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ACQ580-34
ABB ACQ580-34 User Manual
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Optional
input
power
cable
connection
terminals
and
ground
busbar
assembly
(+H370)
Install
the
metallic
shroud
with
ground
bar
as
shown
below
.
Combi
screw
M4×8
T
orx T20 2
N·m
Connect
the
input
power
cable
connection
terminals
as
shown
in
Step-by-step
drawings
for
an
installation
example
of
standard
drive
configuration
in
Rittal
VX25
800
mm
wide
enclosure
(page
229)
.
Mechanical
installation
69
10
68
70
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
20
Optical Components
20
Printed Circuit Boards
20
Grounding
21
General Safety in Operation
22
Additional Instructions for Permanent Magnet Motor Drives
22
Safety in Installation, Start-Up, Maintenance
22
Safety in Operation
23
2 Introduction to the Manual
25
Contents of this Chapter
25
Applicability
25
Target Audience
25
Purpose of the Manual
25
Categorization by Frame Size and Option Code
25
Quick Installation, Commissioning and Operating Flowchart
26
Terms and Abbreviations
27
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
Layout
32
Standard Drive Module Configuration
32
Drive with Clear Plastic Shrouds (Option +B051)
33
Drive Module
34
LCL Filter Module
35
Control Panel
36
Overview of Power and Control Connections
37
Type Designation Label
37
Type Designation Key
38
Basic Code
38
Option Codes
39
4 Generic Cabinet Planning Instructions
41
Contents of this Chapter
41
Limitation of Liability
41
Cabinet Construction
41
Disposition of the Devices
41
Grounding of Mounting Structures
42
Busbar Material and Joints
42
Shrouds
42
Tightening Torques
42
Electrical Connections
42
Mechanical Connections
42
Insulation Supports
43
Cable Lugs
43
Cooling and Degrees of Protection
43
Planning the Cooling
43
Air-Cooled Drive Systems
43
Air Inlets and Outlets
43
Preventing the Recirculation of Hot Air
45
Liquid-Cooled Drive Systems
46
EMC Requirements
46
Attaching the Cabinet
48
Cabinet Placement on a Cable Channel
48
Cubicle Heaters
49
Attaching 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 +B051)
54
Cooling Solutions
55
Preventing the Recirculation of Hot Air
55
Bookshelf Mounting (Standard Drive Module Configuration)
56
Bookshelf Mounting (Option +B051)
58
Required Free Space
58
Free Space at the Top of the Drive Module
59
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
62
Boxes
63
LCL Filter Module Package
66
Examining the Delivery
66
Lifting
66
Attaching the Drive Module and LCL Filter Module to a Mounting Plate or Wall
67
Attaching the Drive Module to the LCL Filter Module
67
Attaching the Drive Module and the LCL Filter Module to the Enclosure Base
67
Grounding the Drive Module and the LCL Filter Module
68
Installing the Drive in Rittal VX25 Enclosure
68
Optional Input Power Cable Connection Terminals and Ground Busbar Assembly (+H370)
69
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
76
Additional Requirements for Explosion-Safe (EX) Motors
76
And am
76
Additional Requirements for the Regenerative and Low Harmonics Drives
76
Additional Requirements for ABB High-Output and IP23 Motors
76
Additional Requirements for Non-ABB High-Output and IP23 Motors
76
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
77
Selecting the Power Cables
78
General Guidelines
78
Typical Power Cable Sizes
79
Power Cable Types
79
Preferred Power Cable Types
79
Alternate Power Cable Types
80
Not Allowed Power Cable Types
81
Additional Guidelines, North America
81
Metal Conduit
82
Power Cable Shield
82
Selecting the Control Cables
83
Shielding
83
Signals in Separate Cables
83
Signals that Can be Run in the same Cable
83
Relay Cable
83
Control Panel to Drive Cable
83
PC Tool Cable
84
Routing the Cables
84
General Guidelines - IEC
84
General Guidelines - North America
85
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable
85
Separate Control Cable Ducts
86
Implementing Motor and Motor Cable Short-Circuit and Thermal Overload Protection
86
Protecting the Motor and Motor Cable in Short-Circuits
86
Protecting the Motor Cables against Thermal Overload
86
Protecting the Motor against Thermal Overload
86
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
87
Protecting the Drive and the Input Power Cable in Short-Circuits
87
Protecting the Drive against Thermal Overload
87
Protecting the Input Power Cable against Thermal Overload
88
Implementing a Motor Temperature Sensor Connection
88
Connecting Motor Temperature Sensor to the Drive Via an Option Module
88
Protecting the Drive against Ground Faults
89
Residual Current Device Compatibility
