ABB ACS880-14 - Page 115

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Electrical installation 115

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Table of Contents5
Table of Contents7
Table of Contents9
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 Maintenance18
Electrical Safety Precautions18
Additional Instructions and Notes20
Optical Components20
Printed Circuit Boards20
Grounding21
General Safety in Operation22
Additional Instructions for Permanent Magnet Motor Drives22
Safety in Installation, Start-Up, Maintenance22
Safety in Operation23
Introduction to the Manual25
Contents of this Chapter25
Applicability25
Target Audience25
Purpose of the Manual25
Categorization by Frame Size and Option Code25
Quick Installation, Commissioning and Operating Flowchart26
Terms and Abbreviations27
Related Documents28
Operation Principle and Hardware Description31
Contents of this Chapter31
Operation Principle31
Block Diagram of the Main Circuit of the Drive Module32
Line-Side Converter32
AC Voltage and Current Waveforms33
Charging33
Motor-Side Converter33
Layout34
Standard Drive Module Configuration34
Drive Module35
LCL Filter Module36
Drive Module with Full Power Cabling Panels (Option +H381)37
Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) and IP20 Shrouds (Option +0B051) and with Common Mode Filter (Option +E208)38
Control Panel39
Overview of Power and Control Connections40
Type Designation Label41
Type Designation Key41
Basic Code41
Option Codes42
Generic Cabinet Planning Instructions45
Contents of this Chapter45
Limitation of Liability45
Cabinet Construction45
Disposition of the Devices45
Grounding of Mounting Structures46
Busbar Material and Joints46
Shrouds46
Tightening Torques46
Electrical Connections46
Mechanical Connections46
Insulation Supports47
Cable Lugs47
Cooling and Degrees of Protection47
Planning the Cooling47
Air Inlets and Outlets47
Preventing the Recirculation of Hot Air49
EMC Requirements49
Attaching the Cabinet51
Cabinet Placement on a Cable Channel52
Heaters52
Mounting the Control Panel on the Cabinet Door53
Guidelines for Planning the Mechanical Installation55
Contents of this Chapter55
Installation Positions of the Drive Module55
Layout Example, Door Closed56
Layout Example, Door Open (Standard Drive Module Configuration)57
Layout Example, Door Open (Option +0B051)58
Cooling Solutions59
Preventing the Recirculation of Hot Air60
Bookshelf Mounting (Standard Drive Module Configuration)60
Bookshelf Mounting (Option +0B051)61
Bookshelf Mounting (Option +H381)62
Required Free Space62
Free Space at the Top of the Drive Module62
Free Space Around the Drive Module63
ABB Air Inlet and Outlet Kits63
Mechanical Installation65
Contents of this Chapter65
Examining the Installation Site65
Moving and Unpacking65
Package Drawings66
Drive Module Package Without Option +E20266
Package with Option +E20267
Boxes68
LCL Filter Module Package71
Examining the Delivery72
Lifting72
Attaching the Drive Module and LCL Filter Module to a Mounting Plate or Wall72
Attaching the Drive Module to the LCL Filter Module73
Attaching the Drive Module and the LCL Filter Module to the Enclosure Base73
Grounding the Drive Module and the LCL Filter Module73
Installing the Drive in Rittal VX25 Enclosure73
Optional Input Power Cable Connection Terminals and Ground Busbar Assembly (+H370)74
Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) and IP20 Shrouds (Option +0B051)74
Guidelines for Planning the Electrical Installation75
Contents of this Chapter75
Limitation of Liability75
Selecting the Main Supply Disconnecting Device75
European Union75
North America76
Other Regions76
Selecting the Main Contactor76
Examining the Compatibility of the Motor and Drive76
Protecting the Motor Insulation and Bearings76
Requirements Table77
Availability of Du/Dt Filter and Common Mode Filter by Drive Type80
Additional Requirements for Explosion-Safe (EX) Motors80
And am80
Additional Requirements for the Regenerative and Low Harmonics Drives80
Additional Requirements for ABB High-Output and IP23 Motors80
Additional Requirements for Non-ABB High-Output and IP23 Motors80
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage81
Additional Note for Sine Filters82
Selecting the Power Cables82
General Guidelines82
Typical Power Cable Sizes83
Power Cable Types83
Preferred Power Cable Types83
Alternate Power Cable Types84
Not Allowed Power Cable Types85
Additional Guidelines, North America85
Metal Conduit86
Power Cable Shield86
Selecting the Control Cables87
Shielding87
Signals in Separate Cables87
Signals that Can be Run in the same Cable87
Relay Cable87
Control Panel to Drive Cable87
PC Tool Cable88
Routing the Cables88
General Guidelines - IEC88
General Guidelines - North America88
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable89
