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ACS880-07-0503A-5
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ABB ACS880-07-0503A-5 manual available for free PDF download: Hardware Manual
ABB ACS880-07-0503A-5 Hardware Manual (270 pages)
INDUSTRIAL DRIVES
Brand:
ABB
| Category:
DC Drives
| Size: 32.89 MB
Table of Contents
Table of Contents
5
Table of Contents
9
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
19
Optical Components
20
Printed Circuit Boards
20
Grounding
20
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
Target Audience
25
Categorization by Frame Size and Option Code
25
Quick Installation, Commissioning and Operation Flowchart
26
Terms and Abbreviations
26
Related Manuals
28
3 Operation Principle and Hardware Description
31
Contents of this Chapter
31
Product Overview
31
Single-Line Circuit Diagram of the Drive
32
Block Diagram of the Brake and DC Options (+D150, +D151 and +H356)
33
General Information on the Cabinet Layout
34
Cabinet Layout of Frames R6 to R8
35
Cabinet Layout of Frames R6 to R8 with Option +C129
36
Cabinet Layout of Frames R6 to R8 with Options +C129 and +F289
37
Cabinet Layout of Frame R9
39
Cabinet Layout of Frame R9 with Options +C129 and +F289
41
Cabinet Layout of Frames R10 and R11 - Bottom Entry and Exit of Cables
43
Cabinet Layout of Frames R10 and R11 - Top Entry and Exit of Cables (Option +C129)
45
Overview of Power and Control Connections
46
Door Switches and Lights
48
Main Switch-Disconnector (Q1)
48
Other Devices on the Door
48
Control Panel
49
Control by PC Tools
49
Descriptions of Options
49
Degree of Protection
49
Definitions
49
IP22 (UL Type 1)
50
IP42 (UL Type 1 Filtered) (Option +B054)
50
IP54 (UL Type 12) (Option +B055)
50
Marine Construction (Option +C121)
50
Cooling Air Intake through Bottom of Cabinet (Option +C128)
50
UL Listed (Option +C129)
50
Channeled Air Outlet (Option +C130)
50
CSA Approved (Option +C134)
51
Plinth Height (Options +C164 and +C179)
51
Seismic Design (Option +C180)
51
Empty Cubicles on Right (Options +C196
51
Empty Cubicles on Left (Options +C199
51
Resistor Braking (Options +D150 and +D151)
51
Du/Dt Filter (Option +E205)
51
Sine Filter (Option +E206)
51
Common Mode Filter (Option +E208)
52
Molded Case Circuit Breaker (MCCB, Option +F289)
52
Cabinet Heater with External Supply (Option +G300)
52
Cabinet Lighting (Option +G301)
52
Terminals for External Control Voltage (Option +G307)
52
Output for Motor Space Heater (Option +G313)
52
Ready/Run/Fault Lights (Options +G327
53
Halogen-Free Wiring and Materials (Option +G330)
53
V-Meter with Selector Switch (Option +G334)
53
A-Meter in One Phase (Option +G335)
53
Wire Markings
53
Standard Wiring
53
Additional Wire Markings
54
Bottom Cable Entry/Exit (Options +H350 and +H352)
54
Top Cable Entry/Exit (Options +H351 and +H353)
54
Cable Conduit Entry (Option +H358)
54
Additional Terminal Block X504 (Option +L504)
54
Thermal Protection with PTC Relays (Options +L505, +2L505, +L513, +2L513, +L536, +L537)
55
L505, +2L505, +L513, +2L513
55
L536, +L537
55
Thermal Protection with Pt100 Relays (Options +Nl506, +Nl514)
56
Starter for Auxiliary Motor Fan (Options +M6Xx)
56
What the Option Contains
56
Description
57
Type Designation Label
58
Type Designation Key
59
Basic Codes
59
Option Codes
59
4 Mechanical Installation
65
Contents of this Chapter
65
Examining the Installation Site
65
Necessary Tools
66
Moving the Drive in Its Package
66
Horizontal Package
66
Vertical Package
68
Unpacking the Transport Package
69
Lifting the Cabinet
70
Lifting from the Cabinet from the Horizontal Package
70
Lifting the Cabinet with Crane
71
Lifting Lugs
71
Certificate of Conformity
71
Declaration of Conformity
72
Moving the Cabinet after Unpacking
73
Moving the Cabinet with Rollers
74
Moving the Cabinet to Its Final Placement with a Slate Bar
74
Moving the Cabinet on Its Back
74
Installing the IP54 Roof
75
Frames R6 to R8
75
Frame R9
76
Frames R10 and R11
76
Attaching the Cabinet to the Floor and Wall or Roof
77
General Rules
