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ABB
DC Drives
ACS880-07
Hardware Manual
Page 288 (MM, Without Main Breaker, Bottom Cable Entry (Including 12-Pulse Units with Grounding Switch))
ABB ACS880-07 - MM, Without Main Breaker, Bottom Cable Entry (Including 12-Pulse Units with Grounding Switch); MM, Without Main Breaker, Top Cable Entry (Including 12-Pulse Units with Grounding Switch)
344 pages
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￭
600
mm,
without
main
breaker,
bottom
cable
entry
(including
12-pulse
units
with
grounding
switch)
￭
600
mm,
without
main
breaker,
top
cable
entry
(including
12-pulse
units
with
grounding
switch)
288
Dimensions
287
289
Table of Contents
Main Page
Section 1
5
Table of Contents
5
Section 2
13
Table of Contents
13
Contents of this Chapter
17
Safety Instructions
17
Use of Warnings and Notes
17
General Safety in Installation, Start-Up and Maintenance
18
Electrical Safety in Installation, Start-Up and Maintenance
21
Electrical Safety Precautions
21
Additional Instructions and Notes
22
Grounding
23
Printed Circuit Boards
23
Additional Instructions for Permanent Magnet Motor Drives
24
General Safety in Operation
24
Safety in Installation, Start-Up, Maintenance
24
Safety in Operation
25
Categorization by Frame Size and Option Code
27
Contents of this Chapter
27
Introduction to the Manual
27
Target Audience
27
Quick Installation, Commissioning and Operation Flowchart
28
Use of Component Designations
28
Related Documents
29
Terms and Abbreviations
29
Contents of this Chapter
31
Operation Principle
31
Operation Principle and Hardware Description
31
Overview Circuit Diagram of the Drive
32
12-Pulse Connection (Option +A004)
33
Cabinet Line-Up and Layout Examples
34
Frame 1×D8T+2×R8I
34
Frame 2×D7T+2×R8I (12-Pulse Connection, Option +A004)
36
Frame 2×D8T+3×R8I
38
Frame 3×D8T+4×R8I (with Main Breaker, Option +F255)
40
Auxiliary Control Cubicle (ACU) Layout
42
Overview of Power and Control Connections (BCU-X2)
44
Overview of Power and Control Connections (UCU-22
46
Door Devices
48
Auxiliary Voltage Switch [Q21]
49
Grounding (Earthing) Switch [Q9], Optional
49
Main Disconnecting Device (Q1.1)
49
Other Devices on the Door
49
Control by PC Tools
50
Control Panel
50
Definitions
51
Degree of Protection
51
Descriptions of Options
51
IP22 (UL Type 1)
51
IP42 (UL Type 1 Filtered) (Option +B054)
51
IP54 (UL Type 12) (Option +B055)
51
Marine Construction (Option +C121)
51
Channeled Air Outlet (Option +C130)
52
Cooling Air Inlet through Bottom of Cabinet (Option +C128)
52
CSA Approved (Option +C134)
52
Plinth Height (Options +C164 and +C179)
52
Seismic Design (Option +C180)
52
UL Listed (Option +C129)
52
Cabinet Heater with External Supply (Option +G300)
53
Cabinet Lighting (Option +G301)
53
EMC Filter (Option +E202)
53
Empty Cubicles on Left (Options +C199
53
Resistor Braking (Options +D150 and +D151)
53
Sine Filter (Option +E206)
53
Terminals for External Control Voltage (Option +G307)
53
Halogen-Free Wiring and Materials (Option +G330)
54
Output for Motor Space Heater (Option +G313)
54
Ready/Run/Fault Lights (Options +G327
54
Standard Wiring
54
Supply Connection by Busbars (Option +G317)
54
V-Meter with Selector Switch (Option +G334)
54
Wire Markings
54
Additional Wire Markings
55
Bottom Cable Entry/Exit (Options +H350 and +H352)
