ABB ACS880-34 Series - Attaching the External Control Unit

ABB ACS880-34 Series

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Attaching the external control unit

The drive control unit can be attached on a mounting plate or onto a DIN rail.

106 Electrical installation

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

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