77
Attaching the Cabinet (Non-Marine Units)
78
Alternative 1 - Clamping
78
Alternative 2 - Using the Holes Inside the Cabinet
79
Alternative 3 - Cabinets with Plinth Options +C164 and +C179
80
Attaching the Cabinet (Marine Units)
81
Miscellaneous
82
Cable Duct in the Floor below the Cabinet
82
Arc Welding
82
Air Inlet through the Bottom of Cabinet (Option +C128)
82
Air Outlet Duct on the Cabinet Roof (Option +C130)
83
Calculating the Required Static Pressure Difference
84
5 Guidelines for Planning the Electrical Installation
85
Contents of this Chapter
85
Limitation of Liability
85
Selecting the Supply Disconnecting Device
85
Selecting the Main Contactor
85
Examining the Compatibility of the Motor and Drive
86
Protecting the Motor Insulation and Bearings
86
Requirements Table
86
Availability of Du/Dt Filter and Common Mode Filter by Drive Type
89
Additional Requirements for Explosion-Safe (EX) Motors
89
And am
89
Additional Requirements for ABB High-Output and IP23 Motors
89
Additional Requirements for Non-ABB High-Output and IP23 Motors
89
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
90
Additional Note for Sine Filters
91
Selecting the Power Cables
91
General Guidelines
91
Typical Power Cable Sizes
92
Power Cable Types
92
Preferred Power Cable Types
92
Alternate Power Cable Types
93
Not Allowed Power Cable Types
94
Additional Guidelines, North America
94
Metal Conduit
95
Power Cable Shield
95
Planning the Resistor Braking System
96
Selecting the Control Cables
96
Shielding
96
Signals in Separate Cables
96
Signals that Can be Run in the same Cable
96
Relay Cable
96
Control Panel to Drive Cable
97
PC Tool Cable
97
Routing the Cables
97
General Guidelines - IEC
97
General Guidelines - North America
98
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable
98
Separate Control Cable Ducts
99
Protecting the Drive, Input Power Cable, Motor and Motor Cable in Short Circuit Situations and against Thermal Overload
99
Protecting the Drive and Input Power Cable in Short-Circuit Situations
99
Protecting the Motor and Motor Cable in Short-Circuits
99
Protecting the Drive and the Power Cables against Thermal Overload
100
Protecting the Motor against Thermal Overload
100
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
100
Protecting the Drive against Ground Faults
100
Residual Current Device Compatibility
100
Implementing the Emergency Stop Function
101
Implementing the Safe Torque off Function
101
Implementing the Prevention of Unexpected Start-Up Function
101
Implementing an ATEX-Certified Motor Thermal Protection
101
Implementing the Functions Provided by the FSO-XX Safety Functions Module
102
Implementing the Power Loss Ride-Through Function
102
Supplying Power for the Auxiliary Circuits
103
Using Power Factor Compensation Capacitors with the Drive
103
Using a Safety Switch between the Drive and the Motor
103
Implementing the Control of a Contactor between Drive and Motor
104
Implementing a Bypass Connection
104
Protecting the Contacts of Relay Outputs
104
Implementing a Motor Temperature Sensor Connection
105
Connecting Motor Temperature Sensor to the Drive Via an Option Module
106
6 Electrical Installation
109
Contents of this Chapter
109
Safety
109
Measuring the Insulation
109
Measuring the Insulation of the Drive
109
Measuring the Insulation of the Input Power Cable
109
Measuring the Insulation of the Motor and Motor Cable
110
Custom Brake Resistor Assembly
110
Grounding System Compatibility Check
111
Corner-Grounded and Midpoint-Grounded 525
111
Connecting the Power Cables
112
Connection Diagram
112
Layout of the Power Cable Connection Terminals and Entries (Frames R6 to R8)
113
Layout of the Power Cable Connection Terminals and Entries
114
Layout of the Power Cable Connection Terminals and Entries (Frames R6 to R8 with Options +C129+F277+F289)
115
Layout of the Input and Motor Cable Connection Terminals (Frame R9 with Option +E205)
116
Layout of the Input and Motor Cable Connection Terminals
116