Separate Control Cable Ducts89
Implementing Motor and Motor Cable Short-Circuit and Thermal Overload Protection90
Protecting the Motor and Motor Cable in Short-Circuits90
Protecting the Motor Cables against Thermal Overload90
Protecting the Motor against Thermal Overload90
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors90
Protecting the Drive and the Input Power Cable in Short-Circuits91
Protecting the Drive against Thermal Overload91
Protecting the Input Power Cable against Thermal Overload91
Implementing a Motor Temperature Sensor Connection91
Connecting Motor Temperature Sensor to the Drive Via an Option Module92
Protecting the Drive against Ground Faults93
Residual Current Device Compatibility93
Implementing the Emergency Stop Function93
Implementing the Safe Torque off Function93
Implementing the Undervoltage Control (Power-Loss Ride-Through)93
Implementing the Functions Provided by the FSO-XX Safety Functions Module94
Using Power Factor Compensation Capacitors with the Drive94
Using a Safety Switch between the Drive and the Motor94
Implementing an ATEX-Certified Motor Thermal Protection94
Controlling a Contactor between Drive and Motor95
Implementing a Bypass Connection95
Example Bypass Connection96
Switching the Motor Power Supply from Drive to Direct-On-Line96
Switching the Motor Power Supply from Direct-On-Line to Drive97
Protecting the Contacts of Relay Outputs97
Electrical Installation99
Contents of this Chapter99
Safety99
Grounding the Motor Cable Shield at the Motor End99
Measuring the Insulation100
Measuring the Insulation of the Drive100
Measuring the Insulation of the Input Power Cable100
Measuring the Insulation of the Motor and Motor Cable100
Grounding System Compatibility Check100
Installing the EMC Filter (Option +E202)101
Connecting the Power Cables101
Power Cable Connection Diagram102
Preparing the Cable Ends and Making 360-Degree Grounding at the Cable Entry104
Power Cable Connection Procedure105
Removing the Control Panel Holder from the External Control Unit106
Attaching the Control Cable Clamp Plate106
Connecting the External Control Unit to the Drive Module107
External Control Unit Connection Cables107
Routing the External Control Unit Cables into the Drive Module108
Connecting Control Cables to the Drive Module108
Connecting Control Cables to the Control Unit108
Attaching the External Control Unit109
Attaching the External Control Unit to a Mounting Plate or Wall110
Attaching the External Control Unit Vertically on a DIN Rail110
Attaching the External Control Unit Horizontally on a DIN Rail111
Connecting the Control Cables to the Terminals of the External Control Unit112
Connecting a Control Panel112
Panel Bus (Control of Several Units from One Control Panel)113
Panel Bus Wiring with FDPI-02 - Single Drive116
Panel Bus Wiring with FDPI-02 and ZDPI-01 - Several Drives117
Panel Bus Wiring with FDPI-02 - Several Drives117
Connecting a PC118
Installing Option Modules118
Installing the FSO-XX Safety Functions Module118
Installing I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules119
Wiring the Option Modules120
External Control Unit121
Contents of this Chapter121
ZCU-14 Layout122
Default I/O Diagram of the Drive Control Unit (ZCU-1X)123
Additional Information on the Connections125
External Power Supply for the Control Unit (XPOW)125
DI6 as a PTC Sensor Input125
AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 Sensor Input125
DIIL Input126
The XD2D Connector126
Safe Torque off (XSTO)127
FSO-XX Safety Functions Module Connection (X12)127
Connector Data128
ZCU-1X Ground Isolation Diagram130
Installation Example of the Standard Drive Module Configuration in Rittal VX25131
Contents of this Chapter131
Limitation of Liability131
Safety131
Required Parts132
Required Tools132
Overall Flowchart of the Installation Process132
Installing the Drive Module and LCL Filter Module into an Enclosure133
Connecting the Motor Cables and Installing the Shrouds134
Connecting the Input Cables and Installing the Shrouds135
Installing the Air Baffles136
Installing the Roof and Door (Rittal Parts)137
Removing the Protective Covering from the Drive Module and LCL Filter Module Air Outlet138
Installation Example with Full Cabling Panels (Option +H381)139
Contents of this Chapter139
Limitation of Liability139
Safety139
Required Parts140
Required Tools140
Overall Flowchart of the Installation Process141
Installing the Mechanical Accessories into a Enclosure141
Connecting the Power Cables143
Connection Diagram143
Power Cable Connection Procedure144
Installing the Drive Module into the Enclosure146
Installation Procedure147
Assembly Drawing of Connecting the Drive Module to the Cabling Panels148
Installing Air Baffles (Non-ABB Parts)149
Miscellaneous149
Installing the Rubber Grommet149
Installation Checklist151
Contents of this Chapter151
