ABB ACS880-04F-880A-3 Manuals

Manuals and User Guides for ABB ACS880-04F-880A-3. We have 1 ABB ACS880-04F-880A-3 manual available for free PDF download: Hardware Manual

ABB ACS880-04F-880A-3 Hardware Manual (202 pages)

Brand: ABB | Category: DC Drives | Size: 35.23 MB

Table of Contents
5
Safety Instructions
13
Contents of this Chapter
13
Use of Warnings and Notes
13
General Safety in Installation, Start-Up and Maintenance
14
Electrical Safety in Installation, Start-Up and Maintenance
16
Electrical Safety Precautions
16
Additional Instructions and Notes
17
Printed Circuit Boards
17
Grounding
18
General Safety in Operation
19
Additional Instructions for Permanent Magnet Motor Drives
19
Safety in Installation, Start-Up, Maintenance
19
Safety in Operation
20
Introduction to the Manual
21
Contents of this Chapter
21
Applicability
21
Target Audience
21
Purpose of the Manual
21
Categorization by Frame Size and Option Code
21
Quick Installation, Commissioning and Operating Flowchart
22
Terms and Abbreviations
23
Related Documents
25
Operation Principle and Hardware Description
27
Contents of this Chapter
27
Product Overview
28
Layout
29
Standard Drive Module Configuration
29
Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) and IP20 Shrouds (Option +0B051), with Common Mode Filter (+E208)
31
Control Unit
31
Overview of Power and Control Connections
32
Type Designation Label
32
Type Designation Key
33
Basic Code
33
Option Codes
34
Guidelines for Planning the Mechanical Installation
37
Contents of this Chapter
37
Installation Alternatives
37
Channel Installation
37
Basic Requirements for the Channel Wall
37
Installation Principle
38
Cabinet Installation
39
Layout Example, Outside View
39
Layout Example, Inside View
40
Mounting the Control Panel on the Cabinet Door
41
Installation Positions Other than Vertical
42
Required Free Space
43
Mechanical Installation
45
Contents of this Chapter
45
Examining the Installation Site
45
Moving and Unpacking the Unit
45
Unpacking
46
Package Drawings
47
Examining the Delivery
49
Lifting
49
Attaching Alternatives
51
Attaching the Drive Module by the Flange
51
Attaching the Drive Module by the Heatsink
52
Attaching the Metallic Shroud (Standard)
53
Attaching the External Control Unit
53
Attaching the External Control Unit to a Mounting Plate or Wall
54
Attaching the External Control Unit Vertically on a DIN Rail
54
Attaching the External Control Unit Horizontally on a DIN Rail
55
Guidelines for Planning the Electrical Installation
57
Contents of this Chapter
57
Limitation of Liability
57
Selecting the Main Supply Disconnecting Device
57
European Union and United Kingdom
57
North America
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 Tables
59
Requirements for ABB Motors, P
59
Requirements for ABB Motors, P
60
Requirements for Non-ABB Motors, P
61
Requirements for Non-ABB Motors, P
62
Abbreviations
62
Availability of D U /D T Filter and Common Mode Filter by Drive Type
63
Additional Requirements for Explosion-Safe (EX) Motors
63
HX_ and am
63
Additional Requirements for Braking Applications
63
Additional Requirements for ABB High-Output and IP23 Motors
63
Additional Requirements for Non-ABB High-Output and IP23 Motors
63
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
64
Additional Note for Sine Filters
65
Selecting the Power Cables
65
General Guidelines
65
Typical Power Cable Sizes
66
Power Cable Types
66
Preferred Power Cable Types
66
Alternate Power Cable Types
66
Not Allowed Power Cable Types
67
Additional Guidelines, North America
67
Metal Conduit
68
Power Cable Shield
68
Grounding Requirements
69
Additional Grounding Requirements - IEC
70
Additional Grounding Requirements - UL (NEC)
70
Selecting the Control Cables
70
Shielding
70
Signals in Separate Cables
71
Signals that Can be Run in the same Cable
71
Relay Cable
71
Control Panel to Drive Cable
71
PC Tool Cable
71
Routing the Cables
71
General Guidelines - IEC
71
General Guidelines - North America
72
Motor Cable
73
Separate Control Cable Ducts
73
Situations and against Thermal Overload
74
