ABB ACS880-34 - Safety Instructions; Installation Instructions

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Hardware manual

ACS880-34 drive modules

(132 to 400 kW, 200 to 450 hp)

3AXD50000035191 Rev B

EN

EFFECTIVE: 2018-09-28

 2018 ABB Oy. All Rights Reserved.

1. Safety instructions

6. Installation instructions

Table of contents

12. Start-up

Table of Contents

Default Chapter5
- Table of Contents5
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
- Additional Instructions for Permanent Magnet Motor Drives21
  - Safety in Installation, Start-Up and Maintenance21
- Additional Instruction for DC Connection21
2 Introduction to the Manual23
- Contents of this Chapter23
- Target Audience23
- Categorization by Frame Size and Option Code23
- Quick Installation, Commissioning and Operating Flowchart24
- Terms and Abbreviations26
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 Guidelines for Planning the Cabinet Installation43
- Contents of this Chapter43
- Limitation of Liability43
- Installation Positions of the Drive Module43
- Basic Requirements for the Cabinet43
- Planning the Layout of the Cabinet44
- Arranging the Grounding Inside the Cabinet48
- Selecting the Busbar Material and Preparation of the Joints48
- Tightening Torques48
- Planning the Fastening of the Cabinet48
- Planning the Cabinet Placement on a Cable Channel49
- Planning the Electromagnetic Compatibility (EMC) of the Cabinet49
- Planning the Cooling50
- Preventing the Recirculation of Hot Air52
- Required Free Space55
  - Free Space at the Top of the Drive Module55
  - Free Space Around the Drive Module55
- Planning the Placement of the Control Panel56
- Planning the Use of Cubicle Heaters56
- ABB Air Inlet and Outlet Kits56
5 Guidelines for Planning the Electrical Installation57
- Contents of this Chapter57
- Selecting the Supply Disconnecting Device58
  - European Union58
  - Other Regions58
- Selecting the Main Contactor58
- Examining the Compatibility of the Motor and Drive58
  - Protecting the Motor Insulation and Bearings59
  - Requirements Table59
- Selecting the Power Cables63
  - General Rules63
  - Typical Power Cable Sizes64
  - Alternative Power Cable Types65
  - Motor Cable Shield66
  - Additional US Requirements66
    - Conduit66
    - Armored Cable / Shielded Power Cable66
- Planning the Braking System67
- Selecting the Control Cables67
  - Shielding67
  - Signals in Separate Cables67
  - Signals Allowed to be Run in the same Cable67
  - Relay Cable Type67
  - Control Panel Cable Length and Type67
  - Routing the Cables67
  - Separate Control Cable Ducts68
  - Continuous Motor Cable Shield or Enclosure for Equipment in the Motor Cable68
- Implementing Thermal Overload and Short-Circuit Protection69
  - Protecting the Drive and Input Power Cable in Short-Circuits69
    - Circuit Breakers69
  - Protecting the Motor and Motor Cable in Short-Circuits69
  - Protecting the Motor against Thermal Overload69
- Protecting the Drive against Ground Faults70
  - Residual Current Device Compatibility70
- Connecting Drive Modules to a Common DC System70
- Implementing the Emergency Stop Function70
- Implementing the Safe Torque off Function70
- Implementing the ATEX-Certified Safe Motor Disconnection Function (Option +Q971)71
- Implementing Safety Functions Provided by the FSO Safety Functions Module71
- Q972 and +Q973)71
  - Declaration of Conformity71
- Implementing the Power Loss Ride-Through Function71
- Using Power Factor Compensation Capacitors with the Drive72
- Implementing a Safety Switch between the Drive and the Motor72
- Using a Contactor between the Drive and the Motor73
- Protecting the Contacts of Relay Outputs73