55
Common Mode Filter Temperature Monitoring (Option +G453)
55
Cable Conduit Entry (Option +H358)
56
Common Motor Terminal Cubicle (Option +H359)
56
Common Output Terminals (Option +H366)
56
Top Cable Entry/Exit (Options +H351 and +H353)
56
Additional Terminal Block X504 (Option +L504)
57
Connectivity for Wired Remote Monitoring (Option +K496)
57
Connectivity for Wireless Remote Monitoring (Option +K497)
57
Thermal Protection with PTC Relays (Options +L505, +2L505, +L513, +2L513, +L536, +L537)
57
L505, +2L505, +L513, +2L513
58
L536, +L537
58
Thermal Protection with Pt100 Relays (Options +Nl506, +Nl514)
58
Description
59
Starter for Auxiliary Motor Fan (Options +M600
59
What the Option Contains
59
Type Designation Label
60
Option Codes
61
Type Designation Key
61
Contents of this Chapter
67
Mechanical Installation
67
Examining the Delivery
68
Examining the Installation Site
68
Necessary Tools
68
Lifting the Crate with a Forklift
69
Moving and Unpacking the Drive
69
Moving the Drive in Its Packaging
69
Lifting the Crate with a Crane
70
Moving the Crate with a Forklift
71
Removing the Transport Package
71
Lifting the Cabinet with a Crane
72
Moving the Cabinet on Rollers
72
Moving the Unpacked Drive Cabinet
72
Moving the Cabinet on Its Back
73
Moving the Cabinet to Its Final Position
73
Attaching the Cabinet to the Floor and Wall or Roof
74
General Rules
74
Alternative 1 - Clamping
75
Attaching the Cabinet (Non-Marine Units)
75
Alternative 2 - Using the Holes Inside the Cabinet
76
Alternative 3 - Cabinets with Plinth Options +C164 and +C179
76
Attaching the Cabinet (Marine Units)
77
Joining Cabinet Sections Together
78
Air Inlet through the Bottom of the Cabinet (Option +C128)
82
Arc Welding
82
Cable Duct in the Floor below the Cabinet
82
Miscellaneous
82
Air Outlet Duct on the Cabinet Roof (Option +C130)
83
Calculating the Required Static Pressure Difference
84
Certificate of Conformity
84
Lifting Lugs and Bars
84
Declarations of Conformity
85
Contents of this Chapter
89
Guidelines for Planning the Electrical Installation
89
Limitation of Liability
89
North America
89
A Drive with a 12-Pulse Diode Supply Unit
90
Additional Notes
90
Basic Guidelines
90
Selecting the Supply Transformer
90
Examining the Compatibility of the Motor and Drive
92
Protecting the Motor Insulation and Bearings
92
Selecting the Main Contactor or Breaker
92
Selecting the Supply Disconnecting Device
92
Requirements for ABB Motors, P
93
Requirements Tables
93
Requirements for ABB Motors, P
94
Requirements for Non-ABB Motors, P
95
Abbreviations
96
Availability of D U /D T Filter and Common Mode Filter by Drive Type
96
Requirements for Non-ABB Motors, P
96
Additional Requirements for ABB High-Output and IP23 Motors
97
Additional Requirements for Braking Applications
97
Additional Requirements for Explosion-Safe (EX) Motors
97
Additional Requirements for Non-ABB High-Output and IP23 Motors
97
And AX
97
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
98
Additional Note for Sine Filters
99
General Guidelines
100
Power Cable Selection Procedure and Applicability Check
100
Selecting the Power Cables
100
Typical Power Cable Sizes
100
Alternate Power Cable Types
101
Power Cable Types
101
Preferred Power Cable Types
101
Not Allowed Power Cable Types
102
Power Cable Shield
102
