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ACS880-34
ABB ACS880-34 User Manual
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du/dt and sine filters 241
Description, installation and tech
nical data of the sine filters
See
Sine filters hardware manual
(3AXD50000016814 [English]) and manuafacturer
’
s site
on the Internet
https://en.tdk.eu/tdk-en/1029
890/
products/product-catalog/emc-
components/output-filters--epcos-
.
240
242
Table of Contents
Default Chapter
5
Table of Contents
5
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
Precautions before Electrical Work
18
Additional Instructions and Notes
19
Grounding
20
Additional Instructions for Permanent Magnet Motor Drives
21
Safety in Installation, Start-Up and Maintenance
21
Additional Instruction for DC Connection
21
2 Introduction to the Manual
23
Contents of this Chapter
23
Target Audience
23
Categorization by Frame Size and Option Code
23
Quick Installation, Commissioning and Operating Flowchart
24
Terms and Abbreviations
26
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
Converter Module
33
LCL Filter Module
34
Power Module with Full Power Cabling Panels (Option +H381)
35
Converter 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 Guidelines for Planning the Cabinet Installation
43
Contents of this Chapter
43
Limitation of Liability
43
Installation Positions of the Drive Module
43
Basic Requirements for the Cabinet
43
Planning the Layout of the Cabinet
44
Layout Example, Door Closed
45
Layout Example, Door Open (Standard Drive Module Configuration)
46
Layout Example, Door Open (Option +0B051)
47
Arranging the Grounding Inside the Cabinet
48
Selecting the Busbar Material and Preparation of the Joints
48
Tightening Torques
48
Planning the Fastening of the Cabinet
48
Planning the Cabinet Placement on a Cable Channel
49
Planning the Electromagnetic Compatibility (EMC) of the Cabinet
49
Planning the Cooling
50
Preventing the Recirculation of Hot Air
52
Bookshelf Mounting (Standard Drive Module Configuration)
53
Bookshelf Mounting (Option +0B051)
54
Bookshelf Mounting (Option +H381)
55
Required Free Space
55
Free Space at the Top of the Drive Module
55
Free Space Around the Drive Module
55
Planning the Placement of the Control Panel
56
Planning the Use of Cubicle Heaters
56
ABB Air Inlet and Outlet Kits
56
5 Guidelines for Planning the Electrical Installation
57
Contents of this Chapter
57
Selecting the Supply Disconnecting Device
58
European Union
58
Other Regions
58
Selecting the Main Contactor
58
Examining the Compatibility of the Motor and Drive
58
Protecting the Motor Insulation and Bearings
59
Requirements Table
59
Additional Requirements for Explosion-Safe (EX) Motors
61
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and
61
Additional Requirements for the Braking Applications
61
Additional Requirements for ABB High-Output and IP23 Motors
61
Additional Requirements for Non-ABB High-Output and IP23 Motors
61
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
62
Additional Note for Sine Filters
62
Additional Note for Common Mode Filters
62
Selecting the Power Cables
63
General Rules
63
Typical Power Cable Sizes
64
Alternative Power Cable Types
65
Recommended Power Cable Types
65
Power Cable Types for Restricted Use
65
Not Allowed Power Cable Types
65
Motor Cable Shield
66
Additional US Requirements
66
Conduit
66
Armored Cable / Shielded Power Cable
66
Planning the Braking System
67
Selecting the Control Cables
67
Shielding
67
Signals in Separate Cables
67
Signals Allowed to be Run in the same Cable
67
Relay Cable Type
67
Control Panel Cable Length and Type
67
Routing the Cables
67
Separate Control Cable Ducts
68
Continuous Motor Cable Shield or Enclosure for Equipment in the Motor Cable
68
Implementing Thermal Overload and Short-Circuit Protection
69
Protecting the Drive and Input Power Cable in Short-Circuits
69
Circuit Breakers
69
