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ACS880-34-585A-3
ABB ACS880-34-585A-3 User Manual
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ABB
INDUSTRIAL
DRIVES
ACS880-34
drive
modules
(132
to
400
kW,
200
to
400
hp)
Hardware
manual
2
Table of Contents
Default Chapter
5
Table of Contents
5
Table of Contents
7
1 Safety Instructions
15
Contents of this Chapter
15
Use of Warnings and Notes
15
General Safety in Installation, Start-Up and Maintenance
16
Electrical Safety in Installation, Start-Up and Maintenance
18
Electrical Safety Precautions
18
Additional Instructions and Notes
19
Optical Components
20
Printed Circuit Boards
20
Grounding
20
General Safety in Operation
21
Additional Instructions for Permanent Magnet Motor Drives
22
Safety in Installation, Start-Up, Maintenance
22
Safety in Operation
22
2 Introduction to the Manual
23
Contents of this Chapter
23
Applicability
23
Target Audience
23
Purpose of the Manual
23
Categorization by Frame Size and Option Code
23
Quick Installation, Commissioning and Operating Flowchart
24
Terms and Abbreviations
25
Related Documents
27
3 Operation Principle and Hardware Description
29
Contents of this Chapter
29
Operation Principle
29
Block Diagram of the Main Circuit of the Drive Module
30
Line-Side Converter
30
AC Voltage and Current Waveforms
31
Charging
31
Motor-Side Converter
31
DC Connection
31
Layout
32
Standard Drive Module Configuration
32
Drive Module
33
LCL Filter Module
34
Drive Module with Full Power Cabling Panels (Option +H381)
35
Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) and IP20 Shrouds (Option +0B051) and with Common Mode Filter (Option +E208)
36
Control Panel
37
Overview of Power and Control Connections
38
Type Designation Label
39
Type Designation Key
39
4 Generic Cabinet Planning Instructions
43
Contents of this Chapter
43
Limitation of Liability
43
Cabinet Construction
43
Disposition of the Devices
43
Grounding of Mounting Structures
44
Busbar Material and Joints
44
Shrouds
44
Tightening Torques
44
Electrical Connections
44
Mechanical Connections
44
Insulation Supports
45
Cable Lugs
45
Cooling and Degrees of Protection
45
Planning the Cooling
45
Air Inlets and Outlets
45
Preventing the Recirculation of Hot Air
46
EMC Requirements
47
Attaching the Cabinet
49
Cabinet Placement on a Cable Channel
49
Cubicle Heaters
49
Mounting the Control Panel on the Cabinet Door
49
5 Guidelines for Planning the Mechanical Installation
51
Contents of this Chapter
51
Installation Positions of the Drive Module
51
Layout Example, Door Closed
52
Layout Example, Door Open (Standard Drive Module Configuration)
53
Layout Example, Door Open (Option +0B051)
54
Cooling Solutions
55
Preventing the Recirculation of Hot Air
56
Bookshelf Mounting (Standard Drive Module Configuration)
56
Bookshelf Mounting (Option +0B051)
57
Bookshelf Mounting (Option +H381)
58
Required Free Space
58
Free Space at the Top of the Drive Module
58
Free Space Around the Drive Module
59
ABB Air Inlet and Outlet Kits
59
6 Mechanical Installation
61
Contents of this Chapter
61
Examining the Installation Site
61
Moving and Unpacking
61
Package Drawings
62
Drive Module Package Without Option +E202
62
Package with Option +E202
63
Boxes
64
LCL Filter Module Package
67
Examining the Delivery
68
Lifting
68
Attaching the Drive Module and LCL Filter Module to a Mounting Plate or Wall
68
Attaching the Drive Module to the LCL Filter Module
69
Attaching the Drive Module and the LCL Filter Module to the Cabinet Base
69
Grounding the Drive Module and the LCL Filter Module
69
Installing the Drive in Rittal VX25 Enclosure
69
Optional Input Power Cable Connection Terminals and Ground Busbar Assembly (+H370)
70
Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) and IP20 Shrouds (Option +0B051)
70
7 Guidelines for Planning the Electrical Installation
71
Contents of this Chapter
71
Limitation of Liability
71
Selecting the Main Supply Disconnecting Device
71
European Union
71
North America
72
Other Regions
72
Selecting the Main Contactor
72
Examining the Compatibility of the Motor and Drive
