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ABB ACQ80-04 Series Hardware Manual
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ABB ACQ80-04 Series Hardware Manual

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Summary of Contents for ABB ACQ80-04 Series

  • Page 1 — ABB DRIVES FOR WATER ACQ80-04 drives Hardware manual...
  • Page 3 ACQ80-04 drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation – IEC © 2022 ABB Oy. All rights reserved. 3AXD50000170661 Rev B EFFECTIVE: 2022-02-15...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ............... Use of warnings and notes .
  • Page 6 6 Table of contents Required tools ..................Unpacking the delivery .
  • Page 7 Table of contents 7 Implementing the Emergency stop function ..........Implementing the Safe torque off function .
  • Page 8 8 Table of contents Replacing the cooling fan, frame R3 ........... . . Capacitors .
  • Page 9 Table of contents 9 10 Dimension drawings Contents of this chapter ............... Frame R0 .
  • Page 10 10 Table of contents Declarations of conformity ..............12 BIO-01 I/O extension module Contents of this chapter .

  • Page 11: Safety Instructions

    Safety instructions 11 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start-up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 12: General Safety In Installation, Start-Up And Maintenance

    12 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
  • Page 13 Safety instructions 13 • The maximum number of drive power-ups is five in ten minutes. Too frequent power-ups can damage the charging circuit of the DC capacitors. • If you have connected safety circuits to the drive (for example, Safe torque off or emergency stop), validate them at start-up.

  • Page 14: Electrical Safety In Installation, Start-Up And Maintenance

    14 Safety instructions Electrical safety in installation, start-up and maintenance ￭ Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 15: Printed Circuit Boards

    Safety instructions 15 • Make sure that the electrical power network, motor/generator, and environmental conditions agree with the drive data. • Do not do insulation or voltage withstand tests on the drive. • If you have a cardiac pacemaker or other electronic medical device, keep away from the area near motor, drive, and the drive power cabling when the drive is in operation.

  • Page 16: General Safety In Operation

    16 Safety instructions General safety in operation These instructions are for all personnel that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you have a cardiac pacemaker or other electronic medical device, keep away from the area near motor, drive, and the drive power cabling when the drive is in operation.

  • Page 17: Safety In Operation

    Safety instructions 17 • If you cannot disconnect the motor, make sure that the motor cannot rotate during work. Make sure that no other system, like hydraulic crawling drives, can rotate the motor directly or through any mechanical connection like felt, nip, rope, etc. •...

  • Page 19: Introduction To The Manual

    Introduction to the manual 19 Introduction to the manual Contents of this chapter The chapter describes the applicability, target audience and purpose of the manual. The chapter contains a list of related manuals and a flowchart for installation and commissioning. Applicability This manual is applicable to ACQ80-04 drives.

  • Page 20: Quick Installation And Commissioning Flowchart

    20 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame size: R1, R2, etc. Type designation key (page 28) Plan the installation. Guidelines for planning the electrical installa- tion (page 35) Check the ambient conditions, ratings and required cooling air flow.

  • Page 21: Terms And Abbreviations

    Introduction to the manual 21 Terms and abbreviations Term Description ACS-AP-… Assistant control panel BCBL-01 Optional USB to RJ45 cable BIO-01 Optional I/O extension module. Can be installed to the drive together with a fieldbus adapter module. CCA-01 Configuration adapter CDPI-01 Communication adapter module Drive...
  • Page 22 Drive composer PC tool user's manual 3AUA0000094606 Converter module capacitor reforming instructions 3BFE64059629 You can find manuals and other product documents in PDF format on the Internet at www.abb.com/drives/documents. The code below opens an online listing of the manuals applicable to this product. ACQ80 manuals...

  • Page 23: Operation Principle And Hardware Description

    Operation principle and hardware description 23 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACQ80-04 is a drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors.

  • Page 24: Simplified Main Circuit Diagram

    AC Grid or DC photo-voltaic array or both AC and DC power Operation principle together. ABB recommends not to use it as an island grid forming inverter or to supply generic 1ph or 3ph loads, other than 3ph AC pump motors.