Protecting the Motor and Motor Cable in Short-Circuits
69
Protecting the Motor against Thermal Overload
69
Protecting the Drive against Ground Faults
70
Residual Current Device Compatibility
70
Connecting Drive Modules to a Common DC System
70
Implementing the Emergency Stop Function
70
Implementing the Safe Torque off Function
70
Implementing the ATEX-Certified Safe Motor Disconnection Function (Option +Q971)
71
Implementing Safety Functions Provided by the FSO Safety Functions Module
71
Q972 and +Q973)
71
Declaration of Conformity
71
Implementing the Power Loss Ride-Through Function
71
Using Power Factor Compensation Capacitors with the Drive
72
Implementing a Safety Switch between the Drive and the Motor
72
Using a Contactor between the Drive and the Motor
73
Protecting the Contacts of Relay Outputs
73
Connecting a Motor Temperature Sensor to the Drive I/O
75
Connection of Motor Temperature Sensor to the Drive Via an Option Module
75
Connection of Motor Temperature Sensor to the Drive Via a Relay
76
Example Circuit Diagram
76
6 Installation Instructions
77
Contents of this Chapter
77
Safety
77
Checking the Installation Site
77
Moving and Unpacking the Unit
78
Package Drawings
78
Drive Module Package Without Option +E202
78
Package with Option +E202
80
Boxes
81
LCL Filter Module Package
84
Checking the Delivery
85
Installing the Motor Cable at the Motor End
85
Checking the Insulation of the Assembly
85
Drive
85
Input Cable
85
Motor and Motor Cable
86
Brake Resistor and Resistor Cable
86
Ed Delta, and TT Systems
87
EMC Filter (Option +E202)
87
Ground-To-Phase Varistor
87
When to Disconnect EMC Filter (Option +E202) or Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta, and Midpoint-Grounded Delta System
88
Guidelines for Installing the Drive to a TT System
88
Identifying Different Types of Electrical Power Systems
89
Disconnecting EMC Filter and Ground-To-Phase Varistor
90
Installation Alternatives
91
Attaching the Drive Module and LCL Filter Module to a Mounting Plate or Wall
91
Attaching the Drive Module to the LCL Filter Module
91
Attaching the Drive Module and the LCL Filter Module to the Cabinet Base
91
Alternatives for Grounding the Drive Module
91
Installing Standard Configuration in Rittal TS Cabinet
92
Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) and IP20 Shrouds (Option +0B051)
93
Installing the EMC Filter (Option +E202)
93
Connecting the Power Cables
93
Power Cable Connection Diagram
94
Power Cable Connection Procedure
95
Connecting the Control Cables and Installing Option Modules
95
Connecting a Control Panel
96
Controlling Several Drives from One Control Panel through Panel Bus
97
Connecting a PC
98
7 External Control Unit
99
Contents of this Chapter
99
Layout
100
Removing the Control Panel Holder from the External Control Unit
101
Attaching the Control Cable Clamp Plate
102
Connecting the External Control Unit to the Drive Module
103
External Control Unit Connection Cables
103
Routing the Control Unit Cables into the Drive Module
103
Connecting Cables between the Drive Module and the Control Unit
104
Mounting the External Control Unit
105
Mounting the External Control Unit to Wall
105
Mounting the External Control Unit Vertically on a DIN Rail
106
Mounting the Control Unit Horizontally on a DIN Rail
106
Connecting the Control Cables to the Terminals of the Control Unit
107
Default I/O Connection Diagram
108
Notes
109
External Power Supply for the Control Unit
109
AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 Sensor Inputs (XAI, XAO)
110
DI6 (XDI:6) as PTC Sensor Input
111
DIIL Input (XD24:1)
111
Drive-To-Drive Link (XD2D)
111
Safe Torque off (XSTO)
112
Safety Functions Module Connection (X12)
112
Installing the Control Panel Holder Back Onto the External Control Unit
112
Installing Optional Modules
112
Installing the FSO Safety Functions Module (Option +Q973)
112
Installing I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules - External
