ABB ACS880-37LC-1000A-7 Manuals

Manuals and User Guides for ABB ACS880-37LC-1000A-7. We have 1 ABB ACS880-37LC-1000A-7 manual available for free PDF download: Hardware Manual

ABB ACS880-37LC-1000A-7 Hardware Manual (242 pages)

INDUSTRIAL DRIVES

Brand: ABB | Category: Industrial Equipment | Size: 10.4 MB

Table of Contents
5
Safety Instructions
15
Contents of this Chapter
15
Use of Warnings and Notes
15
General Safety in Installation, Start-Up and Maintenance
16
Work on the Liquid Cooling System
18
Electrical Safety in Installation, Start-Up and Maintenance
19
Electrical Safety Precautions
19
Additional Instructions and Notes
20
Optical Components
21
Printed Circuit Boards
21
Grounding
21
General Safety in Operation
22
Additional Instructions for Permanent Magnet Motor Drives
22
Safety in Installation, Start-Up, Maintenance
22
Safety in Operation
23
Introduction to the Manual
25
Contents of this Chapter
25
Target Audience
25
Categorization by Frame Size and Option Code
25
Use of Component Designations
26
Quick Installation, Commissioning and Operation Flowchart
26
Terms and Abbreviations
27
Related Manuals
27
Operation Principle and Hardware Description
29
Contents of this Chapter
29
Supply Unit
29
AC Voltage and Current Waveforms
30
Charging
30
Inverter Unit
30
Overview Circuit Diagram of the Drive
31
Cabinet Line-Up and Layout Examples
32
Frame 2×R8I+2×R8I Line-Up
32
Frame 2×R8I+2×R8I Layout
33
Ka Input Cubicle (Option +F274)
34
Overview of Power and Control Connections
35
Door Switches and Lights
36
Main Disconnecting Device [Q1]
36
Auxiliary Voltage Switch [Q21]
36
Grounding (Earthing) Switch [Q9], Optional
36
Other Devices on the Door
37
Control Panel
37
Control by PC Tools
37
Descriptions of Options
38
Degree of Protection
38
Definitions
38
Marine Construction (Option +C121)
38
UL Listed (Option +C129)
38
Plinth Height (Options +C164 and +C179)
38
Resistor Braking (Options +D150 and +D151)
38
Du/Dt Filter
39
Common Mode Filter (Option +E208)
39
Cabinet Heater with External Supply (Option +G300)
39
Cabinet Lighting (Option +G301)
39
Terminals for External Control Voltage (Option +G307)
39
Output for Motor Space Heater (Option +G313)
39
Halogen-Free Wiring and Materials (Option +G330)
40
V-Meter with Selector Switch (Option +G334)
40
Wire Markings
40
Standard Wiring
40
Additional Wire Markings
41
Voltage Measurement with BAMU Auxiliary Measurement Unit (Option +G442)
41
Bottom Cable Entry/Exit (Options +H350 and +H352)
42
Top Cable Entry/Exit (Options +H351 and +H353)
42
Common Motor Terminal Cubicle (Option +H359)
42
Thermal Protection with PTC Relays (Options +L505, +2L505, +L513, +2L513, +L536, +L537)
42
L505, +2L505, +L513, +2L513
42
L536, +L537
43
Thermal Protection with Pt100 Relays (Options +Nl506, +Nl514)
43
Starter for Auxiliary Motor Fan (Options +M600
44
What the Option Contains
44
Description
44
Type Designation Label
45
Type Designation Key
45
Option Codes
46
Mechanical Installation
51
Contents of this Chapter
51
Examining the Installation Site
51
Necessary Tools
51
Examining the Delivery
52
Moving and Unpacking the Drive
53
Moving the Drive in Its Packaging
53
Lifting the Crate with a Forklift
53
Lifting the Crate with a Crane
54
Moving the Crate with a Forklift
55
Removing the Transport Package
55
Moving the Unpacked Drive Cabinet
56
Lifting the Cabinet with a Crane
56
Moving the Cabinet on Rollers
57
Moving the Cabinet on Its Back
57
Final Placement of the Cabinet
58
Attaching the Cabinet to the Floor and Wall or Roof
59
General Rules
59
Attaching the Cabinet (Non-Marine Units)
60
Alternative 1 - Clamping
60
Alternative 2 - Using the Holes Inside the Cabinet
61
Attaching the Cabinet (Marine Units)
62
Joining Cabinet Sections Together
63
Miscellaneous
68
Cable Duct in the Floor below the Cabinet
68
Arc Welding
68
Lifting Lugs and Bars
69
Certificate of Conformity
69
Declarations of Conformity
69
Guidelines for Planning the Electrical Installation
73
Contents of this Chapter
73
Limitation of Liability
73
Selecting the Supply Disconnecting Device
73
Selecting the Main Breaker Option
73
Examining the Compatibility of the Motor and Drive
74
Protecting the Motor Insulation and Bearings
74
Requirements Table
74
Availability of Du/Dt Filter and Common Mode Filter by Drive Type
77
Additional Requirements for Explosion-Safe (EX) Motors
77
And am
77
Additional Requirements for Braking Applications