72
Protecting the Motor Insulation and Bearings
72
Requirements Table
73
Availability of Du/Dt Filter and Common Mode Filter by Drive Type
75
Additional Requirements for Explosion-Safe (EX) Motors
75
And am
75
Additional Requirements for the Regenerative and Low Harmonics Drives
75
Additional Requirements for ABB High-Output and IP23 Motors
75
Additional Requirements for Non-ABB High-Output and IP23 Motors
75
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
76
Additional Note for Sine Filters
77
Selecting the Power Cables
77
General Guidelines
77
Typical Power Cable Sizes
78
Power Cable Types
78
Preferred Power Cable Types
78
Alternate Power Cable Types
79
Not Allowed Power Cable Types
80
Additional Guidelines, North America
80
Metal Conduit
81
Power Cable Shield
81
Selecting the Control Cables
81
Shielding
81
Signals in Separate Cables
82
Signals that Can be Run in the same Cable
82
Relay Cable
82
Control Panel to Drive Cable
82
PC Tool Cable
82
Routing the Cables
82
General Guidelines - IEC
82
General Guidelines - North America
83
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable
84
Separate Control Cable Ducts
84
Implementing Motor and Motor Cable Short-Circuit and Thermal Overload Protection
85
Protecting the Motor and Motor Cable in Short-Circuits
85
Protecting the Motor Cables against Thermal Overload
85
Protecting the Motor against Thermal Overload
85
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
85
Protecting the Drive and Input Cable in Short-Circuits and against Thermal Overload
86
Protecting the Drive and the Input Power Cable in Short-Circuits
86
Circuit Breakers
86
Protecting the Drive and the Input Power Cable against Thermal Overload
86
Implementing a Motor Temperature Sensor Connection
86
Connecting Motor Temperature Sensor to the Drive Via an Option Module
87
Protecting the Drive against Ground Faults
88
Residual Current Device Compatibility
88
Implementing the Emergency Stop Function
88
Implementing the Safe Torque off Function
88
Implementing the Functions Provided by the FSO-XX Safety Functions Module
88
Using Power Factor Compensation Capacitors with the Drive
89
Using a Safety Switch between the Drive and the Motor
89
Implementing an ATEX-Certified Motor Thermal Protection
89
Implementing the Undervoltage Control (Power-Loss Ride-Through)
89
Controlling a Contactor between Drive and Motor
90
Implementing a Bypass Connection
90
Protecting the Contacts of Relay Outputs
90
8 Electrical Installation
93
Contents of this Chapter
93
Safety
93
Grounding the Motor Cable Shield at the Motor End
93
Measuring the Insulation
94
Measuring the Insulation of the Drive
94
Measuring the Insulation of the Input Power Cable
94
Measuring the Insulation of the Motor and Motor Cable
94
Measuring the Insulation of Brake Resistor and Resistor Cable
94
Compatibility with IT (Ungrounded), Corner-Grounded Delta, Midpoint-Grounded Delta, and TT Systems
95
EMC Filter (Option +E202)
95
Ground-To-Phase Varistor
95
Corner-Grounded and Midpoint-Grounded Delta Systems
95
When to Disconnect EMC Filter (Option +E202) or Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta, and Midpoint-Grounded Delta System
95
Guidelines for Installing the Drive to a TT System
97
Disconnecting EMC Filter and Ground-To-Phase Varistor
97
Identifying the Earthing System of the Electrical Power Network
98
Installing the EMC Filter (Option +E202)
98
Connecting the Power Cables
98
Power Cable Connection Diagram
99
Preparing the Cable Ends and Making 360-Degree Grounding at the Cable Entry
101
Power Cable Connection Procedure
102
Removing the Control Panel Holder from the External Control Unit
103
Attaching the Control Cable Clamp Plate
103
Connecting the External Control Unit to the Drive Module
104
External Control Unit Connection Cables
104
Routing the External Control Unit Cables into the Drive Module
105
Connecting Control Cables to the Drive Module
105
Connecting Control Cables to the Control Unit
105
Attaching the External Control Unit
106
Attaching the External Control Unit to a Mounting Plate or Wall