  • Page 25: Layout

    Operation principle and hardware description 25 Layout Type designation label Motor terminals and DC input power termin- Model information label Cooling fan (on frames R0…R3) Firmware information label Front cover Control panel connection Control terminals Control panel Cold configuration adapter connection (CCA- EMC filter grounding screw Front option slot Varistor grounding screw...

  • Page 26: Control Connections

    26 Operation principle and hardware description Control connections There are fixed control connections on the base unit and additional control connections on the installed option module. ￭ Standard unit (with RIIO-01) Connections of the base unit: 1. Auxiliary voltage output (24VDC 250mA peak) 2.

  • Page 27: Base Unit

    Operation principle and hardware description 27 ￭ Base unit Connections of the base unit: 1. Auxiliary voltage output (24VDC 250mA peak) 2. Digital inputs 3. Safe torque-off connections 4. Relay output connection 5. Cold configuration adapter connection for CCA- 6. Front option module slot 1 +24V DGND RO1C...

  • Page 28: Control Panel Options

    28 Operation principle and hardware description Control panel options The drive supports these control panels: • ACS-AP-S assistant control panel • ACS-AP-W assistant control panel with Bluetooth • ACS-AP-I assistant control panel • ACS-BP-S basic control panel • RDUM-01 blank panel with RJ-45 connector In addition, you can order a control panel platform for cabinet door installation.

  • Page 29: Basic Code

    0L540 Base unit without RIIO-01 I/O & EIA-485 module Fieldbus adapters K454 FPBA-01 PROFIBUS DP K457 FCAN-01 CANopen K458 FSCA-01 Modbus/RTU K469 FECA-01 EtherCAT K491 FMBT-21 Modbus/TCP Documentation R700 English 1) Manuals are available from ABB website in English language.

  • Page 31: Mechanical Installation

    Mechanical installation 31 Mechanical installation Contents of this chapter This chapter tells how to examine the installation site, unpack and examine the delivery and install the drive mechanically. Installation alternatives You can install the drive: • with screws on to a wall •...

  • Page 32: Required Tools

    32 Mechanical installation • The ambient conditions of the drive meet the specifications. See the technical data. • The wall behind the drive and the material above and below the unit is of non-flammable material. • There is sufficient free space around the drive for cooling, maintenance, and operation.

  • Page 33: Installing The Drive

    Mechanical installation 33 Installing the drive ￭ To install the drive with screws Make marks onto the surface for the mounting holes. Use the included mounting template for frame R3. For other frames, see the dimension drawings. 2. Drill the holes for the mounting screws. 3.
  • Page 34 34 Mechanical installation 2. Push and hold the locking button down. 3. Put the top tabs of the drive onto the top edge of the DIN installation rail. 4. Put the drive against the bottom edge of the DIN installation rail. 5.

  • Page 35: Guidelines For Planning The Electrical Installation

    Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 36: Other Regions

    The disconnecting device must conform to the applicable local safety regulations. Checking the compatibility of the motor and drive Use asynchronous AC induction motor, permanent magnet synchronous motor or ABB synchronous reluctance motor (SynRM motors) with the drive. Multiple induction motors can be connected to the drive at a time when using the scalar motor control mode.

  • Page 37: Selecting The Power Cables

    Guidelines for planning the electrical installation 37 Selecting the power cables ￭ General guidelines Select the input power and motor cables according to local regulations. • Current: Select a cable capable of carrying the maximum load current and suitable for the prospective short-circuit provided by the supply network. The method of installation and ambient temperature affect the cable current carrying capacity.

  • Page 38: Alternate Power Cable Types

    38 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or ar- mored) cable with three phase conductors and a shield (or ar- mor), and separate PE conduct- or/cable 1) A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the PE use. Alternate power cable types Cable type Use as input power cabling...

  • Page 39: Not Allowed Power Cable Types

    Guidelines for planning the electrical installation 39 Cable type Use as input power cabling Use as motor cabling WARNING! A single-core cable system: three If you use unshielded phase conductors and PE conduct- single-core cables in an IT or on cable tray network, make sure that the non-conductive outer sheath (jacket) of the...

  • Page 40: Selecting Dc Power Cables

    40 Guidelines for planning the electrical installation Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Selecting DC power cables DC cable should be able to handle 1000V VOC voltage. WARNING! Open joints in the DC power cable wiring results in damage of equipment or injury or loss of life of personal.