89
Implementing the Emergency Stop Function
89
Implementing the Safe Torque off Function
89
Implementing the Undervoltage Control (Power-Loss Ride-Through)
90
Implementing the Functions Provided by the FSO-XX Safety Functions Module
90
Using Power Factor Compensation Capacitors with the Drive
90
Using a Safety Switch between the Drive and the Motor
90
Implementing an ATEX-Certified Motor Thermal Protection
91
Controlling a Contactor between Drive and Motor
91
Implementing a Bypass Connection
91
Example Bypass Connection
92
Switching the Motor Power Supply from Drive to Direct-On-Line
92
Switching the Motor Power Supply from Direct-On-Line to Drive
93
Protecting the Contacts of Relay Outputs
93
8 Electrical Installation
95
Contents of this Chapter
95
Safety
95
Grounding the Motor Cable Shield at the Motor End
95
Measuring the Insulation
96
Measuring the Insulation of the Drive
96
Measuring the Insulation of the Input Power Cable
96
Measuring the Insulation of the Motor and Motor Cable
96
Grounding System Compatibility Check
96
Corner-Grounded and Midpoint-Grounded Delta Systems
97
Identifying the Grounding System of the Electrical Power Network
97
When to Disconnect EMC Filter and Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta, and Midpoint-Grounded Delta Systems
98
Guidelines for Installing the Drive to a TT System
98
Disconnecting Instructions
99
Connecting the Power Cables
99
Power Cable Connection Diagram
100
Preparing the Cable Ends and Making 360-Degree Grounding at the Cable Entry
102
Power Cable Connection Procedure
103
Connecting the Control Cables to the Integrated Control Unit
104
Connecting External Power Supply Wires to the Control Units
105
Connecting a Control Panel
106
Connecting a Remote Panel, or Chaining One Panel to Several Drives
106
Connecting a PC
107
Installing Option Modules
107
Option Slot 2 (I/O Extension Modules)
108
Option Slot 1 (Fieldbus Adapter Modules)
109
Wiring the Optional Modules
109
9 Control Unit
111
Contents of this Chapter
111
Layout
112
Default I/O Connection Diagram
113
Switches
114
Additional Information on I/O Connections
114
PNP Configuration for Digital Inputs (X2 & X3)
114
NPN Configuration for Digital Inputs (X2 & X3)
115
Connection for Obtaining 0
115
Connection Examples of Two-Wire and Three-Wire Sensors to Analog Input (AI2)
116
DI5 as Frequency Input
116
DI6 as PTC Input
116
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)
116
Safe Torque off (X4)
117
Technical Data
118
10 External Control Unit (Option +P906)
123
Contents of this Chapter
123
Product Overview
123
Layout
124
Cables
124
Unpacking the Delivery
125
Installing the Control Unit
125
Installation Procedure
126
Optical Components
126
Connecting the Control Unit to the Drive Module
130
Maintenance
131
Dimension Drawing
132
11 Installation Example in Rittal VX25 Enclosure
133
Contents of this Chapter
133
Limitation of Liability
133
Safety
133
Required Parts
134
Required Tools
134
Overall Flowchart of the Installation Process
134
Installing the Drive Module and LCL Filter Module into an Enclosure
135
Connecting the Motor Cables and Installing the Shrouds (Option +B051)
136
Connecting the Input Cables and Installing the Shrouds (Option +B051)
137
Installing the Air Baffles
137
Installing the Roof and Door (Rittal Parts)
138
Removing the Protective Covering from the Drive Module and LCL Filter Module Air Outlet
139
12 Installation Checklist
141
Contents of this Chapter
141
Checklist
141
13 Start-Up
143
Contents of this Chapter
143
Start-Up Procedure
143
14 Fault Tracing
145
Contents of this Chapter
145
Leds
145
Drive Leds
145
Control Panel Leds
146
Warning and Fault Messages
146
15 Maintenance
147
Contents of this Chapter
147
Maintenance Intervals
147
Descriptions of Symbols
147
Recommended Annual Maintenance Actions by the User
147
Recommended Maintenance Intervals after Start-Up
148
Recommended Functional Safety Actions
148
Cleaning the Interior of the Cabinet
148
Cleaning the Interior of the Heatsink
149
Cleaning the Interior of the LCL Filter
150
Fans
150
Replacing the Auxiliary Cooling Fans of the Drive Module
150
Replacing the Drive Module Main Cooling Fans
151
Replacing the LCL Filter Module Cooling Fan
152
Replacing the Standard Drive Module
153
Replacing the LCL Filter Module
156
Capacitors
157
Reforming the Capacitors
157
Control Panel
157
Cleaning the Control Panel
157
Replacing the Battery
157
Functional Safety Components
158
16 Ordering Information
159
Contents of this Chapter
159
Control Panel Options
159
Output (Du/Dt) Filters
160
Cabinet Ventilation
160
Air Inlet Kits