Protecting the Drive and the Input Power Cable in Short-Circuits
74
Protecting the Motor and Motor Cable in Short-Circuits
74
Protecting the Motor Cables against Thermal Overload
74
Protecting the Motor against Thermal Overload
75
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
75
Protecting the Drive against Ground Faults
75
Residual Current Device Compatibility
76
Connecting Drive Modules to a Common DC System
76
Implementing a Motor Temperature Sensor Connection
76
Connecting a Motor Temperature Sensor to the Drive through an Option Module
76
Implementing the Emergency Stop Function
78
Implementing the Safe Torque off Function
78
Implementing the Functions Provided by the FSO Safety Functions Module
78
Using Power Factor Compensation Capacitors with the Drive
78
Using a Safety Switch between the Drive and the Motor
79
Implementing an ATEX-Certified Motor Thermal Protection
79
Implementing the Power Loss Ride-Through Function
79
Controlling a Contactor between Drive and Motor
80
Implementing a Bypass Connection
80
Example Bypass Connection
81
Switching the Motor Power Supply from Drive to Direct-On-Line
81
Switching the Motor Power Supply from Direct-On-Line to Drive
82
Protecting the Contacts of Relay Outputs
82
Electrical Installation
83
Contents of this Chapter
83
Safety
83
Grounding the Motor Cable Shield at the Motor End
83
Measuring the Insulation
84
Measuring the Insulation Resistance of the Drive
84
Measuring the Insulation Resistance of the Input Power Cable
84
Measuring the Insulation Resistance of the Motor and Motor Cable
84
Measuring the Insulation Resistance of the Brake Resistor Circuit
84
Grounding System Compatibility Check
85
Corner-Grounded and Midpoint-Grounded 525
85
Grounding the Drive Module
85
Connecting the Power Cables
86
Power Cable Connection Diagram
87
Preparing the Cable Ends and Making 360-Degree Grounding at the Cable Entry
88
Power Cable Connection Procedure
89
DC Connection
90
Removing the Control Panel Holder from the External Control Unit
90
Attaching the Control Cable Clamp Plate
91
Connecting the External Control Unit to the Drive Module
91
Control Unit Connection Cables
91
Routing the Control Unit Cables into the Drive Module
92
Connections to the Drive Module
92
Connections to the Control Unit
93
Connecting the Control Cables to the Terminals of the External Control Unit
94
Installing the Control Panel Holder Back Onto the External Control Unit
95
Connecting a Control Panel
96
Panel Bus (Control of Several Units from One Control Panel)
96
Connecting a PC
98
Installing Option Modules
99
Control Unit of the Drive
101
Contents of this Chapter
101
ZCU-14 Layout
102
Default I/O Diagram of the Drive Control Unit (ZCU-1X)
103
Additional Information on the Connections
105
External Power Supply for the Control Unit (XPOW)
105
DI6 as a PTC Sensor Input
105
AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 Sensor Input
105
DIIL Input
106
The XD2D Connector
106
Safe Torque off (XSTO)
107
FSO Safety Functions Module Connection (X12)
107
Connector Data
108
ZCU-1X Ground Isolation Diagram
110
Installation Checklist
111
Contents of this Chapter
111
Checklist
111
Start-Up
113
Contents of this Chapter
113
Reforming the Capacitors
113
Start-Up Procedure
113
Fault Tracing
115
Contents of this Chapter
115
Leds
115
Warning and Fault Messages
115
Maintenance
117
Contents of this Chapter
117
Maintenance Intervals
117
Description of Symbols
117
Recommended Maintenance Intervals after Start-Up
118
Cabinet
119
Cleaning the Interior of the Cabinet
119
Heatsink
119
Cleaning the Interior of the Heatsink
120
Fans
121
Replacing the Circuit Board Compartment Cooling Fans
121
Replacing the Main Cooling Fans
123
Replacing the Standard Drive Module
124
Capacitors
125
Reforming the Capacitors
125
Control Panel
125
Replacing the ZCU-14 Control Unit Battery
125
Replacing the Memory Unit of ZCU-14
126
Functional Safety Components
127
Ordering Information
129
Contents of this Chapter
129
Output (D U /D T ) Filters
129
Sine Filters
129
FSO Accessories Kit
130
Retrofit Accessory Kits
130