77
Additional Requirements for the Regenerative and Low Harmonics Drives
77
Additional Requirements for ABB High-Output and IP23 Motors
77
Additional Requirements for Non-ABB High-Output and IP23 Motors
77
Additional Note for Sine Filters
78
Selecting the Power Cables
79
General Guidelines
79
Typical Power Cable Sizes
79
Power Cable Types
79
Preferred Power Cable Types
79
Alternate Power Cable Types
80
Not Allowed Power Cable Types
81
Power Cable Shield
81
Grounding Requirements
81
Additional Grounding Requirements - IEC
82
Additional Grounding Requirements - UL (NEC)
82
Selecting the Control Cables
83
Shielding
83
Signals in Separate Cables
83
Signals that Can be Run in the same Cable
83
Relay Cable
83
Control Panel to Drive Cable
83
PC Tool Cable
83
Routing the Cables
84
General Guidelines - IEC
84
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable
84
Separate Control Cable Ducts
85
Protecting the Drive, Input Power Cable, Motor and Motor Cable in Short Circuit Situations and against Thermal Overload
85
Protecting the Input Cabling and the Drive Upon a Short-Circuit
85
Protecting the Motor and Motor Cable in Short-Circuits
85
Protecting the Drive and the Power Cables against Thermal Overload
85
Protecting the Motor against Thermal Overload
85
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
86
Protecting the Drive against Ground Faults
86
Residual Current Device Compatibility
86
Implementing the Emergency Stop Function
86
Implementing the Safe Torque off Function
86
Implementing the Prevention of Unexpected Start-Up Function
87
Implementing an ATEX-Certified Motor Thermal Protection
87
Implementing the Functions Provided by the FSO Safety Functions Module
87
Implementing the Power Loss Ride-Through Function
88
Implementing a Bypass Connection
88
Supplying Power for the Auxiliary Circuits
89
Using Power Factor Compensation Capacitors with the Drive
89
Using a Safety Switch between the Drive and the Motor
89
Implementing the Control of a Contactor between Drive and Motor
89
Protecting the Contacts of Relay Outputs
90
Implementing a Motor Temperature Sensor Connection
91
Connecting a Motor Temperature Sensor to the Drive through an Option Module
91
Electrical Installation
93
Contents of this Chapter
93
Warnings
93
Measuring the Insulation
93
Measuring the Insulation Resistance of the Drive
93
Measuring the Insulation Resistance of the Motor and Motor Cable
93
Measuring the Insulation Resistance of the Input Power Cable
94
Connecting the Control Cables
95
Control Cable Connection Procedure
95
Grounding the Outer Shields of the Control Cables 360° at the Cabinet Entry
95
Routing the Control Cables Inside the Cabinet
96
Connecting Control Cabling
97
Connecting the Motor Cables (Units Without Common Motor Terminal Cubicle)
98
Motor Connection Diagram (Without Option +H366)
98
Procedure
99
Connecting the Motor Cables (Units with Common Motor Terminal Cubicle)
102
Output Busbars
102
Connection Diagram
102
Procedure
103
Connecting an External Brake Resistor Assembly
103
Connecting the Input Power Cables
104
Connection Diagram
104
Layout of the Input Cable Connection Terminals and Cable Entries
104
Connection Procedure
104
Connecting Input Power Cables - Cable Entry in 100 Ka Input Cubicle (Option +F274)
107
Connection Diagram
107
Connection Procedure
107
Connecting a PC
111
Panel Bus (Control of Several Units from One Control Panel)
111
Installing Option Modules
114
Mechanical Installation of I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules
114
Installation of an FSO Safety Functions Module Onto BCU
114
Wiring of Option Modules
116
Control Units of the Drive
117
Contents of this Chapter
117
General
117
BCU-X2 Layout
118
Default I/O Diagram of the Supply Control Unit
120
Default I/O Diagram of the Inverter Control Unit (A41)
123
Additional Information on the Connections
127
External Power Supply for the Control Unit (XPOW)
127
DI6 as a PTC Sensor Input
127
AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 Sensor Input
127
DIIL Input
128
The XD2D Connector
128
Safe Torque off (XSTO, XSTO OUT)
129
FSO Safety Functions Module Connection (X12)
129
SDHC Memory Card Slot
129
Connector Data
130
BCU-X2 Ground Isolation Diagram
133
Installation Checklist
135
Contents of this Chapter
135
Checklist
135
Start-Up
137
Contents of this Chapter
137
Start-Up Procedure
137
Switching off the Drive
