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Installation instructions 77

Installation instructions

Contents of this chapter

This chapter contains the general installation instructions for the drive module. The

chapter refers to the installation example chapters which contain instructions that depend

on the selected drive configuration.

Safety

WARNING! If you are not a qualified electrical professional do not do the

installation work described in this chapter. Obey the instructions in chapter

Safety instructions. If you ignore them, injury or death, or damage to the

equipment can occur.

Checking the installation site

The material below the drive must be non-flammable and strong enough to carry the

weight of the drive.

See section Ambient conditions on page 196 for the allowed ambient conditions and

section Losses, cooling data and noise on page 192 for the required cooling air.

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

Brand	ABB
Model	ACS880-34
Category	DC Drives
Language	English

ABB ACS880-34 User Manual

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