- Connecting a Motor Temperature Sensor to the Drive I/O75
  - Connection of Motor Temperature Sensor to the Drive Via an Option Module75
  - Connection of Motor Temperature Sensor to the Drive Via a Relay76
- Example Circuit Diagram76
6 Installation Instructions77
- Contents of this Chapter77
- Safety77
- Checking the Installation Site77
- Moving and Unpacking the Unit78
  - Package Drawings78
- Checking the Delivery85
- Installing the Motor Cable at the Motor End85
- Checking the Insulation of the Assembly85
- Ed Delta, and TT Systems87
- Installation Alternatives91
- Installing the EMC Filter (Option +E202)93
- Connecting the Power Cables93
  - Power Cable Connection Diagram94
  - Power Cable Connection Procedure95
- Connecting the Control Cables and Installing Option Modules95
- Connecting a Control Panel96
- Controlling Several Drives from One Control Panel through Panel Bus97
- Connecting a PC98
7 External Control Unit99
- Contents of this Chapter99
- Layout100
- Removing the Control Panel Holder from the External Control Unit101
- Attaching the Control Cable Clamp Plate102
- Connecting the External Control Unit to the Drive Module103
- Mounting the External Control Unit105
- Connecting the Control Cables to the Terminals of the Control Unit107
  - Default I/O Connection Diagram108
  - Installing the Control Panel Holder Back Onto the External Control Unit112
- Installing Optional Modules112
- Technical Data (ZCU-14)115
8 Internal Control Unit (Option +P905)119
- Contents of this Chapter119
- Layout120
  - Connecting the Control Cables to the Internal Control Unit (Option +P905)121
  - Connecting the Control Cables to the Internal Control Unit (Options +P905 and +0B051)122
- Default I/O Connection Diagram123
- Installing Optional Modules125
  - Installing the FSO Safety Functions Module (Option +Q973)125
  - Installing I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules127
    - Wiring the Optional Modules127
- Technical Data (ZCU-12)128
9 Installation Example of the Standard Drive Module Configuration131
- 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 a Cabinet133
- Connecting the Power Cables and Installing the Shrouds134
- Installing the Roof and Door (Rittal Parts)136
10 Installation Example with Full Cabling Panels (Option +H381)137
- Contents of this Chapter137
- Limitation of Liability137
- Safety137
- Required Parts138
- Required Tools138
- Overall Flowchart of the Installation Process139
- Installing the Mechanical Accessories into the Cabinet139
- Connecting the Power Cables141
  - Connection Diagram141
  - Power Cable Connection Procedure142
- Installing the Drive Module into the Cabinet144
  - Installation Procedure145
    - Assembly Drawing of Connecting the Drive Module to the Cabling Panels146
- Miscellaneous147
  - Installing the Rubber Grommet147
  - Modular Design of Rittal TS8 Cabinets148
11 Installation Checklist149
- Contents of this Chapter149
12 Start-Up153
- Contents of this Chapter153
- Start-Up Procedure153
13 Fault Tracing157
- Contents of this Chapter157
- Leds with Options +J410157
- Warning and Fault Messages157
14 Maintenance159
- Contents of this Chapter159
- Maintenance Intervals159
- Cabinet160
  - Cleaning the Interior of the Cabinet160
- Heatsink161
  - Cleaning the Interior of the Heatsink161
- Cleaning the Interior of the LCL Filter161
- Fans162
- Replacing the Standard Drive Module166
- Replacing the LCL Filter Module168
- Replacing the Drive Module with Option +H381169
- Replacing the LCL Filter Module with Option +H381171
- Capacitors171
  - Reforming the Capacitors171
- Control Panel171
  - Replacing the Control Panel Battery171