114
Control Unit
114
Wiring the Optional Modules
114
Technical Data (ZCU-14)
115
8 Internal Control Unit (Option +P905)
119
Contents of this Chapter
119
Layout
120
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 Diagram
123
Notes
124
Jumpers and Switches
124
Drive-To-Drive Link (XD2D)
124
Installing Optional Modules
125
Installing the FSO Safety Functions Module (Option +Q973)
125
Installing I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules
127
Wiring the Optional Modules
127
Technical Data (ZCU-12)
128
9 Installation Example of the Standard Drive Module Configuration
131
Contents of this Chapter
131
Limitation of Liability
131
Safety
131
Required Parts
132
Required Tools
132
Overall Flowchart of the Installation Process
132
Installing the Drive Module and LCL Filter Module into a Cabinet
133
Connecting the Power Cables and Installing the Shrouds
134
Installing the Roof and Door (Rittal Parts)
136
10 Installation Example with Full Cabling Panels (Option +H381)
137
Contents of this Chapter
137
Limitation of Liability
137
Safety
137
Required Parts
138
Required Tools
138
Overall Flowchart of the Installation Process
139
Installing the Mechanical Accessories into the Cabinet
139
Connecting the Power Cables
141
Connection Diagram
141
Power Cable Connection Procedure
142
Installing the Drive Module into the Cabinet
144
Installation Procedure
145
Assembly Drawing of Connecting the Drive Module to the Cabling Panels
146
Miscellaneous
147
Installing the Rubber Grommet
147
Modular Design of Rittal TS8 Cabinets
148
11 Installation Checklist
149
Contents of this Chapter
149
12 Start-Up
153
Contents of this Chapter
153
Start-Up Procedure
153
Checks/Settings with no Voltage Connected
153
Powering up the Auxiliary Circuit of the Drive
154
Setting up the Line-Side Converter Parameters
154
Setting up the Motor-Side Converter Parameters, and Performing the First Start
154
On-Load Checks
154
13 Fault Tracing
157
Contents of this Chapter
157
Leds with Options +J410
157
Warning and Fault Messages
157
14 Maintenance
159
Contents of this Chapter
159
Maintenance Intervals
159
Descriptions of Symbols
160
Recommended Annual Maintenance Actions by the User
160
Recommended Maintenance Intervals after Start-Up
160
Cabinet
160
Cleaning the Interior of the Cabinet
160
Heatsink
161
Cleaning the Interior of the Heatsink
161
Cleaning the Interior of the LCL Filter
161
Fans
162
Replacing the Auxiliary Cooling Fans of the Drive Module
162
Replacing the Drive Module Main Cooling Fans
164
Replacing the LCL Filter Module Cooling Fan
165
Replacing the Standard Drive Module
166
Replacing the LCL Filter Module
168
Replacing the Drive Module with Option +H381
169
Replacing the LCL Filter Module with Option +H381
171
Capacitors
171
Reforming the Capacitors
171
Control Panel
171
Replacing the Control Panel Battery
171
Cleaning
172
Replacing the Control Unit Battery - External Control Unit
172
Memory Unit
172
Replacing the Drive Control Unit Memory Unit
172
Replacing the Line-Side Converter Control Unit Memory Unit
173
15 Ordering Information
175
Contents of this Chapter
175
Brake Choppers and Resistors
175
Output (Du/Dt) Filters
175
Sine Filters
175
EMC Filter ARFI-10
175
Cabinet Ventilation
176
Air Inlet Kits
176
Air Outlet Kits
178
Cooling Fans
180
FSO Accessories Kit
181
Retrofit Accessory Kits
182
16 Technical Data
183
Contents of this Chapter
183
Ratings
183
When Is Derating Needed
185
Ambient Temperature Derating
185
Altitude Derating
186
Deratings for Special Settings in the Drive Control Program
186
Ex Motor, Sine Filter, Low Noise
186
High Speed Mode
188
Derating for Output Voltage Boosting
189
Fuses (IEC)
190
Ultrarapid (Ar) Fuses
190
Fuses (UL Recognized)
191
Dimensions, Weights and Free Space Requirements
192
Losses, Cooling Data and Noise
192
Terminal and Entry Data for the Power Cables
193
Units with Optional Cabling Panels (+H381)
193