Grounding Requirements
103
Additional Grounding Requirements - IEC
104
Additional Grounding Requirements - UL (NEC)
104
Selecting the Control Cables
104
Shielding
104
Control Panel to Drive Cable
105
General Guidelines - IEC
105
PC Tool Cable
105
Relay Cable
105
Routing the Cables
105
Signals in Separate Cables
105
Signals that Can be Run in the same Cable
105
Separate Control Cable Ducts
106
The Motor Cable
106
Protecting the Drive and the Power Cables against Thermal Overload
107
Protecting the Input Cabling and the Drive Upon a Short-Circuit
107
Protecting the Motor against Thermal Overload
107
Protecting the Motor and Motor Cable in Short-Circuits
107
Situations and against Thermal Overload
107
Implementing the Emergency Stop Function
108
Protecting the Drive against Ground Faults
108
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
108
Residual Current Device Compatibility
108
Implementing an ATEX-Certified Motor Thermal Protection
109
Implementing the Prevention of Unexpected Start-Up Function
109
Implementing the Safe Torque off Function
109
Implementing a Bypass Connection
110
Implementing the Functions Provided by the FSO Safety Functions Module
110
Implementing the Power Loss Ride-Through Function
110
Supplying Power for the Auxiliary Circuits
111
Using a Safety Switch between the Drive and the Motor
111
Using Power Factor Compensation Capacitors with the Drive
111
Implementing the Control of a Contactor between Drive and Motor
112
Protecting the Contacts of Relay Outputs
112
Implementing a Motor Temperature Sensor Connection
113
Connecting a Motor Temperature Sensor to the Drive through an Option Module
114
Contents of this Chapter
115
Electrical Installation
115
Measuring the Insulation
115
Measuring the Insulation Resistance of the Drive
115
Warnings
115
Attaching the Device Stickers to the Cabinet Door
116
Compatibility Check - IT (Ungrounded) Earthing System
116
Measuring the Insulation Resistance of the Input Power Cable
116
Measuring the Insulation Resistance of the Motor and Motor Cable
116
Checking the Settings of Transformers T21, T101 and T111
117
T21 and T101 Tap Settings (400
117
T21 and T101 Tap Settings (690 V Units)
118
T111 Tap Settings
119
Connecting the Control Cables
120
Control Cable Connection Procedure
120
Grounding the Outer Shields of the Control Cables 360° at the Cabinet Entry
120
Connecting Control Cabling
122
Routing the Control Cables Inside the Cabinet
122
Connecting the Motor Cables (Units Without Common Motor Terminal Cubicle or Sine Output Filter)
123
Motor Connection Diagram (with Option +H366)
124
Motor Connection Diagram (Without Option +H366)
124
Procedure
125
Removing an Inverter Module
125
Removing the Fan Carriage of an Inverter Module
125
Connecting the Motor Cables
128
Connecting the Motor Cables (Units with Common Motor Terminal Cubicle or Sine Output Filter)
130
Connection Diagram
130
Installing an Inverter Module
130
Installing the Fan Carriage of an Inverter Module
130
Output Busbars
130
Procedure
130
Connecting an External Brake Resistor Assembly
131
Connecting the Input Power Cables
132
Connection Diagram, 12-Pulse Units
132
Connection Diagram, 6-Pulse Units
132
Connection Procedure
133
Layout of the Input Cable Connection Terminals and Cable Entries
133
Connecting a PC
135
Use of Fasteners in Cable Lug Connections
