power Cables
70
Connection Diagram
70
Connection Procedure: Frames R0
72
Motor Cable
72
Input Power Cable
73
Finalization
74
Connection Procedure, Frames R3
76
Motor Cable
76
Note
77
Input Power Cable
77
Finalization
78
Connection Procedure, Frames R5
80
Motor Cable
80
Input Power Cable
81
DC Connection
84
Connecting the Control Cables
84
Default Control Connections of ABB Standard Macro
85
Connection Diagram
85
Terminal Sizes
85
Notes
86
Switches
86
PNP Configuration for Digital Inputs
86
NPN Configuration for Digital Inputs
87
Connection for Obtaining 0
87
Connection Examples of Two-Wire and Three-Wire Sensors
88
DI5 as Frequency Input
89
AI1 and AI2 as Pt100 Sensor Inputs (X1)
89
Safe Torque off (X4)
89
Control Cable Connection Procedure R0
90
R0...R2
91
R3...R5
92
Option Modules
93
To Install a Front Option
93
R6...R8
93
Front Option Slot
94
To Remove a Front Option
95
Wiring the Modules
95
Reinstalling Covers
95
Reinstalling Cover, Frames Size R0
95
Reinstalling Covers, Frame Size
95
Reinstalling Side Plates and Covers, Frames Size R5
96
Connecting a PC
96
7 Installation Checklist of the Drive
99
Contents of this Chapter
99
Checklist
99
8 Maintenance and Hardware Diagnostics
101
Contents of this Chapter
101
Maintenance Intervals
101
Description of Symbols
101
Recommended Annual Maintenance Actions by the User
102
Recommended Maintenance Action by the User
102
Heatsink
103
Fans
103
Replacing the Cooling Fan, Frames Size R0
104
Replacing the Main Cooling Fan, Frame R5
104
Replacing the Main Cooling Fan, Frames Size R6
105
Replacing the Auxiliary Cooling Fan, Frames R6
106
Capacitors
107
Reforming the Capacitors
107
Control Panel
107
Cleaning the Control Panel
107
Replacing the Battery in the Control Panel
107
Leds
108
Drive Leds (R3~R8)
108
Control Panel Leds
108
9 Technical Data
111
Contents of this Chapter
111
Ratings
111
IEC Ratings
111
Definitions
112
Sizing
112
Derating
113
Ambient Temperature Derating, IP20
113
Switching Frequency Derating
114
Altitude Derating
115
Fuses (IEC)
115
Ur and Ar Fuse
115
Gg Fuses
116
Gr Fuses
117
DC Fuses
118
Circuit Breakers
119
Dimensions, Weights and Free Space Requirements
120
Standard Frame Size (R0-R8)
120
Thermal Losses, Cooling Data and Noise
121
Terminal and Lead-Through Data for the Power Cables
122
Terminal and Lead-Through Data for the Control Cables
123
Electrical Power Network Specification
124
Motor Connection Data
124
EMC Compatibility and Motor Cable Length
125
Control Connection Data
126
Auxiliary Circuit Power Consumption
130
Efficiency
131
Degree of Protection
131
Ambient Conditions
131
For R0
131
For R3
132
Materials
133
Applicable Standards
133
CE Marking
134
Compliance with the European EMC Directive
134
Compliance with the European ROHS II Directive 2011/65/EU
134
Compliance with the en 61800-3:2004 + A1:2012
134
Definitions
134
Category C1
135
Category C2
135
Category C3
135
Category C4
136
10 Dimension Drawings
137
Contents of this Chapter
137
Frame R0, IP20
138
Frame R1, IP20
139
Frame R3, IP20
140
Frame R4, IP20
141
Frame R5, IP20
142
Frame R6, IP20
143
Frame R7, IP20
144
Frame R8, IP20
145
11 The Safe Torque off Function
147
Contents of this Chapter
147
Description
147
Compliance with the European Machinery Directive
148
Wiring
149
Connection Principle (R0
149
Connection with Internal Power Supply
149
Connection with External Power Supply
149
Wiring Examples (R0
150
Wiring with Internal Power Supply
150
Wiring with External Power Supply
150
Connection Principle (R3
151
Connection with Internal Power Supply
151
Connection with External Power Supply
151
Wiring Examples (R3
152
Wiring with Internal Power Supply
152
Wiring with External Power Supply
152
Activation Switch
152
Cable Types and Lengths
153
Grounding of Protective Shields
153
Operation Principle
154
Start-Up Including Acceptance Test
155
Competence
155
Acceptance Test Reports
155
Acceptance Test Procedure
155
Use
157
Maintenance
158
Competence
158
Fault Tracing
159
Safety Data
160
Abbreviations
161
12 BIO-01 I/O Extension Module
163
Contents of this Chapter
163
Safety Instructions
163
BIO-01 Product Overview
163
Layout
164
Mechanical Installation
164
Electrical Installation
165
Start-Up
166
Technical Data
166
Control Connection Data
166
Dimensions
167
Further Information
169
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ABB ACQ80-04 Series Specifications
General
Brand
ABB
Model
ACQ80-04 Series
Category
Controller
Language
English
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