Mode Filter (+E208)
193
Terminal Data for the Control Cables
193
Electrical Power Network Specification
193
Motor Connection Data
194
DC Connection Data
195
Control Panel Type
195
Efficiency
195
Protection Classes
195
Degree of Protection
195
Ambient Conditions
196
Materials
196
Applicable Standards
197
Markings
198
EMC Compliance (IEC/EN 61800-3:2004)
198
Definitions
198
Category C2
198
Category C3
199
Category C4
199
UL Checklist
200
EU Declaration of Conformity (Machinery Directive)
202
Disclaimers
203
Generic Disclaimer
203
Cybersecurity Disclaimer
203
17 Dimension Drawings
205
Contents of this Chapter
205
Standard Configuration
206
Location of Power Cable Connection Terminals with Options +H370, +H356
207
Drive Module with Options +0B051+H356+0H371
208
LCL Filter Module
210
Bottom Plate
211
Air Baffles for the Standard Drive Module
212
Material of the Air Baffles
213
Air Baffles for Option +H381 in Rittal TS 8 800 MM Wide Cabinet
213
External Control Unit
214
18 Example Circuit Diagram
215
Contents of this Chapter
215
Example Circuit Diagram
216
19 Safe Torque off Function
217
Contents of this Chapter
217
Description
217
Compliance with the European Machinery Directive
218
Wiring
218
Activation Switch
219
Cable Types and Lengths
219
Grounding of Protective Shields
219
Single Drive (Internal Power Supply)
220
Dual-Channel Connection
220
Single-Channel Connection
220
Multiple Drives (Internal Power Supply)
221
Multiple Drives (External Power Supply)
222
Operation Principle
223
Start-Up Including Acceptance Test
223
Competence
223
Acceptance Test Reports
223
Acceptance Test Procedure
223
Use
225
Maintenance
225
Competence
226
Fault Tracing
226
Safety Data (SIL, PL)
226
Abbreviations
227
20 Resistor Braking
229
Contents of this Chapter
229
Operation Principle and Hardware Description
229
Planning the Braking System
229
Selecting the Default Brake Circuit Components
229
Selecting Custom Resistors
230
Selecting and Routing External Brake Resistor Cables
230
Minimizing Electromagnetic Interference
230
Maximum Cable Length
230
EMC Compliance of the Complete Installation
231
Placing the Brake Resistors
231
Protecting the System against Thermal Overload
231
Protecting the Resistor Cable against Short-Circuits
231
Mechanical Installation of Brake Resistors
231
Electrical Installation
232
Checking the Insulation of the Assembly
232
Connection Diagram
232
Connection Procedure
232
Start-Up
232
Technical Data
232
Ratings
232
Brake Choppers
232
Brake Resistors
233
Calculating the Maximum Allowed Braking Power for a Custom Duty Cycle
234
SAFUR Resistors
235
Dimensions and Weights
236
Ordering Codes
237
Terminals and Cable Entry Data
237
21 Du/Dt and Sine Filters
239
Contents of this Chapter
239
Du/Dt Filters
239
When Is a Du/Dt Filter Needed
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 Needed
240
Selection Table
240
ABB Ordering Codes
240
Derating
240
Description, Installation and Technical Data of the Sine Filters
241
22 Step-By-Step Drawings for an Installation Example of Standard Drive Configuration
243
In Rittal TS 8 800 MM Wide Cabinet
243
In Rittal TS 8 800 MM Wide Cabinet
244
In Rittal TS 8 800 MM Wide Cabinet
245
In Rittal TS 8 800 MM Wide Cabinet
246
In Rittal TS 8 800 MM Wide Cabinet
247
In Rittal TS 8 800 MM Wide Cabinet
248
In Rittal TS 8 800 MM Wide Cabinet
249
In Rittal TS 8 800 MM Wide Cabinet
250
In Rittal TS 8 800 MM Wide Cabinet
251
In Rittal TS 8 800 MM Wide Cabinet
252
In Rittal TS 8 800 MM Wide Cabinet
253
In Rittal TS 8 800 MM Wide Cabinet
254
Further Information
255
Product and Service Inquiries
255
Product Training
255
Providing Feedback on ABB Drives Manuals
255
Document Library on the Internet
255
Other manuals for ABB ACS880-34
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ABB ACS880-34 Specifications
General
Brand
ABB
Model
ACS880-34
Category
DC Drives
Language
English
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