107
Attaching the External Control Unit Vertically on a DIN Rail
107
Attaching the External Control Unit Horizontally on a DIN Rail
108
Connecting the Control Cables to the Terminals of the External Control Unit
109
Connecting a Control Panel
109
Panel Bus (Control of Several Units from One Control Panel)
110
Panel Bus Wiring with FDPI-02 - Single Drive
113
Panel Bus Wiring with FDPI-02 and ZDPI-01 - Several Drives
114
Panel Bus Wiring with FDPI-02 - Several Drives
114
Connecting a PC
115
Installing Option Modules
115
Installing the FSO-XX Safety Functions Module
115
Installing I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules
116
Wiring the Option Modules
117
9 External Control Unit
119
Contents of this Chapter
119
ZCU-14 Layout
120
Default I/O Connection Diagram
121
Additional Information on I/O Connections
122
External Power Supply for the Control Unit (XPOW)
122
DI6 as a PTC Sensor Input
122
AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 Sensor Input
123
DIIL Input
124
The XD2D Connector
124
Safe Torque off (XSTO)
124
FSO-XX Safety Functions Module Connection (X12)
125
Connector Data
126
ZCU-1X Ground Isolation Diagram
128
10 Installation Example of the Standard Drive Module Configuration
129
Contents of this Chapter
129
Limitation of Liability
129
Safety
129
Required Parts
130
Required Tools
130
Overall Flowchart of the Installation Process
130
Installing the Drive Module and LCL Filter Module into a Cabinet
131
Connecting the Power Cables and Installing the Shrouds
133
Installing the Roof and Door (Rittal Parts)
134
11 Installation Example with Full Cabling Panels (Option +H381)
135
Contents of this Chapter
135
Limitation of Liability
135
Safety
135
Required Parts
136
Required Tools
136
Overall Flowchart of the Installation Process
137
Installing the Mechanical Accessories into the Cabinet
137
Connecting the Power Cables
139
Connection Diagram
139
Power Cable Connection Procedure
140
Installing the Drive Module into the Cabinet
142
Installation Procedure
143
Assembly Drawing of Connecting the Drive Module to the Cabling Panels
144
Installing Air Baffles (Non-ABB Parts)
145
Miscellaneous
145
Installing the Rubber Grommet
145
12 Installation Checklist of the Drive
147
Contents of this Chapter
147
Checklist
147
13 Start-Up
149
Contents of this Chapter
149
Start-Up Procedure
149
14 Fault Tracing
151
Contents of this Chapter
151
Leds
151
Warning and Fault Messages
151
15 Maintenance
153
Contents of this Chapter
153
Maintenance Intervals
153
Cleaning the Interior of the Cabinet
154
Cleaning the Interior of the Heatsink
155
Cleaning the Interior of the LCL Filter
156
Fans
156
Replacing the Auxiliary Cooling Fans of the Drive Module
156
Replacing the Drive Module Main Cooling Fans
157
Replacing the LCL Filter Module Cooling Fan
158
Replacing the Standard Drive Module
159
Replacing the LCL Filter Module
162
Replacing the Drive Module with Option +H381
162
Replacing the LCL Filter Module with Option +H381
164
Capacitors
165
Reforming the Capacitors
165
Control Panel
165
Cleaning the Control Panel
165
Replacing the Control Panel Battery
165
Replacing the ZCU-14 Control Unit Battery
165
Memory Unit
166
Replacing the Memory Unit
166
Replacing the Line-Side Converter Control Unit Memory Unit
167
16 Ordering Information
169
Contents of this Chapter
169
ACS-AP-W and ACS-AP-I Control Panel
169
Brake Choppers and Resistors
170
Output (Du/Dt) Filters
170
Sine Filters
170
EMC Filter ARFI-10
170
Cabinet Ventilation
170
Air Inlet Kits
170
Air Outlet Kits
172
Cooling Fans
173
FSO Accessories Kit
174
Control Panel Mounting Platforms
174
Retrofit Accessory Kits
174
17 Technical Data
175
Contents of this Chapter
175
Ratings
175
When Is Derating Necessary
177
Ambient Temperature Derating
177
Altitude Derating
177
Deratings for Special Settings in the Drive Control Program
178
High Speed Mode
179
Derating for Output Voltage Boosting
181
Fuses (IEC)
183
Fuses (UL Recognized)
184
Dimensions, Weights and Free Space Requirements
185
Losses, Cooling Data and Noise
186