135
Panel Bus (Control of Several Units from One Control Panel)
136
Installation of an FSO Safety Functions Module Onto BCU
139
Installing Option Modules
139
Interface Modules
139
Mechanical Installation of I/O Extension, Fieldbus Adapter and Pulse Encoder
139
Wiring of Option Modules
141
Contents of this Chapter
143
Control Units of the Drive
143
General
143
BCU Layout
144
Default I/O Diagram of the Supply Control Unit (BCU-X2)
146
Default I/O Diagram of the Inverter Control Unit (BCU)
149
Ucu-22
153
Default I/O Diagram of the Supply Control Unit (UCU-22
156
Default I/O Diagram of the Inverter Control Unit (UCU-22
159
Additional Information on the Connections
163
DIIL Input
163
Power Supply for the Control Unit (XPOW)
163
The XD2D Connector
163
FSO Safety Functions Module Connection (X12, with BCU Only)
164
Microsdhc Memory Card Slot
164
Safe Torque off (XSTO, XSTO OUT)
164
SDHC Memory Card Slot
164
Connector Data
165
BCU Ground Isolation Diagram
168
Ucu-22
169
Checklist
171
Contents of this Chapter
171
Installation Checklist
171
Contents of this Chapter
173
Start-Up
173
Start-Up Procedure
173
Switching off the Drive
176
Contents of this Chapter
177
Control Unit Leds (BCU-X2)
177
Fault Tracing
177
Control Panel and Panel Platform/Holder Leds
178
Control Unit Leds (UCU-22
178
Warning and Fault Messages
178
Contents of this Chapter
179
Handling Fiber Optic Cables
179
Maintenance
179
Description of Symbols
180
Maintenance Intervals
180
Recommended Maintenance Intervals after Start-Up
181
Cabinet
183
Cleaning the Exterior of the Drive
183
Cleaning the Interior of the Cabinet
183
Cleaning the Door Air Inlets (IP22 and IP42)
184
Cleaning the Roof Outlet Filters (IP54)
185
Replacing the Inlet Door Filters (IP54)
185
Replacing the Roof Outlet Filters (IP54)
185
Fans
186
Replacing a Supply Module (D7T) Cooling Fan
186
Replacing a Supply Module (D8T) or Inverter Module (R8I) Cooling Fan
187
Replacing the Circuit Board Compartment Fan
188
Replacing the Cooling Fan in the Auxiliary Control Cubicle
190
Replacing the Cooling Fan in the Incoming Cubicle
190
Replacing the Roof Fan (IP54/UL Type 12)
191
Fan Attached to the Cabinet Door
192
Replacing the Common Motor Terminal Cubicle Fan
192
Roof Fan (with Options +C128 and +H353)
192
Floor Fan (with Options +C128 and +H353)
193
Replacing the Brake Chopper and Resistor Cubicle Fans (Options +D150 and +D151)
193
Replacing a Frame D7T Supply Module
194
Supply and Inverter Modules
194
Replacing a Frame D8T Supply Module
197
Removing an Inverter Module
202
Installing an Inverter Module
207
Activating the Reduced Run of the Supply Unit
209
Cleaning the Heatsink
209
Starting Reduced Run Operation
209
Activating the Reduced Run Function of the Inverter Unit
210
Resuming Normal Operation
210
Capacitors
212
Reforming the Capacitors
212
Returning the Module
212
Checking and Replacing the DC Fuses of a D7T Supply Module
213
Fuses
213
Checking and Replacing the DC Fuses of a D8T Supply Module
214
Control Panel
216
BCU Control Unit Types
217
Control Units
217
Replacing the BCU Control Unit Battery
217
Replacing the Memory Unit (BCU)
217
Replacing the Memory Unit (UCU-22
218
UCU Control Unit Types
218
Replacing the UCU Control Unit Battery
219
Replacing the Microsdhc Memory Card (UCU-22
220
Functional Safety Components
