ABB ACS880-34 Series User Manual

ABB ACS880-34 Series

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ABB INDUSTRIAL DRIVES

ACS880-34 drive modules (132 to 400 kW, 200

to 400 hp)

Hardware manual

Table of Contents

Default Chapter5
- Table of Contents5
- Table of Contents7
1 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
- General Safety in Operation21
- Additional Instructions for Permanent Magnet Motor Drives22
  - Safety in Installation, Start-Up, Maintenance22
  - Safety in Operation22
2 Introduction to the Manual23
- Contents of this Chapter23
- Applicability23
- Target Audience23
- Purpose of the Manual23
- Categorization by Frame Size and Option Code23
- Quick Installation, Commissioning and Operating Flowchart24
- Terms and Abbreviations25
- Related Documents27
3 Operation Principle and Hardware Description29
- Contents of this Chapter29
- Operation Principle29
- Layout32
- Overview of Power and Control Connections38
- Type Designation Label39
- Type Designation Key39
4 Generic Cabinet Planning Instructions43
- Contents of this Chapter43
- Limitation of Liability43
- Cabinet Construction43
- Cooling and Degrees of Protection45
- EMC Requirements47
- Attaching the Cabinet49
- Cabinet Placement on a Cable Channel49
- Cubicle Heaters49
- Mounting the Control Panel on the Cabinet Door49
5 Guidelines for Planning the Mechanical Installation51
- Contents of this Chapter51
- Installation Positions of the Drive Module51
- Layout Example, Door Closed52
- Layout Example, Door Open (Standard Drive Module Configuration)53
- Layout Example, Door Open (Option +0B051)54
- Cooling Solutions55
- Preventing the Recirculation of Hot Air56
- Required Free Space58
  - Free Space at the Top of the Drive Module58
  - Free Space Around the Drive Module59
- ABB Air Inlet and Outlet Kits59
6 Mechanical Installation61
- Contents of this Chapter61
- Examining the Installation Site61
- Moving and Unpacking61
  - Package Drawings62
- Lifting68
- Attaching the Drive Module and LCL Filter Module to a Mounting Plate or Wall68
- Attaching the Drive Module to the LCL Filter Module69
- Attaching the Drive Module and the LCL Filter Module to the Cabinet Base69
- Grounding the Drive Module and the LCL Filter Module69
- Installing the Drive in Rittal VX25 Enclosure69
- 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 Installation71
- Contents of this Chapter71
- Limitation of Liability71
- Selecting the Main Supply Disconnecting Device71
  - European Union71
  - North America72
  - Other Regions72
- Selecting the Main Contactor72
- Examining the Compatibility of the Motor and Drive72
  - Protecting the Motor Insulation and Bearings72
  - Requirements Table73
- Selecting the Power Cables77
  - General Guidelines77
  - Typical Power Cable Sizes78
  - Power Cable Types78
  - Additional Guidelines, North America80
    - Metal Conduit81
  - Power Cable Shield81
- Selecting the Control Cables81
  - Shielding81
  - Signals in Separate Cables82
  - Signals that Can be Run in the same Cable82
  - Relay Cable82
  - Control Panel to Drive Cable82
  - PC Tool Cable82
  - Routing the Cables82
  - General Guidelines - IEC82
  - General Guidelines - North America83
  - Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable84
  - Separate Control Cable Ducts84
- Implementing Motor and Motor Cable Short-Circuit and Thermal Overload Protection85
  - Protecting the Motor and Motor Cable in Short-Circuits85
  - Protecting the Motor Cables against Thermal Overload85
  - Protecting the Motor against Thermal Overload85
  - Protecting the Motor against Overload Without Thermal Model or Temperature Sensors85
- Protecting the Drive and Input Cable in Short-Circuits and against Thermal Overload86
  - Protecting the Drive and the Input Power Cable in Short-Circuits86
    - Circuit Breakers86
  - Protecting the Drive and the Input Power Cable against Thermal Overload86
- Implementing a Motor Temperature Sensor Connection86
  - Connecting Motor Temperature Sensor to the Drive Via an Option Module87
- Protecting the Drive against Ground Faults88
  - Residual Current Device Compatibility88
- Implementing the Emergency Stop Function88
- Implementing the Safe Torque off Function88
- Implementing the Functions Provided by the FSO-XX Safety Functions Module88
- Using Power Factor Compensation Capacitors with the Drive89
- Using a Safety Switch between the Drive and the Motor89
- Implementing an ATEX-Certified Motor Thermal Protection89
- Implementing the Undervoltage Control (Power-Loss Ride-Through)89
- Controlling a Contactor between Drive and Motor90
- Implementing a Bypass Connection90
- Protecting the Contacts of Relay Outputs90
8 Electrical Installation93
- Contents of this Chapter93
- Safety93
- Grounding the Motor Cable Shield at the Motor End93
- Measuring the Insulation94
- Compatibility with IT (Ungrounded), Corner-Grounded Delta, Midpoint-Grounded Delta, and TT Systems95
- Installing the EMC Filter (Option +E202)98
- Connecting the Power Cables98
- Attaching the External Control Unit106
- Connecting the Control Cables to the Terminals of the External Control Unit109
- Connecting a Control Panel109
- Panel Bus (Control of Several Units from One Control Panel)110
- Connecting a PC115
- Installing Option Modules115
9 External Control Unit119
- Contents of this Chapter119
- ZCU-14 Layout120
- Default I/O Connection Diagram121