Checklist151
Start-Up153
Contents of this Chapter153
Start-Up Procedure153
Fault Tracing155
Contents of this Chapter155
Leds155
Warning and Fault Messages155
Maintenance157
Contents of this Chapter157
Maintenance Intervals157
Descriptions of Symbols157
Recommended Annual Maintenance Actions by the User157
Recommended Maintenance Intervals after Start-Up158
Recommended Functional Safety Actions158
Cleaning the Interior of the Cabinet158
Cleaning the Interior of the Heatsink159
Cleaning the Interior of the LCL Filter160
Fans160
Replacing the Auxiliary Cooling Fans of the Drive Module160
Replacing the Drive Module Main Cooling Fans161
Replacing the LCL Filter Module Cooling Fan162
Replacing the Standard Drive Module163
Replacing the LCL Filter Module166
Replacing the Drive Module with Option +H381166
Replacing the LCL Filter Module with Option +H381168
Capacitors169
Reforming the Capacitors169
Control Panel169
Cleaning the Control Panel169
Replacing the Battery169
Replacing the ZCU-14 Control Unit Battery170
Replacing the ZCU-12 Control Unit Battery171
Memory Unit171
Replacing the Memory Unit of ZCU-14171
Replacing the Memory Unit of the Line-Side Converter Control Unit (ZCU-12)171
Functional Safety Components172
Ordering Information173
Contents of this Chapter173
ACS-AP-W and ACS-AP-I Control Panel173
Control Panel Mounting Platforms173
Output (Du/Dt) Filters174
Sine Filters174
EMC Filter ARFI-10174
Cabinet Ventilation174
Air Inlet Kits174
Air Outlet Kits176
Cooling Fans177
FSO Accessories Kit178
Control Panel Mounting Platforms178
Retrofit Accessory Kits178
Technical Data179
Contents of this Chapter179
Ratings179
When Is Derating Necessary181
Surrounding Air Temperature Derating181
Altitude Derating182
Deratings for Special Settings in the Drive Control Program182
High Speed Mode184
Derating for Output Voltage Boosting185
400 V and 500 V Drive Types185
575 V and 690 V Drives185
Fuses (IEC)187
Fuses (UL)188
Circuit Breakers (UL)189
Dimensions, Weights and Free Space Requirements189
Losses, Cooling Data and Noise190
Typical Power Cable Sizes190
Terminal and Entry Data for the Power Cables191
Units with Optional Cabling Panels (+H381)192
Units Without Full-Size Output Cable Connection Terminals (+0H371) and with a Common Mode Filter (+E208)192
Terminal Data for the Control Cables192
Electrical Power Network Specification192
Motor Connection Data193
DC Connection Data194
Control Panel Type194
Efficiency195
Protection Classes for Module195
Ambient Conditions195
Materials196
Applicable Standards197
Markings197
EMC Compliance (IEC/EN 61800-3:2004)198
Definitions198
Category C2198
Category C3199
Category C4200
UL and CSA Checklist200
EU Declaration of Conformity (Machinery Directive)201
Disclaimers201
Generic Disclaimer201
Cybersecurity Disclaimer202
Dimension Drawings203
Contents of this Chapter203
Standard Configuration204
Location of Power Cable Connection Terminals with Options +H370, +H356205
Drive Module with Options +0B051+H356+0H371206
Configuration with Option +H381207
LCL Filter Module208
Bottom Plate209
Air Baffles210
Material of the Air Baffles210
Air Baffles for Option +H381 in 800 MM Wide Rittal VX25 Enclosure211
External Control Unit212
Example Circuit Diagrams213
Contents of this Chapter213
Example Circuit Diagram213
The Safe Torque off Function215
Contents of this Chapter215
Description215
Compliance with the European Machinery Directive216
Wiring217
Activation Switch217
Cable Types and Lengths217
Grounding of Protective Shields217
Single Drive (Internal Power Supply)218
Dual-Channel Connection218
Single-Channel Connection219
Multiple Drives220
Internal Power Supply220
External Power Supply221
Operation Principle222
Start-Up Including Validation Test223
Competence223
Validation Test Reports223
Validation Test Procedure223
Use225
Maintenance226
Competence226
Fault Tracing227
Safety Data228
Abbreviations228
TÜV Certificate229
Declaration of Conformity230
Filters231
Contents of this Chapter231
Du/Dt Filters231
When Is a Du/Dt Filter Necessary231
Selection Table231
Ordering Codes231
Description, Installation and Technical Data of the FOCH Filters232
Sine Filters232
When Is a Sine Filter Necessary232
Selection Table232
ABB Ordering Codes232
Derating232
Description, Installation and Technical Data of the Sine Filters232
Step-By-Step Drawings for an Installation Example of Standard Drive Configuration in Rittal VX25 800 MM Wide Enclosure233
Handling the Drive Module, Power Cable Connection Diagram233
Installing the Drive Module and LCL Filter Module into a Rittal VX25 Enclosure235
Connecting the Motor Cables and Installing the Shrouds240
Connecting the Input Power Cables and Installing the Shrouds243
Installing the Air Baffles and Removing the Cardboard Covers244
Further Information247

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