Typical Power Cable Sizes
186
Terminal and Entry Data for the Power Cables
187
Units with Optional Cabling Panels (+H381)
188
Units Without Full-Size Output Cable Connection Terminals (+0H371) and with a Common Mode Filter (+E208)
188
Terminal Data for the Control Cables
188
Electrical Power Network Specification
188
Motor Connection Data
189
DC Connection Data
190
Control Panel Type
190
Efficiency
191
Protection Classes
191
Ambient Conditions
191
Materials
192
Applicable Standards
193
Markings
193
EMC Compliance (IEC/EN 61800-3:2004)
194
Definitions
194
Category C2
194
Category C3
195
Category C4
196
UL and CSA Checklist
196
EU Declaration of Conformity (Machinery Directive)
197
Disclaimer
197
Generic Disclaimer
197
Cybersecurity Disclaimer
198
18 Dimension Drawings
199
Contents of this Chapter
199
Standard Configuration
200
Location of Power Cable Connection Terminals with Options +H370, +H356
201
Drive Module with Options +0B051+H356+0H371
202
Configuration with Option +H381
203
LCL Filter Module
204
Bottom Plate
205
Air Baffles
206
Material of the Air Baffles
206
Air Baffles for Option +H381 in 800 MM Wide Rittal VX25 Enclosure
207
External Control Unit
208
19 Example Circuit Diagrams
209
Contents of this Chapter
209
Example Circuit Diagram
209
20 The Safe Torque off Function
211
Contents of this Chapter
211
Description
211
Compliance with the European Machinery Directive
212
Wiring
213
Activation Switch
213
Cable Types and Lengths
213
Grounding of Protective Shields
213
Single Drive (Internal Power Supply)
214
Dual-Channel Connection
214
Single-Channel Connection
215
Multiple Drives
216
Internal Power Supply
216
External Power Supply
217
Operation Principle
218
Start-Up Including Acceptance Test
219
Competence
219
Acceptance Test Reports
219
Acceptance Test Procedure
219
Use
221
Maintenance
222
Competence
222
Fault Tracing
223
Safety Data
224
Abbreviations
224
TÜV Certificate
225
Declaration of Conformity
226
21 Resistor Braking
227
Contents of this Chapter
227
Operation Principle and Hardware Description
227
Planning the Braking System
227
Selecting the Default Brake Circuit Components - ABB Chopper and ABB Resistor
227
Calculating the Maximum Allowed Braking Power for a Custom Duty Cycle - ABB Chopper and ABB Resistor
228
Example
228
Selecting the Default Brake Circuit Components - ABB Brake Chopper and Custom Resistor
228
Selecting Custom Resistors
229
Calculating the Maximum Allowed Braking Power for a Custom Duty Cycle - ABB Chopper and Custom Resistor
230
Example 1
230
Example 2
230
Selecting and Routing Brake Resistor Cables
231
Minimizing Electromagnetic Interference
231
Maximum Cable Length
231
Placing the Brake Resistors
231
Protecting the System against Thermal Overload
232
Protecting the Resistor Cable against Short-Circuits
232
Mechanical Installation of Resistors
232
Electrical Installation
232
Measuring the Insulation of the Brake Resistor Circuit
232
Connection Diagram
233
Connection Procedure
233
Start-Up
234
Technical Data
235
Ratings
235
ABB Brake Chopper and DC Fuse Ratings
235
ABB Brake Resistor Ratings
236
ABB Resistors (SAFUR) - Additional Data
237
Dimensions, Weights and Ordering Codes
237
Brake Chopper Types and Ordering Codes
237
Terminals and Cable Entry Data
237
22 Filters
239
Contents of this Chapter
239
Du/Dt Filters
239
When Is a Du/Dt Filter Necessary
239
Selection Table
239
Ordering Codes
240
Description, Installation and Technical Data of the FOCH Filters
240
Sine Filters
240
When Is a Sine Filter Necessary
240
Selection Table
240
ABB Ordering Codes
240
Derating
240
Description, Installation and Technical Data of the Sine Filters
240
23 Step-By-Step Drawings for an Installation Example of Standard Drive Configuration in Rittal VX25 800 MM Wide Enclosure
241
Contents of this Chapter
241
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ABB ACS880-34-585A-3 Specifications
General
Cooling Method
Air
Enclosure Type
IP21
Rated Current
585 A
Model
ACS880-34-585A-3
Control Method
Direct Torque Control (DTC)
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