Layout of the Power Cable Connection Terminals and Entries (Frame R9 with Option +C129)
117
Layout of the Input and Motor Cable Connection Terminals (Frames R10 and R11)
118
Option +C129)
118
Entry of External Resistor and DC Cables
118
Connection Procedure (IEC)
119
Connection Procedure (US)
120
Grounding the Motor Cable Shield at the Motor End
121
DC Connection (Option +H356)
121
Connecting the Control Cables
121
Control Cable Connection Procedure
122
Grounding the Outer Shields of the Control Cables at the Cabinet Entry
122
Routing the Control Cables Inside the Cabinet (Frames R6 to R8)
124
Routing the Control Cables Inside the Cabinet (Frame R9)
125
Routing the Control Cables Inside the Cabinet (Frames R10 and R11)
126
Connecting the Control Unit Cables
126
Connecting a 230/115 V AC Auxiliary Voltage Supply (UPS, Option +G307)
128
Connecting the Emergency Stop Push Buttons (Options +Q951, +Q952, +Q963, +Q964, +Q978,+Q979)
128
Wiring the Starter for Auxiliary Motor Fan (Options +M6Xx)
128
Wiring the PTC Thermistor Relay(S) (Options +L505, +2L505, +L513 and +2L513)
128
Wiring the Pt100 Relays (Option +Nl506)
129
Wiring the Pt100 Relays (Option +Nl514)
130
Powering the Heating and Lighting Equipment (Options +G300, +G301 and +G313)
131
Wiring Ground Fault Monitoring for IT Ungrounded Systems (Option +Q954)
132
Setting the Voltage Range of the Auxiliary Control Voltage Transformer (T21)
132
Connecting a PC
133
Panel Bus (Control of Several Units from One Control Panel)
133
Installing Option Modules
136
Installation of an FSO-XX Safety Functions Module Beside the ZCU-12 Control Unit
137
Installation of an FSO-XX Safety Functions Module Onto ZCU-14
138
Safety Functions Module FSO-XX Beside the ZCU-14 Control Unit
139
7 Control Units of the Drive
141
Contents of this Chapter
141
General
141
Layout
142
Layout
143
Default I/O Diagram of the Drive Control Unit (ZCU-1X)
144
Additional Information on the Connections
146
External Power Supply for the Control Unit (XPOW)
146
DI6 as a PTC Sensor Input
146
AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 Sensor Input
146
DIIL Input
147
The XD2D Connector
147
Safe Torque off (XSTO)
148
FSO-XX Safety Functions Module Connection (X12)
148
Connector Data
149
ZCU-1X Ground Isolation Diagram
151
8 Installation Checklist
153
Contents of this Chapter
153
Checklist
153
9 Start-Up
155
Contents of this Chapter
155
Start-Up Procedure
155
10 Fault Tracing
159
Contents of this Chapter
159
Leds
159
Warning and Fault Messages
159
11 Maintenance
161
Contents of this Chapter
161
Maintenance Intervals
161
Descriptions of Symbols
161
Recommended Annual Maintenance Actions by the User
161
Recommended Maintenance Intervals after Start-Up
162
Cabinet
163
Cleaning the Interior of the Cabinet
163
Cleaning the Door Air Inlets (IP22 and IP42)
163
Replacing the Inlet Door Filters (IP54)
164
Cleaning the Roof Outlet Filters (IP54)
164
Replacing the Outlet (Roof) Filters (IP54)
164
Cleaning the Heatsink
165
Fans
165
Replacing Cooling Fans
165
Replacing the Cabinet "Door" Fans
166
Replacing the Cabinet Fans (Frames R6 to R9)
167
Replacing the Drive Module Main Fans (Frames R6 to R8)
168
Replacing the Auxiliary Cooling Fan of the Drive Module (Frames R6 to R9)
169
Replacing the Drive Module Main Fans (Frame R9)
170
Replacing the Drive Module Main Fans (Frames R10 and R11)
171
Replacing the Circuit Board Compartment Cooling Fan (Frames R10 and R11)
172
Replacing the IP54 (UL Type 12) Roof Fan of Frames R6 to R8
173
Replacing the IP54 (UL Type 12) Roof Fan of Frame R9
174
Replacing the IP54 (UL Type 12) Roof Fan of Frames R10 and R11
175
Replacing the NSIN Sine Filter Cooling Fan
175
Replacing the Drive Module (Frames R6 to R8)
176
Replacing the Drive Module (Frame R9)
181
Replacing the Drive Module (Frames R10 and R11)
185
Capacitors
192
Reforming the Capacitors
192
Control Panel
192
Cleaning the Control Panel
192
Replacing the Battery
192
ZCU-12 Control Unit
193
Replacing the Memory Unit of ZCU-12
193
Replacing the ZCU-12 Control Unit Battery
194
