ABB ACS880-01 - Page 171

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Maintenance 171

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Table of Contents5
Safety Instructions15
Contents of this Chapter15
Use of Warnings and Notes15
General Safety in Installation, Start-Up and Maintenance16
Electrical Safety in Installation, Start-Up and Maintenance17
Electrical Safety Precautions17
Additional Instructions and Notes18
Optical Components19
Printed Circuit Boards19
Grounding19
General Safety in Operation21
Additional Instructions for Permanent Magnet Motor Drives21
Safety in Installation, Start-Up, Maintenance21
Safety in Operation22
Introduction to the Manual23
Contents of this Chapter23
Applicability23
Target Audience23
Categorization by Frame Size and Option Code23
Quick Installation, Commissioning and Operation Flowchart24
Terms and Abbreviations25
Related Manuals26
Operation Principle and Hardware Description29
Contents of this Chapter29
Product Overview29
Main Circuit30
Layout31
IP21, UL Type 131
IP55 (Option +B056)32
UL Type 12 (Option +B056)33
IP20 (UL Type Open, Options +P940 and +P944)33
Overview of Power and Control Connections34
Control Panel35
Control Panel Mounting Platform Cover35
Control Panel Door Mounting Kits35
Type Designation Label36
Type Designation Key36
Basic Code37
Option Codes37
Mechanical Installation41
Contents of this Chapter41
Safety41
Mounting Orientations42
Required Free Space42
Examining the Installation Site42
Required Tools43
Moving the Drive43
Unpacking and Examining the Delivery43
Package of Frames R1 to R544
Frame R5 Cable Box (IP21, UL Type 1)46
Package of Frames R6 and R747
Frame R6 Cable Box (IP21, UL Type 1)49
Frame R7 Cable Box (IP21, UL Type 1)50
Package of Frames R8 and R951
Frame R8 Cable Box (IP21, UL Type 1)53
Frame R9 Cable Box (IP21, UL Type 1)54
Installing the Drive54
Vibration Dampers (Option +C131)54
Flange Mounting (Option +C135)55
Gland Plate (Option +H358)55
Cabinet Installation (Options +P940 and +P944)55
Frames R1 to R4 (IP21, UL Type 1)56
Frames R5 to R9 (IP21, UL Type 1)57
Frames R1 to R9 (IP55, UL Type 12)59
Guidelines for Planning the Electrical Installation61
Contents of this Chapter61
Limitation of Liability61
Selecting the Main Supply Disconnecting Device61
European Union62
North America62
Other Regions62
Selecting the Main Contactor62
Examining the Compatibility of the Motor and Drive62
Protecting the Motor Insulation and Bearings63
Requirements Table63
Availability of Du/Dt Filter and Common Mode Filter by Drive Type66
Additional Requirements for Explosion-Safe (EX) Motors66
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and am66
Additional Requirements for Braking Applications66
Additional Requirements for ABB High-Output and IP23 Motors66
Additional Requirements for Non-ABB High-Output and IP23 Motors67
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage68
Additional Note for Sine Filters69
Selecting the Power Cables69
General Guidelines69
Typical Power Cable Sizes70
Power Cable Types71
Preferred Power Cable Types71
Alternate Power Cable Types72
Not Allowed Power Cable Types73
Additional Guidelines, North America73
Metal Conduit74
Power Cable Shield74
Selecting the Control Cables75
Shielding75
Signals in Separate Cables75
Signals that Can be Run in the same Cable75
Relay Cable75
Control Panel to Drive Cable75
PC Tool Cable75
Routing the Cables76
General Guidelines - IEC76
General Guidelines - North America76
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable77
Separate Control Cable Ducts78
Implementing Short-Circuit and Thermal Overload Protection78
Protecting the Drive and the Input Power Cable in Short-Circuits78
Protecting the Motor and Motor Cable in Short-Circuits79
Protecting the Motor Cables against Thermal Overload79
Protecting the Motor against Thermal Overload79
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors Using an External Overload Device79
Protecting the Drive against Ground Faults80
Residual Current Device Compatibility80
Connecting Drives to a Common DC System80
Implementing the Emergency Stop Function80
Implementing the Safe Torque off Function80