221
Contents of this Chapter
223
Ratings
223
Technical Data
223
Altitude Derating
225
Definitions
225
Derating
225
Surrounding Air Temperature Derating
225
Output Frequency Derating
226
Switching Frequency Derating
226
Frame Sizes and Power Module Types
227
AC Fuses
228
Fuses
228
DC Fuses
230
Brake Chopper DC Fuses
231
Fuses on CVAR Varistor Board
231
Supply Module Internal DC Fuses
231
Dimensions and Weights
232
Free Space Requirements
232
Losses, Cooling Data and Noise
232
Sine Output Filter Data
234
Typical Power Cable Sizes
235
Terminal and Cable Entry Data for the Power Cables
236
Terminal Data for the Motor Cables
236
Electrical Power Network Specification
237
Terminal Data for Block X504
237
Terminal Data for the Supply and Inverter Control Units
237
Efficiency
238
Energy Efficiency Data (Ecodesign)
238
Motor Connection Data
238
Protection Classes
238
Ambient Conditions
239
Storage Conditions
240
Transportation
240
Colors
241
Drive
241
Manuals
241
Materials
241
Packaging of Drive
241
Packaging of Options
241
Applicable Standards
242
Disposal
242
Markings
243
Category C2
244
Definitions
244
EMC Compliance (IEC/EN 61800-3)
244
Category C3
245
Category C4
245
UL and CSA Checklist
247
Cable Lugs
248
Electrical Connections
248
Insulation Supports
248
Mechanical Connections
248
Tightening Torques
248
Cyber Security Disclaimer
249
Disclaimers
249
Generic Disclaimer
249
Cabinet Line-Up Dimensions
251
Dimensions
251
Dimension Tables
252
Weights
260
Dimension Drawing Examples
261
Frame 2×D7T + 2×R8I, 12-Pulse (+A004)
261
Frame 1×D8T + 2×R8I (IP22)
262
Frame 1×D8T + 2×R8I, IP54 (+B055)
263
Frame 1×D8T + 2×R8I with Common Motor Terminal Cubicle (+H359), 1/2
264
Frame 1×D8T + 2×R8I with Common Motor Terminal Cubicle (+H359), 2/2
265
Frame 1×D8T + 2×R8I with Brake Choppers and Resistors (+D150 +D151), 1/2
266
Frame 1×D8T + 2×R8I with Brake Choppers and Resistors (+D150 +D151), 2/2
267
Frame 1×D8T + 2×R8I with Sine Output Filter (+E206), 1/2
268
Frame 1×D8T + 2×R8I with Sine Output Filter (+E206), 2/2
269
Frame 2×D8T + 2×R8I, 12-Pulse (+A004) with Grounding Switch (+F259)
270
Frame 2×D8T + 3×R8I, 1/2
271
Frame 2×D8T + 3×R8I, 2/2
272
Frame 2×D8T + 3×R8I with Common Motor Terminal Cubicle (+H359), 1/2
273
Frame 2×D8T + 3×R8I with Common Motor Terminal Cubicle (+H359), 2/2
274
Frame 2×D8T + 3×R8I with Top Entry / Top Exit (+H351/+H353), 1/2
275
Frame 2×D8T + 3×R8I with Top Entry/Top Exit, 2/2
276
Frame 3×D8T + 4×R8I, 1/2
277
Frame 3×D8T + 4×R8I, 2/2
278
Frame 3×D8T + 4×R8I with Common Motor Terminal Cubicle (+H359), 1/2
279
Frame 3×D8T + 4×R8I with Common Motor Terminal Cubicle (+H359), 2/2
280
Frame 3×D8T + 4×R8I with Top Entry / Top Exit (+H351/+H353), 1/2
281
Frame 3×D8T + 4×R8I with Top Entry / Top Exit (+H351/+H353), 2/2
282
Frame 4×D8T + 5×R8I (6-Pulse) with Top Entry/Exit, UL Listed (+C129), 1/2
283
Frame 4×D8T + 5×R8I (6-Pulse) with Top Entry/Exit, UL Listed (+C129), 2/2
284
Dimensions of Empty Cubicles (Options +C199, +C200, +C201)
285
Ip22/Ip42
285
Ip54
286
400 MM, Bottom Cable Entry
287
400 MM, Top Cable Entry
287
Location and Size of Input Terminals
287
MM, Without Main Breaker, Bottom Cable Entry (Including 12-Pulse Units with Grounding Switch)
288
MM, Without Main Breaker, Top Cable Entry (Including 12-Pulse Units with Grounding Switch)
288