Technical Data
131
Contents of this Chapter
131
Electrical Ratings
131
Output Derating
133
When Is Derating Necessary
133
Ambient Temperature Derating
133
Altitude Derating
134
Deratings for Special Settings in the Drive Control Program
135
High Speed Mode
137
Fuses (IEC)
139
Calculating the Short-Circuit Current of the Installation
139
Calculation Example
140
Fuses (UL)
141
Circuit Breakers
142
Dimensions, Weights and Free Space Requirements
142
Package Dimensions
143
Losses, Cooling Data and Noise
144
Typical Power Cable Sizes
145
Terminal and Entry Data for the Power Cables
146
Units Without Full-Size Output Cable Connection Terminals and with a Common Mode Filter (+E208)
146
Terminal Data for the Control Cables
146
Electrical Power Network Specification
146
Motor Connection Data
146
Brake Resistor Data
147
D U /D T and Sine Filters
147
DC Connection Data
148
Control Panel Type
148
Efficiency
148
Energy Efficiency Data (Ecodesign)
149
Protection Classes for Module
149
Ambient Conditions
150
Colors
151
Materials
151
Drive
151
Package Materials for Module Products
151
Package Materials for Options, Accessories and Spare Parts
151
Materials of Manuals
151
Disposal
151
Applicable Standards
152
Markings
152
EMC Compliance (IEC/EN 61800-3)
153
Definitions
153
Category C3
154
Category C4
154
Compliance with the European Machinery Directive
155
UL Checklist
156
Disclaimers
156
Generic Disclaimer
156
Cybersecurity Disclaimer
157
Dimension Drawings
159
Contents of this Chapter
159
Standard Configuration - IP20 (UL Type Open)
160
Drive Module with Options +E208 and +H370 - IP20 (UL Type Open)
161
Drive Module with Options +0B051+E208+0H371 - IP00 (UL Type Open)
162
Drive Module with Options +0B051+E208+0H371+C217 - IP00 (UL Type Open)
163
Drive Module with Options +0B051+0H371 - IP00 (UL Type Open)
164
Mounting Plate Opening
165
External Control Unit
167
Example Circuit Diagram
169
Contents of this Chapter
169
The Safe Torque off Function
171
Contents of this Chapter
171
Description
171
Chinery (Safety) Regulations
172
Wiring
173
Activation Switch
173
Cable Types and Lengths
173
Grounding of Protective Shields
173
Single Drive (Internal Power Supply)
174
Dual-Channel Connection
174
Single-Channel Connection
175
Multiple Drives
176
Internal Power Supply
176
External Power Supply
177
Operation Principle
178
Start-Up Including Validation Test
179
Competence
179
Validation Test Reports
179
Validation Test Procedure
179
Use
181
Maintenance
182
Competence
182
Perfect Proof Test Procedure
183
Simplified Proof Test Procedure
183
Fault Tracing
184
Safety Data
185
Terms and Abbreviations
187
TÜV Certificate
188
Declarations of Conformity
189
Resistor Braking
191
Contents of this Chapter
191
When Is Resistor Braking Necessary
191
Operation Principle and Hardware Description
191
Planning the Braking System
191
Generic Guidelines
191
Resistor Cables
192
Resistor Thermal Switch
192
Protecting the System against Thermal Overload
192
EMC Compliance of the Complete Installation
193
Placing the Brake Resistors
193
Protecting the System in Fault Situations
193
Selecting the Default Brake System Components
193
Calculation Example
193
Selecting a Custom Brake Resistor
194
Mechanical Installation of Resistors
195
Electrical Installation
195
Measuring the Insulation of the Assembly
195
Connection Diagram
195
Connection Procedure
195
Start-Up
195
Parameter Settings
195
Technical Data
197
Ratings
197
SAFUR Resistors
198
Dimensions, Weights and Ordering Codes
198
Terminals and Cable Entry Data
198
Filters
199
Contents of this Chapter
199
D U /D T Filters
199
When Is a D U /D T Filter Necessary
199
Selection Table
199
Ordering Codes
200
Description, Installation and Technical Data of the FOCH Filters
200
Sine Filters
200
When Is a Sine Filter Necessary
200
Selection Table
200
Derating
200
Description, Installation and Technical Data of the Sine Filters
200
Further Information
201

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ABB ACS880-04F-880A-3 Hardware Manual (202 pages)

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