160
Air Outlet Kits
162
Cooling Fans
163
Control Panel Mounting Platforms
163
Retrofit Accessory Kits
163
17 Technical Data
165
Contents of this Chapter
165
Electrical Ratings
165
When Is Derating Necessary
167
Surrounding Air Temperature Derating
167
Altitude Derating
167
Fuses (IEC)
169
Fuses (UL)
170
Dimensions, Weights and Free Space Requirements
171
Losses, Cooling Data and Noise
172
Terminal and Entry Data for the Power Cables
172
Power Cables
173
Terminal Data for the Control Cables
173
Electrical Power Network Specification
174
Motor Connection Data
175
Control Panel Type
176
Efficiency
176
Energy Efficiency Data (EU Ecodesign)
176
Protection Classes for Module
176
Surrounding Air Conditions
176
Materials
177
Applicable Standards
178
Markings
178
EMC Compliance (IEC/EN 61800-3:2004)
179
Definitions
179
Category C3
179
Category C4
180
UL and CSA Checklist
181
Design Lifetime Expectancy
181
EU Declaration of Conformity (Machinery Directive)
181
Disclaimer
182
Generic Disclaimer
182
Cybersecurity Disclaimer
182
18 Dimension Drawings
183
Contents of this Chapter
183
Standard Configuration (+E208 and +E210 Included)
184
Drive Module with Option +B051
185
Drive Module with Options +B051, +H370
186
LCL Filter Module
187
Bottom Plate
188
Air Baffles
189
Material of the Air Baffles
189
19 Example Circuit Diagrams
191
Contents of this Chapter
191
Example Circuit Diagram
191
20 The Safe Torque off Function
193
Contents of this Chapter
193
Description
193
Compliance with the European Machinery Directive
194
Wiring
195
Connection Principle
195
Single ACQ580-34 Drive, Internal Power Supply
195
Single ACQ580-34 Drive, External Power Supply
195
Wiring Examples
196
Single ACQ580-34 Drive, Internal Power Supply
196
Single ACQ580-34 Drive, External Power Supply
196
Multiple ACQ580-34 Drives, Internal Power Supply
197
Multiple ACQ580-34 Drives, External Power Supply
198
Activation Switch
198
Cable Types and Lengths
199
Grounding of Protective Shields
199
Operation Principle
200
Start-Up Including Validation Test
201
Competence
201
Validation Test Reports
201
Validation Test Procedure
201
Use
203
Maintenance
204
Competence
204
Fault Tracing
205
Safety Data
206
Abbreviations
206
TÜV Certificate
207
Declaration of Conformity
208
21 CHDI-01 115/230 V Digital Input Extension Module
209
Contents of this Chapter
209
Product Overview
209
Layout and Connection Examples
210
Mechanical Installation
211
Necessary Tools
211
Unpacking and Examining the Delivery
211
Installing the Module
211
Electrical Installation
211
Wiring
211
Start-Up
212
Setting the Parameters
212
Parameter Setting Example for Relay Output
212
Fault and Warning Messages
212
Technical Data
212
Dimension Drawing
213
22 CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)
215
Contents of this Chapter
215
Product Overview
215
Layout and Example Connections
216
Mechanical Installation
217
Necessary Tools
217
Unpacking and Examining the Delivery
217
Installing the Module
217
Electrical Installation
217
Wiring
217
Start-Up
218
Setting the Parameters
218
Diagnostics
219
Faults and Warning Messages
219
Leds
219
Technical Data
219
Dimension Drawing
220
23 CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)
221
Contents of this Chapter
221
Product Overview
221
Layout and Example Connections
222
Mechanical Installation
222
Necessary Tools
222
Unpacking and Examining the Delivery
223
Installing the Module
223
Electrical Installation
223
Necessary Tools and Instructions
223
Wiring
223
Start-Up
223
Setting the Parameters
223
Diagnostics
224
Faults and Warning Messages
224
Leds
224
Technical Data
224
Dimension Drawing
225
24 Filters
227
Contents of this Chapter
227
Du/Dt Filters
227
When Is a Du/Dt Filter Necessary
227
Selection Table
227
Ordering Codes
228
Description, Installation and Technical Data of the FOCH Filters
228
25 Step-By-Step Drawings for an Installation Example of Standard Drive Configuration in Rittal VX25 800 MM Wide Enclosure
229
Handling the Drive Module, Power Cable Connection Diagram
229
Installing the Drive Module and LCL Filter Module into a Rittal VX25 Enclosure
231
Connecting the Motor Cables and Installing the Shrouds
236
Connecting the Input Power Cables and Installing the Shrouds
239
Installing the Air Baffles and Removing the Cardboard Covers
240
Further Information
243
Other manuals for ABB ACQ580-34
Quick Installation Guide
22 pages
4
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ABB ACQ580-34 Specifications
General
Brand
ABB
Model
ACQ580-34
Category
Control Unit
Language
English
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