  • Page 41: Grounding Requirements

    Guidelines for planning the electrical installation 41 Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient. Unless local wiring regulations state otherwise, the cross-sectional area of the protective earth conductor must agree with the conditions that require automatic disconnection of the supply required in 411.3.2 of IEC 60364-4-41:2005 and be capable...

  • Page 42: Additional Grounding Requirements - Ul (Nec)

    Shielding Only use shielded control cables. Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable also for the pulse encoder signals. Use one individually shielded pair for each signal. Do not use common return for different analog signals.

  • Page 43: Control Panel To Drive Cable

    Guidelines for planning the electrical installation 43 ￭ Control panel to drive cable Use EIA-485, Cat 5e (or better) cable with male RJ-45 connectors. The maximum length of the cable is 100 m (328 ft). ￭ PC tool cable Connect the Drive Composer PC tool to the drive through the USB port of the control panel.

  • Page 44: Motor Cable

    44 Guidelines for planning the electrical installation ￭ Continuous motor cable shield/conduit or enclosure for equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...

  • Page 45: Protecting The Drive, And The Input Power And Motor Cables Against Thermal Overload

    Guidelines for planning the electrical installation 45 ￭ Protecting the drive, and the input power and motor cables against thermal overload If the cables have the correct size for the nominal current, the drive protects itself and the input and motor cables against thermal overload. No additional thermal protection devices are needed.

  • Page 46: Protecting The Drive Against Ground Faults

    46 Guidelines for planning the electrical installation of the drive. See the control cable connection instructions. Make sure that the voltage does not exceed the maximum allowed voltage over the sensor. 2. You can connect a sensor to a digital input of the drive via an external relay. The sensor and the relay must form a double or reinforced insulation between the motor live parts and the digital input of the drive.

  • Page 47: Implementing The Safe Torque Off Function

    Guidelines for planning the electrical installation 47 Implementing the Safe torque off function See chapter The Safe torque off function (page 107) Implementing the control of a contactor between drive and motor Implementing the control of the output contactor depends on the motor control mode and stopping method selected.
  • Page 48 48 Guidelines for planning the electrical installation 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode...

  • Page 49: Electrical Installation - Iec

    Electrical installation – IEC 49 Electrical installation – IEC Contents of this chapter This chapter describes how to: • measure the insulation • do the grounding system compatibility check • change the EMC filter or ground-to-phase varistor connection • connect the power and control cables •...

  • Page 50: Measuring The Insulation Resistance - Iec

    Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.

  • Page 51: Emc Filter

    Electrical installation – IEC 51 ￭ EMC filter The drive has an internal EMC filter as standard. You can install a drive that has the internal EMC filter connected to a symmetrically grounded TN-S system (center-grounded wye). For other systems, refer to Compatibility of EMC filter and ground-to-phase varistor with the grounding system (page 51) Note: If you disconnect the EMC filter, the electromagnetic compatibility of the drive...

  • Page 52: Disconnecting The Emc Filter Or Ground-To-Phase Varistor

    52 Electrical installation – IEC you connect the drive to the input power, examine the screws and do the necessary actions shown in the table. Screw la- Screw material When to remove EMC screw or VAR screw Symmetrically groun- Corner-grounded IT systems (ungroun- ded TN-S systems, i.e, delta (B1), midpoint-...

  • Page 53: Identifying The Grounding System Of The Electrical Power Network

    2. The internal EMC filter is disconnected. If the EMC filter is not disconnected, its leakage current will cause the residual current device to trip. Note: • ABB does not guarantee the EMC performance, because the internal EMC filter is disconnected. • ABB does not guarantee the functioning of the ground leakage detector built inside the drive.

  • Page 54: Connecting The Power Cables - Iec (Shielded Cables)

    Note: ACQ80 is intended to be used for speed control of 3ph AC pump motors and is loads, other than 3ph AC pump motors. powered from either AC Grid or DC photo-voltaic array. ABB recommends not to use t of it as an island grid forming inverter or to supply generic 1ph or 3ph loads, other than ...

  • Page 55: Connecting The Control Cables - Iec

    Electrical installation – IEC 55 3. Attach the residual voltage warning sticker in the local language to the drive. 4. Strip the motor cable. 5. Ground the motor cable shield under the grounding clamp for 360-degree grounding. 6. Twist the motor cable shield into a bundle, mark it with yellow-green insulation tape, install a cable lug, and connect it to the grounding terminal.