- Additional Information on I/O Connections122
- Connector Data126
  - ZCU-1X Ground Isolation Diagram128
10 Installation Example of the Standard Drive Module Configuration129
- Contents of this Chapter129
- Limitation of Liability129
- Safety129
- Required Parts130
- Required Tools130
- Overall Flowchart of the Installation Process130
- Installing the Drive Module and LCL Filter Module into a Cabinet131
- Connecting the Power Cables and Installing the Shrouds133
- Installing the Roof and Door (Rittal Parts)134
11 Installation Example with Full Cabling Panels (Option +H381)135
- Contents of this Chapter135
- Limitation of Liability135
- Safety135
- Required Parts136
- Required Tools136
- Overall Flowchart of the Installation Process137
- Installing the Mechanical Accessories into the Cabinet137
- Connecting the Power Cables139
  - Connection Diagram139
  - Power Cable Connection Procedure140
- Installing the Drive Module into the Cabinet142
  - Installation Procedure143
    - Assembly Drawing of Connecting the Drive Module to the Cabling Panels144
- Installing Air Baffles (Non-ABB Parts)145
- Miscellaneous145
  - Installing the Rubber Grommet145
12 Installation Checklist of the Drive147
- Contents of this Chapter147
- Checklist147
13 Start-Up149
- Contents of this Chapter149
- Start-Up Procedure149
14 Fault Tracing151
- Contents of this Chapter151
- Leds151
- Warning and Fault Messages151
15 Maintenance153
- Contents of this Chapter153
- Maintenance Intervals153
- Cleaning the Interior of the Cabinet154
- Cleaning the Interior of the Heatsink155
- Cleaning the Interior of the LCL Filter156
- Fans156
- Replacing the Standard Drive Module159
- Replacing the LCL Filter Module162
- Replacing the Drive Module with Option +H381162
- Replacing the LCL Filter Module with Option +H381164
- Capacitors165
  - Reforming the Capacitors165
- Control Panel165
- Cleaning the Control Panel165
- Replacing the Control Panel Battery165
- Replacing the ZCU-14 Control Unit Battery165
- Memory Unit166
- Replacing the Memory Unit166
- Replacing the Line-Side Converter Control Unit Memory Unit167
16 Ordering Information169
- Contents of this Chapter169
- ACS-AP-W and ACS-AP-I Control Panel169
- Brake Choppers and Resistors170
- Output (Du/Dt) Filters170
- Sine Filters170
- EMC Filter ARFI-10170
- Cabinet Ventilation170
  - Air Inlet Kits170
  - Air Outlet Kits172
- Cooling Fans173
- FSO Accessories Kit174
- Control Panel Mounting Platforms174
- Retrofit Accessory Kits174
17 Technical Data175
- Contents of this Chapter175
- Ratings175
  - When Is Derating Necessary177
  - Ambient Temperature Derating177
  - Altitude Derating177
  - Deratings for Special Settings in the Drive Control Program178
    - High Speed Mode179
  - Derating for Output Voltage Boosting181
- Fuses (IEC)183
- Fuses (UL Recognized)184
- Dimensions, Weights and Free Space Requirements185
- Losses, Cooling Data and Noise186
- Typical Power Cable Sizes186
- Terminal and Entry Data for the Power Cables187
  - 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 Cables188
- Electrical Power Network Specification188
- Motor Connection Data189
- DC Connection Data190
- Control Panel Type190
- Efficiency191
- Protection Classes191
- Ambient Conditions191
- Materials192
- Applicable Standards193
- Markings193
- EMC Compliance (IEC/EN 61800-3:2004)194
  - Definitions194
  - Category C2194
  - Category C3195
  - Category C4196
- UL and CSA Checklist196
- EU Declaration of Conformity (Machinery Directive)197
- Disclaimer197
  - Generic Disclaimer197
  - Cybersecurity Disclaimer198
18 Dimension Drawings199
- Contents of this Chapter199
- Standard Configuration200
- Location of Power Cable Connection Terminals with Options +H370, +H356201
- Drive Module with Options +0B051+H356+0H371202
- Configuration with Option +H381203
- LCL Filter Module204
- Bottom Plate205
- Air Baffles206
  - Material of the Air Baffles206
- Air Baffles for Option +H381 in 800 MM Wide Rittal VX25 Enclosure207
- External Control Unit208
19 Example Circuit Diagrams209
- Contents of this Chapter209
- Example Circuit Diagram209
20 The Safe Torque off Function211
- Contents of this Chapter211
- Description211
  - Compliance with the European Machinery Directive212
- Wiring213
- Operation Principle218
- Start-Up Including Acceptance Test219
- Use221
- Maintenance222
  - Competence222
- Fault Tracing223
- Safety Data224
21 Resistor Braking227
- Contents of this Chapter227
- Operation Principle and Hardware Description227
- Planning the Braking System227
- Selecting and Routing Brake Resistor Cables231
- Mechanical Installation of Resistors232
- Electrical Installation232
- Start-Up234
- Technical Data235
22 Filters239
- Contents of this Chapter239
- Du/Dt Filters239
- Sine Filters240
23 Step-By-Step Drawings for an Installation Example of Standard Drive Configuration in Rittal VX25 800 MM Wide Enclosure241
- Contents of this Chapter241

Questions and Answers:

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ABB ACS880-34 Series Specifications

General

Voltage Range	380 V to 690 V
Control Method	Direct Torque Control (DTC)
Cooling Method	Air or liquid cooling
Protection Class	IP21
Communication Protocols	Modbus, Profibus, CANopen, Ethernet
Protection Features	Overcurrent, overvoltage, overtemperature, short circuit
Power Range	0.55 to 5.6 MW

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