600 MM, 12-Pulse Units Without Grounding Switch, Bottom Cable Entry
289
600 MM, 12-Pulse Units Without Grounding Switch, Top Cable Entry
289
600 MM, with Main Breaker, Bottom Cable Entry
290
600 MM, with Main Breaker, Top Cable Entry
290
1000 MM (UL/CSA), Top Cable Entry
291
1000 MM (UL/CSA), Bottom Cable Entry
292
Location and Size of Output Terminals
292
Units Without Common Motor Terminal Cubicle
292
Inverter Module Cubicle with Two R8I Modules, Bottom Cable Exit
293
Inverter Module Cubicle with Two R8I Modules, Top Cable Exit
294
Inverter Module Cubicle with Three R8I Modules, Bottom Cable Exit
295
Inverter Module Cubicle with Three R8I Modules, Top Cable Exit
296
Brake Chopper Cubicle
297
Sine Filter Cubicle, 1000 MM, Bottom Cable Exit
298
Sine Filter Cubicle, 1000 MM, Top Cable Exit
299
Cubicle Width 300 MM, Bottom Cable Exit
300
Units with Common Motor Terminal Cubicle (+H359)
300
Cubicle Width 300 MM, Top Cable Exit
301
Cubicle Width 400 MM, Bottom Cable Exit
302
Cubicle Width 400 MM, Top Cable Exit
303
Cubicle Width 600 MM, Bottom Cable Exit
304
Cubicle Width 600 MM, Top Cable Exit
305
Contents of this Chapter
307
Description
307
The Safe Torque off Function
307
Chinery (Safety) Regulations
308
Activation Switch
309
Cable Types and Lengths
309
Grounding of Protective Shields
309
Wiring
309
Dual-Channel Connection with Internal Power Supply (BCU-X2)
310
Dual-Channel Connection with Internal Power Supply (UCU-22
311
Single-Channel Connection of Activation Switch (BCU-X2)
312
Single-Channel Connection of Activation Switch (UCU-22
312
Internal Power Supply (Example, Drives with ZCU-XX and BCU-X2)
313
Multiple Drives
313
Internal Power Supply (Example, Drives with UCU-22
314
External Power Supply (Example, Drives with ZCU-XX and BCU-X2)
315
External Power Supply (Example, Drives with UCU-22
316
Operation Principle
317
Competence
318
Start-Up Including Validation Test
318
Validation Test Procedure
318
Validation Test Reports
318
Use
320
Competence
322
Maintenance
322
Perfect Proof Test Procedure
323
Simplified Proof Test Procedure
323
Fault Tracing
324
Safety Data
325
Terms and Abbreviations
327
TÜV Certificate
328
Declarations of Conformity
329
Contents of this Chapter
333
Operation Principle
333
Resistor Braking
333
Factory-Installed Brake Choppers and Resistors
334
Definitions
335
Ratings of Chopper/Resistor Combinations
335
Technical Data
335
SAFUR Resistor Data
336
Terminals and Cable Lead-Through Data of Factory-Installed Chopper/Resistor Cubicles
336
Calculating the Maximum Braking Power for a Custom Duty Cycle
337
Custom Resistor
337
Planning the Braking System
337
Verifying the Load Capacity of the Braking Equipment
337
Minimizing Electromagnetic Interference
338
Selecting and Routing the Cables of a Custom Resistor
338
Maximum Cable Length
339
Mechanical Installation of Custom Brake Resistors
339
Protecting the Brake System against Thermal Overload
339
Protecting the Resistor Cable against Short-Circuits
339
Selecting the Installation Location for the Brake Resistors
339
Thermal Protection of the Resistors
339
Connection Diagram
340
Connection Procedure
340
Electrical Installation of Custom Brake Resistors
340
Brake System Start-Up
341
Maintenance
342
Replacing the Brake Resistor Cabinet Fan
342
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