  • Page 56: Additional Information On The Control Connections

    56 Electrical installation – IEC WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 57: Pnp Configuration For Digital Inputs

    Electrical installation – IEC 57 seconds. If the drive detects the control panel, remove the control panel and reboot the drive again. Cable connection diagram Note: • When an external IO module (RIIO, BIO-01 etc) is connected to drive, this changeover does not happen and only external IO is used for communication.

  • Page 58: Connection Examples Of Two-Wire And Three-Wire Sensors

    58 Electrical installation – IEC Connection examples of two-wire and three-wire sensors The figures give examples of connections for a two-wire or three-wire sensor/transmitter that is supplied by the auxiliary voltage output of the drive. 4…20 mA AGND +24V DGND Process actual value measurement or reference, 0(4) …...
  • Page 59 Electrical installation – IEC 59 The sensor resistance increases as the motor temperature rises, as does the voltage over the sensor. The temperature measurement function calculates the resistance of the sensor and generates an indication if overtemperature is detected. Leave the sensor end of the cable shield unconnected.

  • Page 60: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs

    60 Electrical installation – IEC AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or •...

  • Page 61: Auxiliary Voltage Connection

    Electrical installation – IEC 61 Auxiliary voltage connection The drive has 24 V DC (±10%) auxiliary power supply terminals both on the base unit and on the module. You can use them: • to supply auxiliary power from the drive to external control circuits or option modules •...

  • Page 63: Installation Checklist

    Installation checklist 63 Installation checklist Contents of this chapter This chapter contains a checklist of the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 64 64 Installation checklist Make sure that … The drive cabinet is having a rating IP54 or higher. The cooling air flows freely in and out of the drive. If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground-to-phase varistor).

  • Page 65: Maintenance

    Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (https://new.abb.com/drives/services/maintenance/preventive-maintenance). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). ￭ Description of symbols...

  • Page 66: Recommended Maintenance Intervals After Start-Up

    • Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 67: Cleaning The Heatsink

    Parameter 05.04 Fan on-time counter shows the running time of the cooling fan. After you replace the fan, reset the fan counter. Refer to the firmware manual. You can get replacement fans from ABB. Use only ABB specified spare parts. ￭...
  • Page 68 68 Maintenance 4. Remove the fan power cable from the cable slot in the drive. 5. Disconnect the fan power cable. 6. Free the fan clips and remove the fan from the fan cover. 7. Install the new fan into the fan cover. Make sure that the air flow is in the correct direction.

  • Page 69: Replacing The Cooling Fan, Frame R3

    Maintenance 69 ￭ Replacing the cooling fan, frame R3 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 70: Capacitors

    The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more. The manufacturing date is on the type designation label. For information on reforming the capacitors, see Capacitor reforming instructions (3BFE64059629 [English]) in the ABB Library (https://library.abb.com/en).

  • Page 71: Technical Data

    Technical data 71 Technical data Contents of this chapter The chapter contains the technical specifications of the drive, for example ratings, sizes and technical requirements as well as provisions for fulfilling the requirements for CE and other approval marks. Electrical ratings ￭...

  • Page 72: Definitions

    72 Technical data Drive Type Nominal In Nominal Max. current Output ratings Frame size ACQ80-04- Nominal use 011kW-4 25.0 20.4 30.6 25.0 11.0 15.0 015kW-4 33.0 30.0 45.0 32.0 15.0 20.0 18kW5-4 39.0 31.9 57.6 38.0 18.5 25.0 022kW-4 50.0 40.9 81.0 50.0...

  • Page 73: Sizing

    Technical data 73 Short circuit current Open circuit voltage Direct current voltage ￭ Sizing Drive sizing is based on the rated motor current and power. To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current.

  • Page 74: Surrounding Air Temperature Derating

    74 Technical data Altitude derating: The derating factor for 1800 m is Surrounding air temperature derating: Derating is not necessary at 35 °C surrounding air temperature. To see if the derated output current of a drive is sufficient for the application, multiply the nominal output current ( I ) by all the applicable derating factors.