Implementing the Functions Provided by the FSO-XX Safety Functions Module80
Implementing an ATEX-Certified Motor Thermal Protection81
Implementing the Power-Loss Ride-Through Function81
Using Power Factor Compensation Capacitors with the Drive81
Controlling a Contactor between Drive and Motor82
Implementing a Bypass Connection82
Example Bypass Connection83
Switching the Motor Power Supply from Drive to Direct-On-Line85
Switching the Motor Power Supply from Direct-On-Line to Drive85
Protecting the Contacts of Relay Outputs85
Implementing a Motor Temperature Sensor Connection86
Connecting Motor Temperature Sensor to the Drive Via an Option Module87
Connection of Motor Temperature Sensor to the Drive Via a Relay88
Ptc (Iec 60800-5-1)88
Pt100 (IEC 90800-5-1)88
Electrical Installation - IEC89
Contents of this Chapter89
Safety89
Required Tools89
Grounding the Motor Cable Shield at the Motor End89
Measuring the Insulation90
Measuring the Insulation of the Drive90
Measuring the Insulation of the Input Power Cable90
Measuring the Insulation of the Motor and Motor Cable90
Measuring the Insulation of the Brake Resistor Circuit91
Grounding System Compatibility Check91
Corner-Grounded and Midpoint-Grounded 52592
Connecting the Power Cables92
Connection Diagram92
Connection Procedure for Frames R1 to R394
Connection Procedure for Frames R4 and R597
Connection Procedure for Frames R6 to R9102
Connecting the Control Cables108
Connection Process108
Connecting a PC110
Panel Bus (Control of Several Units from One Control Panel)110
Installing Option Modules114
Installing FSO-XX Safety Functions Modules115
Installation Procedure116
Electrical Installation - North America117
Contents of this Chapter117
Safety117
Required Tools117
Measuring the Insulation117
Grounding System Compatibility Check118
Corner-Grounded and Midpoint-Grounded 525118
Connecting the Power Cables118
Connection Diagram with Conduits118
Connection Procedure for Frames R1 to R3120
Connection Procedure for Frames R4 and R5123
Connection Procedure for Frames R6 to R9127
Connecting the Control Cables131
Connection Procedure for Frames R1 to R3131
Connection Procedure for Frames R4 to R5133
Connection Procedure for Frames R6 to R9134
Connecting a PC137
Panel Bus (Control of Several Units from One Control Panel)137
Installing Option Modules140
Control Units of the Drive141
Contents of this Chapter141
ZCU-12 Layout142
Default I/O Diagram of the Drive Control Unit (ZCU-1X)143
Additional Information on the Connections145
External Power Supply for the Control Unit (XPOW)145
DI6 as a PTC Sensor Input145
AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 Sensor Input145
DIIL Input146
The XD2D Connector146
Safe Torque off (XSTO)147
FSO-XX Safety Functions Module Connection (X12)147
Connector Data148
ZCU-1X Ground Isolation Diagram150
Installation Checklist151
Contents of this Chapter151
Checklist151
Start-Up155
Contents of this Chapter155
Start-Up Procedure155
Fault Tracing157
Contents of this Chapter157
Leds157
Warning and Fault Messages157
Maintenance159
Contents of this Chapter159
Maintenace Intervals159
Descriptions of Symbols160
Recommended Annual Maintenance Actions by the User160
Recommended Maintenance Intervals after Start-Up160
Heatsink160
Fans161
Replacing the Main Cooling Fan of Frames R1 to R3162
Replacing the Auxiliary Cooling Fan of IP55 Frames R1 to R3163
Replacing the Main Cooling Fan of Frames R4 and R5165
Replacing the Auxiliary Cooling Fan of Frames R4 and R5166
Replacing the Main Cooling Fan of Frames R6 to R8168
Replacing the Auxiliary Cooling Fan of Frames R6 to R9 (IP21, UL Type 1)169
Replacing the Auxiliary Cooling Fan of Frames R8 and R9 (IP55, UL Type 12)170
Replacing the Main Cooling Fans of Frame R9172
Replacing the Drive (IP21, UL Type 1, Frames R1 to R9)172
Capacitors174
Reforming the Capacitors174
Control Panel174
Control Unit174
Replacing the Memory Unit of ZCU-12174
Replacing the ZCU-12 Control Unit Battery175
Replacing Safety Functions Modules (FSO-12, Option +Q973 and FSO-21, Option +Q972)175
Technical Data177
Contents of this Chapter177
Marine Type-Approved Drives (Option +C132)177
Drives for Synrm Motors177
Ratings177
Definitions183
Derating184