  - Cleaning172
- Replacing the Control Unit Battery - External Control Unit172
- Memory Unit172
  - Replacing the Drive Control Unit Memory Unit172
  - Replacing the Line-Side Converter Control Unit Memory Unit173
15 Ordering Information175
- Contents of this Chapter175
- Brake Choppers and Resistors175
- Output (Du/Dt) Filters175
- Sine Filters175
- EMC Filter ARFI-10175
- Cabinet Ventilation176
  - Air Inlet Kits176
  - Air Outlet Kits178
- Cooling Fans180
- FSO Accessories Kit181
- Retrofit Accessory Kits182
16 Technical Data183
- Contents of this Chapter183
- Ratings183
  - When Is Derating Needed185
  - Ambient Temperature Derating185
  - Altitude Derating186
  - Deratings for Special Settings in the Drive Control Program186
    - Ex Motor, Sine Filter, Low Noise186
    - High Speed Mode188
  - Derating for Output Voltage Boosting189
- Fuses (IEC)190
  - Ultrarapid (Ar) Fuses190
- Fuses (UL Recognized)191
- Dimensions, Weights and Free Space Requirements192
- Losses, Cooling Data and Noise192
- Terminal and Entry Data for the Power Cables193
  - Units with Optional Cabling Panels (+H381)193
  - Mode Filter (+E208)193
- Terminal Data for the Control Cables193
- Electrical Power Network Specification193
- Motor Connection Data194
- DC Connection Data195
- Control Panel Type195
- Efficiency195
- Protection Classes195
- Degree of Protection195
- Ambient Conditions196
- Materials196
- Applicable Standards197
- Markings198
- EMC Compliance (IEC/EN 61800-3:2004)198
  - Definitions198
  - Category C2198
  - Category C3199
  - Category C4199
- UL Checklist200
- EU Declaration of Conformity (Machinery Directive)202
- Disclaimers203
  - Generic Disclaimer203
  - Cybersecurity Disclaimer203
17 Dimension Drawings205
- Contents of this Chapter205
- Standard Configuration206
- Location of Power Cable Connection Terminals with Options +H370, +H356207
- Drive Module with Options +0B051+H356+0H371208
- LCL Filter Module210
- Bottom Plate211
- Air Baffles for the Standard Drive Module212
  - Material of the Air Baffles213
- Air Baffles for Option +H381 in Rittal TS 8 800 MM Wide Cabinet213
- External Control Unit214
18 Example Circuit Diagram215
- Contents of this Chapter215
- Example Circuit Diagram216
19 Safe Torque off Function217
- Contents of this Chapter217
- Description217
  - Compliance with the European Machinery Directive218
- Wiring218
- Operation Principle223
- Start-Up Including Acceptance Test223
- Use225
- Maintenance225
  - Competence226
- Fault Tracing226
- Safety Data (SIL, PL)226
  - Abbreviations227
20 Resistor Braking229
- Contents of this Chapter229
- Operation Principle and Hardware Description229
- Planning the Braking System229
- Mechanical Installation of Brake Resistors231
- Electrical Installation232
- Start-Up232
- Technical Data232
21 Du/Dt and Sine Filters239
- Contents of this Chapter239
- Du/Dt Filters239
- Sine Filters240
22 Step-By-Step Drawings for an Installation Example of Standard Drive Configuration243
In Rittal TS 8 800 MM Wide Cabinet243
- In Rittal TS 8 800 MM Wide Cabinet244
- In Rittal TS 8 800 MM Wide Cabinet245
- In Rittal TS 8 800 MM Wide Cabinet246
- In Rittal TS 8 800 MM Wide Cabinet247
- In Rittal TS 8 800 MM Wide Cabinet248
- In Rittal TS 8 800 MM Wide Cabinet249
- In Rittal TS 8 800 MM Wide Cabinet250
- In Rittal TS 8 800 MM Wide Cabinet251
- In Rittal TS 8 800 MM Wide Cabinet252
- In Rittal TS 8 800 MM Wide Cabinet253
- In Rittal TS 8 800 MM Wide Cabinet254
Further Information255
- Product and Service Inquiries255
- Product Training255
- Providing Feedback on ABB Drives Manuals255
- Document Library on the Internet255

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