  • Page 75: Fuses (Iec)

    AC fuses gG fuses Drive type Input cur- gG (IEC 60269) Minimum ACQ80-04- rent short cir- Rated cur- Rated ABB designa- IEC 60269 cuit cur- rent I voltage tion type size rent 3 phases U = 400 V (380...480 V) 0kW75-4...

  • Page 76: Dc Fuses (Gg)

    76 Technical data Drive type Input cur- gR (IEC 60269) Minimum ACQ80-04- rent short cir- Rated cur- Rated ABB desig- IEC 60269 cuit cur- rent I voltage nation type size rent 01kW1-4 170M2694 01kW5-4 170M2695 02kW2-4 170M2695 03kW0-4 11.5 170M2696 04kW0-4 15.0...

  • Page 77: Mov

    170M2702 170M 2678 2678 63A,1000V 6 3 A , 1 0 0 0 V 3AXD10000715646.xls Note: ABB recommends to use above fuses for reverse polarity protection between ACQ80 drive and solar array/solar string. ￭ Ordering code Type code VRMS (TDK)

  • Page 78: Dc Emi Filter

    18kW5-4 IRKE-56/12 022kW-4 IRKE-71/12 Alternate short-circuit protection The table below lists MCB circuit breakers that can be used with the drive. Type MCBs ACQ80- ABB type Max. Tmax Tmax rat- Electronic SACE ordering short-cir- frame XT / release code for breaker...

  • Page 79: Dimensions And Weights

    Technical data 79 Type MCBs ACQ80- ABB type Max. Tmax Tmax rat- Electronic SACE ordering short-cir- frame XT / release code for breaker cuit T class and release unit 02kW2-4 S 203P-B/C/Z 10 03kW0-4 S 203P-B/C/Z 10 04kW0-4 S 203P-B/C/Z 10...

  • Page 80: Free Space Requirements

    80 Technical data Depth Mounting hole distance Mounting hole distance Free space requirements Frame Free space requirement Above Below Sides 1) A side-mounted option module requires 20 mm (0.8 in) of free space on the right side of the drive. Thermal losses, cooling data and noise Drives with frame size R0…R3 have a cooling fan.

  • Page 81: Terminal Data For The Control Cables

    Technical data 81 ACQ80-04 L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ UDC+ Minimum Maximum Tightening Minimum Maximum Tightening torque (solid/stran- (solid/stran- torque (solid/stran- (solid/stran- ded) ded) ded) ded) N·m N·m 01kW5-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 02kW2-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 03kW0-4 0.5/0.5...

  • Page 82: Electrical Power Network Specification

    DC voltage max limit is 800 VDC Network type Public low voltage networks. TN (grounded), IT (ungrounded) and corner- grounded TN systems. Consult ABB before connecting to other systems (for example, TT, or midpoint grounded delta) Rated conditional short-cir- 65 kA when protected by fuses given in the fuse tables...

  • Page 83: Emc Compatibility And Motor Cable Length

    Technical data 83 Frame Maximum motor cable length Standard drive, without external options R0…R3 Notes: Terminal data for the power • Applicable for cable types mentioned in section cables (page 80) • Conducted and radiated emissions of these motor cable lengths do not comply with the EMC requirements of IEC/EN 61800-3.

  • Page 84: Control Connection Data

    100 … 165 ohm, for example Belden 9842 Transmission rate: 9.6 … 115.2 kbit/s Termination by switch Energy efficiency data (ecodesign) Energy efficiency data according to IEC-61800-9-2 is available from the ecodesign tool (https://ecodesign.drivesmotors.abb.com).

  • Page 85: Protection Classes

    Technical data 85 Protection classes Degree of protection IP20. The drive must be installed in a cabinet to fulfill the requirements for (IEC/EN 60529) shielding from contact. Overvoltage category (IEC 60664-1) Protective classes (IEC/EN 61800-5-1) Ambient conditions Environmental limits for the drive are given below. The drive must be used in a heated indoor controlled environment.

  • Page 86: Materials

    IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.

  • Page 87: Markings

    Technical data 87 EN 62061:2005 + AC:2010 Safety of machinery – Functional safety of safety-related electrical, electronic + A1:2013 + A2:2015 and programmable electronic control systems EN 61800-3:2004 + Adjustable speed electrical power drive systems. Part 3: EMC requirements A1:2012 and specific test methods IEC 61800-3:2004 + A1:2011...