Surrounding Air Temperature Derating184
IP21 (UL Type 1) Drives and IP55 (UL Type 12) Frames R1184
IP55 (UL Type 12) Frames R8 and R9184
Altitude Derating186
Deratings for Special Settings in the Drive Control Program187
Ex Motor, Sine Filter, Low Noise187
Definitions190
Definitions192
High Speed Mode193
Definitions195
Fuses (IEC)196
Ar Fuses DIN 43653 Stud-Mount (Frames R1 to R9)196
Ar Fuses DIN 43620 Blade Style (Frames R1 to R9)200
Gg Fuses DIN 43620 Blade Style (Frames R1 to R9)203
Quick Guide for Selecting between Gg and Ar Fuses206
Calculating the Short-Circuit Current of the Installation209
Calculation Example210
Fuses (UL)210
Circuit Breakers (IEC)213
ABB Miniature and Molded Case Circuit Breakers213
Circuit Breakers (UL)216
ABB Inverse Time Circuit Breakers216
Dimensions, Weights and Free Space Requirements217
Definitions219
Package Dimensions219
Free Space Requirements220
Losses, Cooling Data and Noise220
Cooling Air Flow and Heat Dissipation for Flange Mounting (Option +C135)222
Connector and Entry Data for the Power Cables225
Iec225
UL Listed Cable Lugs and Tools227
Connector Data for the Control Cables228
Typical Power Cable Sizes228
Electrical Power Network Specification231
Motor Connection Data232
Efficiency233
Protection Classes233
Ambient Conditions233
Materials235
Applicable Standards236
Markings237
Compliance with the en 61800-3:204 + A1:2012238
Definitions238
Category C2238
Category C3239
Category C4239
UL and CSA Checklist240
Approvals241
Design Lifetime Expectancy242
Disclaimers242
Generic Disclaimer242
Cybersecurity Disclaimer242
Dimension Drawings243
Contents of this Chapter243
Frame R1 (IP21, UL Type 1)244
Frame R1 (IP55, UL Type 12)245
Frame R2 (IP21, UL Type 1)246
Frame R2 (IP55, UL Type 12)247
Frame R3 (IP21, UL Type 1)248
Frame R3 (IP55, UL Type 12)249
Frame R4 (IP21, UL Type 1)250
Frame R4 (IP55, UL Type 12)251
Frame R5 (IP21, UL Type 1)252
Frame R5 (IP55, UL Type 12)253
Frame R6 (IP21, UL Type 1)254
Frame R6 (IP55, UL Type 12)255
Frame R7 (IP21, UL Type 1)256
Frame R7 (IP55, UL Type 12)257
Frame R8 (IP21, UL Type 1)258
Frame R8 (IP55, UL Type 12)259
Frame R9 (IP21, UL Type 1)260
Frame R9 (IP55, UL Type 12)261
Resistor Braking263
Contents of this Chapter263
Operation Principle and Hardware Description263
Planning the Braking System263
Selecting the Brake Circuit Components263
Selecting a Custom Resistor264
Selecting and Routing the Brake Resistor Cables265
Minimizing Electromagnetic Interference265
Maximum Cable Length265
EMC Compliance of the Complete Installation265
Placing the Brake Resistors265
Protecting the System against Thermal Overload266
Frames R1 to R4266
Frames R5 to R9266
Protecting the Resistor Cable against Short-Circuits267
Mechanical Installation267
Electrical Installation267
Measuring the Insulation of the Assembly267
Connection Diagram267
Connection Procedure267
Start-Up268
Technical Data268
Ratings268
Degree of Protection and Thermal Constant of the Resistor271
Dimensions and Weights of External Resistors272
Sace08Re44273
SACE15RE13 and SACE15RE2274
SAFUR80F500 and SAFUR90F575274
SAFUR125F500 and SAFUR200F500275
The Safe Torque off Function277
Contents of this Chapter277
Description277
Compliance with the European Machinery Directive278
Wiring279
Activation Switch279
Cable Types and Lengths279
Grounding of Protective Shields279
Single Drive (Internal Power Supply)280
Dual-Channel Connection280
Single-Channel Connection281
Multiple Drives282
Internal Power Supply282
External Power Supply283
Operation Principle284
Start-Up Including Acceptance Test285
Competence285
Acceptance Test Reports285
Acceptance Test Procedure285
Use287
Maintenance288
Competence288
Fault Tracing289
Safety Data290
Abbreviations292
TÜV Certificate293
Declaration of Conformity294
Filters295
Contents of this Chapter295
When Is a Common Mode Filter or Du/Dt Filter Needed295
Common Mode Filters295
Du/Dt Filters296
Du/Dt Filter Types296
Description, Installation and Technical Data of the Du/Dt Filters296
Sine Filters297
Selecting a Sine Filter for a Drive297
Definitions299
Derating299
Description, Installation and Technical Data299

ABB ACS880-01 - Page 171

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