ZCU-14 Control Unit
194
Replacing the Memory Unit of ZCU-14
194
Replacing the ZCU-14 Control Unit Battery
195
Replacing Safety Functions Modules (FSO-12, Option +Q973 and FSO-21, Option +Q972)
196
12 Technical Data
197
Contents of this Chapter
197
Ratings
197
Definitions
200
Derating
201
Ambient Temperature Derating
201
Altitude Derating
201
Switching Frequency Derating
202
Deratings for Special Settings in the Drive Control Program
202
High Speed Mode
204
Fuses (IEC)
207
Fuses (UL)
209
Dimensions and Weights
210
Dimensions and Weights of Sine Filter Cubicle (Option +E206)
210
Free Space Requirements
211
Losses, Cooling Data and Noise
211
Cooling Data and Noise for Drives with Sine Filter (Option +E206)
213
Typical Power Cable Sizes
214
Terminal and Entry Data for the Power Cables
216
Iec
216
Us
216
Terminal Data for the Control Cables
223
Electrical Power Network Specification
224
Motor Connection Data
224
Control Unit Connection Data
225
Efficiency
225
Protection Classes
225
Ambient Conditions
225
Auxiliary Circuit Power Consumption
226
Materials
226
Cabinet
226
Package
227
Disposal
227
Applicable Standards
228
Markings
228
CE Marking
229
Compliance with the European Low Voltage Directive
229
Compliance with the European EMC Directive
229
Compliance with the en 61800-3:2004
230
Definitions
230
Category C2
230
Category C3
230
Category C4
231
UL and CSA Checklist
232
Tightening Torques
232
Electrical Connections
233
Mechanical Connections
233
Insulation Supports
233
Cable Lugs
233
Disclaimers
233
Generic Disclaimer
233
Cybersecurity Disclaimer
234
13 Dimension Drawings
235
Frames R6 to R8 (IP22, IP42 [+B054], UL Type 1) - with and Without Options +C129, +H350, +H352
236
Frames R6 to R8 (IP54 / UL Type 12 [+B055]) - with and Without Options +C129, +H350, +H352
237
Frame R9 (IP22 and IP42 [+B054], UL Type 1) - with and Without Options +C129, +H350, +H352
238
Frame R9 (IP54 / UL Type 12 [+B055]) - with and Without Options +C129, +H350, +H352
239
Frame R9 Marine (IP22, IP42 [+B054], UL Type 1) - Option +C121)
240
Frames R6 to R8 with Options +F289, +C129 with and Without +H350, +H352 (UL Type 1)
241
Frames R6 to R8 with Options +F289, +C129, with and Without +H350, +H352 (UL Type 12 [+B055])
242
Frames R10 and R11 (IP22, IP42 [+B054], UL Type 1) - with and Without Options +C129, +H350, +H352
243
Frames R10 and R11 (IP54 / UL Type 12) - with and Without Options +C129, +H350, +H352
244
14 The Safe Torque off Function
245
Contents of this Chapter
245
Description
245
Compliance with the European Machinery Directive
246
Wiring
247
Activation Switch
247
Cable Types and Lengths
247
Grounding of Protective Shields
247
Single ACS880-07 Drive, Internal Power Supply
248
Dual-Channel Connection
248
Single-Channel Connection
248
Multiple Drives
249
Internal Power Supply
249
External Power Supply
250
Operation Principle
251
Start-Up Including Validation Test
252
Competence
252
Validation Test Reports
252
Validation Test Procedure
252
Use
254
Maintenance
255
Competence
255
Fault Tracing
256
Safety Data
257
Abbreviations
258
TÜV Certificate
259
Declaration of Conformity
259
15 Resistor Braking
261
Contents of this Chapter
261
When Is Resistor Braking Necessary
261
Operation Principle and Hardware Description
261
Planning the Braking System
262
Selecting the Brake Circuit Components
262
Selecting the Default Brake System Components
262
Selecting a Custom Brake Resistor
262
Selecting and Routing the Cables of Custom Resistors
263
Placing the Brake Resistor
264
Protecting the System against Thermal Overload
264
Protecting the Brake Resistor Cable against Short-Circuits
265
Mechanical Installation of Custom Brake Resistors
265
Electrical Installation of Custom Brake Resistors
265
Measuring the Insulation of the Custom Brake Resistor Circuit
265
Start-Up
265
Parameter Settings
265
Technical Data
266
Ratings
266
Degree of Protection of SAFUR Resistors
268
Terminals and Cable Entry Data
268
Further Information
269
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