  • Page 88: Category C1

    88 Technical data Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes. Second environment includes establishments connected to a network not supplying domestic premises.

  • Page 89: Category C4

    Technical data 89 WARNING! Do not install a drive with the internal EMC filter connected to a grounding system that the EMC filter is not compatible with (for example, an IT system). The supply network becomes connected to ground potential through the internal EMC filter capacitors, which can cause danger or damage to the drive.

  • Page 90: Disclaimers

    Notwithstanding any other provision to the contrary and regardless whether the contract is terminated or not, ABB and its affiliates are under no circumstances liable for damages and/or losses related to such security breaches, any unauthorized access,...

  • Page 91: Dimension Drawings

    Dimension drawings 91 Dimension drawings Contents of this chapter The chapter contains the dimension drawings of the drive. The dimensions are in millimeters and inches.

  • Page 92: Frame R0

    92 Dimension drawings Frame R0 ￭ Frame R0(front & side) - IP20...

  • Page 93: Frame R0(Bottom & Rear) - Ip20

    Dimension drawings 93 ￭ Frame R0(bottom & rear) - IP20...

  • Page 94: Frame R1

    94 Dimension drawings Frame R1 ￭ Frame R1(front & side) - IP20...

  • Page 95: Frame R1(Bottom & Rear) - Ip20

    Dimension drawings 95 ￭ Frame R1(bottom & rear) - IP20...

  • Page 96: Frame R2

    96 Dimension drawings Frame R2 ￭ Frame R2(front & side) - IP20...

  • Page 97: Frame R2(Bottom & Rear) - Ip20

    Dimension drawings 97 ￭ Frame R2(bottom & rear) - IP20...

  • Page 98: Frame R3

    98 Dimension drawings Frame R3 ￭ Frame R3(front & side) - IP20...

  • Page 99: Frame R3(Bottom & Rear) - Ip20

    Dimension drawings 99 ￭ Frame R3(bottom & rear) - IP20...

  • Page 100: Recommended Cabinet Design

    100 Dimension drawings Recommended cabinet design ￭ Cabinet assembly drawings...
  • Page 101 Dimension drawings 101...

  • Page 102: Module Mounting Plate Detail Drawing

    102 Dimension drawings ￭ Module mounting plate detail drawing...

  • Page 103: Supporting C Clamp Detail Drawing

    Dimension drawings 103 ￭ Supporting C clamp detail drawing...

  • Page 104: Emi Filter Layout Diagram

    104 Dimension drawings EMI filter layout diagram ￭ EMI filter layout - Horizontal position Metallic backplabe (enclosure) Solar pump drive ACQ80 Max. 10 cm DC wires max 20 cm Connection to ground (Drive to EMI filter) - short as possible DC EMI filter Varistors Earth wire - Max 15 cm...

  • Page 105: Emi Filter Layout - Vertical Position

    Dimension drawings 105 ￭ EMI filter layout - Vertical position Solar pump drive ACQ80 Max. 10 cm DC wires max. 20 cm Connection to ground (Drive to EMI filter) - short as possible Earth wire - Max. 15 cm DC EMI filter Earth wire - Max.
  • Page 106 106 Dimension drawings Note: • Keep AC, DC and motor cables separated to avoid interferences. • Do not connect reverse polarity diodes directly to ground.

  • Page 107: The Safe Torque Off Function

    The Safe torque off function 107 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, as the final actuator device of safety circuits that stop the drive in case of danger (such as an emergency stop circuit).

  • Page 108: Chinery (Safety) Regulations

    108 The Safe torque off function Standard Name IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC requirements – Part 3-1: Immunity requirements for safety-re- lated systems and for equipment intended to perform safety-related functions (functional safety) – General industrial applications IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety-related systems –...

  • Page 109: Wiring

    The Safe torque off function 109 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Connection principle Single ACQ80-04 drive, internal power supply + 24 V DC OUT1 SGND UDC+ UDC- Drive Control unit Control logic...

  • Page 110: Single Acq80-04 Drive, External Power Supply

    110 The Safe torque off function Single ACQ80-04 drive, external power supply 24 V DC OUT1 + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch ￭ Wiring examples Single ACQ80-04 drive, internal power supply OUT1 SGND Drive...

  • Page 111: Single Acq80-04 Drive, External Power Supply

    The Safe torque off function 111 Single ACQ80-04 drive, external power supply 24 V DC OUT1 SGND ÍN2 Drive Safety PLC Safety relay...

  • Page 112: Multiple Acq80-04 Drives, Internal Power Supply

    112 The Safe torque off function Multiple ACQ80-04 drives, internal power supply OUT1 +24 V SGND OUT1 SGND OUT1 SGND Drive Control unit Activation switch...

  • Page 113: Multiple Acq80-04 Drives, External Power Supply

    The Safe torque off function 113 Multiple ACQ80-04 drives, external power supply 24 V DC – OUT1 +24 V SGND OUT1 SGND OUT1 SGND Drive Control unit Activation switch ￭ Activation switch In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC.

  • Page 114: Grounding Of Protective Shields

    114 The Safe torque off function • Maximum cable lengths: • 300 m (1000 ft) between activation switch [K] and drive control unit • 60 m (200 ft) between external power supply and control unit Note: A short-circuit in the wiring between the switch and an STO terminal causes a dangerous fault.

  • Page 115: Operation Principle

    The Safe torque off function 115 Operation principle The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.

  • Page 116: Start-Up Including Validation Test

    116 The Safe torque off function Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed •...
  • Page 117 The Safe torque off function 117 Action Test the operation of the STO function when the motor is running. • Start the drive and make sure the motor is running. • Open the STO circuit. The motor should stop. The drive generates an indication if one is defined for the 'running' state in parameter 31.22 (see the firmware manual).

  • Page 118: Use

    118 The Safe torque off function Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. 3.

  • Page 119: Maintenance

    If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 116) Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭...

  • Page 120: Fault Tracing

    See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.

  • Page 121: Safety Data

    The Safe torque off function 121 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. MTTF Frame = 20 a)

  • Page 122: Tüv Certificate

    After the mission time elapses, the safety device must be replaced. Note that any T values given cannot be regarded as a guarantee or warranty. ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.

  • Page 123: Declarations Of Conformity

    The Safe torque off function 123 ￭ Declarations of conformity EU Declaration of Conformity Machinery Directive 2006/42/EC Manufacturer: ABB INDIA LIMITED. Address: Plot No 5 & 6,2nd Phase, Peenya Industrial Area, Bangalore, 560058, India. Phone: +91 80 22949359 Declare under our sole responsibility that the following product:...
  • Page 124 Name and address: Jussi Vesti, Hiomotie 13, 00380 Helsinki, Finland. Bangalore, 15 Dec 2021 Signed for and on behalf of: A R Madhusudan Laxmikantha Shenoy Vice President – Drive Products, ABB India PE Manager, ABB India 3AXD10000715412 Rev. C IMS template code: 3AFE011906, Rev. C...

  • Page 125: Bio-01 I/O Extension Module

    BIO-01 I/O extension module 125 BIO-01 I/O extension module Contents of this chapter This chapter contains a description and technical data of the optional BIO-01 I/O extension module. Safety instructions WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 126: Layout

    126 BIO-01 I/O extension module ￭ Layout 1. Locking tab 2. Option module slot 3. Chassis screw 4. I/O connector 5. Switches for configur- ing terminals S1 and S2 Mechanical installation See the electrical installation instructions of the drive. Before you install the BIO-01 option module, make sure that the chassis screw slider is in the top position.

  • Page 127: Start-Up

    BIO-01 I/O extension module 127 The connection diagram below is applicable to drives with the BIO-01 I/O extension module when the ABB standard macro is selected (parameter 96.04 ). Start-up The BIO-01 module is automatically identified by the drive firmware. To configure the inputs and outputs, refer to the drive firmware manual.
  • Page 128 128 BIO-01 I/O extension module Internal connections of GND and SCR terminals Dimensions...
  • Page 129 Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 130 3AXD50000170661B © 2022 ABB Oy. All rights reserved. Specifications subject to change without notice.

This manual is also suitable for:

Acq80-04-0kw75-4Acq80-04-01kw1-4Acq80-04-01kw5-4Acq80-04-02kw2-4Acq80-04-03kw0-4Acq80-04-04kw0-4 ... Show all

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