139
Fault Tracing
141
Contents of this Chapter
141
Control Unit Leds
141
Control Panel and Panel Platform/Holder Leds
141
Warning and Fault Messages
142
Maintenance
143
Contents of this Chapter
143
Maintenance Intervals
143
Description of Symbols
143
Recommended Maintenance Intervals after Start-Up
144
Cabinet
146
Cleaning the Interior of the Cabinet
146
Cleaning the Exterior of the Drive
146
Power Connections and Quick Connectors
147
Retightening the Power Connections
147
Fans
147
Frame R8I Fan Replacement
147
Replacing the Heat Exchanger Fan in the Filter Cubicle
149
Replacing the Fan in the Incoming Cubicle
150
Replacing the Fan in the Auxiliary Control Cubicle
152
Replacing the Common Motor Terminal Cubicle Fan
152
Replacing the Brake Chopper and Resistor Cubicle Fans (Options +D150 and +D151)
153
Supply and Inverter Modules
154
Assembling the Service Platform
154
Replacing a Supply or Inverter Module
154
Removing the Module
155
Reinstalling the Module
157
Capacitors
158
Reforming the Capacitors
158
Fuses
159
Replacing the AC and DC Fuses in Cabinet
159
Replacing AC Fuses - 100 Ka Input Cubicle (Option +F274)
160
Control Panel
161
Control Units
161
BCU Control Unit Types
161
Replacing the Memory Unit
162
Replacing the BCU Control Unit Battery
162
Functional Safety Components
163
Internal Cooling Circuit
165
Contents of this Chapter
165
Applicability
165
Internal Cooling System
165
Connection to a Cooling Unit
167
Connection to an ACS880-1007LC Cooling Unit
167
Connection to a Custom Cooling Unit
167
General Requirements
167
Coolant Temperature Control
167
Filling up and Bleeding the Internal Cooling Circuit
168
Drive Line-Ups with an ACS880-1007LC Cooling Unit
168
Drive Line-Ups with a Custom Cooling Unit
168
Draining the Internal Cooling Circuit
170
Maintenance Intervals
170
Technical Data
170
Coolant Specification
170
Coolant Type
170
Temperature Limits
170
Pressure Limits
172
Coolant Flow Rate Limits
172
Cooling Circuit Materials
172
Technical Data
175
Contents of this Chapter
175
Ratings
175
Definitions
176
Derating
176
Surrounding Air Temperature Derating
176
Coolant Temperature Derating
177
Antifreeze Content Derating
177
Altitude Derating
177
Switching Frequency Derating
177
Output Frequency Derating
177
Frame Sizes and Power Module Types
177
Fuses
178
AC Fuses
178
DC Fuses
179
Charging Circuit Fuses
180
Brake Chopper DC Fuses
180
Dimensions and Weights
180
Free Space Requirements
180
Cooling Data, Noise
180
Typical Power Cable Sizes
182
Terminal and Cable Entry Data for the Power Cables
184
Terminal Data for the Supply and Inverter Control Units
184
Electrical Power Network Specification
184
Motor Connection Data
185
Relay Contact Data for Control of External Main Contactor/Breaker
185
General
185
K3 Contact Data
186
K62 Contact Data
186
Efficiency
186
Energy Efficiency Data (Ecodesign)
187
Optical Components
187
Protection Classes
187
Ambient Conditions
188
Colors
188
Materials
189
Drive
189
Packaging of Drive
189
Packaging of Options
189
Manuals
189
Disposal
189
Applicable Standards
190
Markings
190
EMC Compliance (IEC/EN 61800-3)
191
Definitions
191
Category C3
191
Category C4
192
UL Checklist
193
Tightening Torques
194
Electrical Connections
194
Mechanical Connections
194
Insulation Supports
194
Cable Lugs
194
Disclaimers
194
Generic Disclaimer
194
Cybersecurity Disclaimer
195
Dimensions
197
Cabinet Line-Up Dimensions
197
Dimension Drawing Examples
199
ACS880-37LC-0390A-7 with Main Contactor
199
ACS880-37LC-0600A-7 with Brake Chopper and Resistors
200
ACS880-37LC-1270A-7 with Common Motor Terminal Cubicle
201
ACS880-37LC-1940A-7 with Common Motor Terminal Cubicle
202
Cabinet Height and Depth
203
Location and Size of Input Terminals
205
Ka Input Cubicle (Option +F274)
206
Location and Size of Output Terminals
207
Units Without Common Motor Terminal Cubicle
207
Inverter Module Cubicle with One R8I Module, Bottom Cable Exit
207
Inverter Module Cubicle with Two R8I Modules, Bottom Cable Exit
208
Inverter Module Cubicle with Three R8I Modules, Bottom Cable Exit
209
Brake Chopper Cubicle
210
Units with Common Motor Terminal Cubicle (+H359)
211
Cubicle Width 300 MM, Bottom Cable Exit
211
Cubicle Width 300 MM, Top Cable Exit
212
Cubicle Width 400 MM, Bottom Cable Exit
213
Cubicle Width 400 MM, Top Cable Exit
214
Cubicle Width 600 MM, Bottom Cable Exit
215
Cubicle Width 600 MM, Top Cable Exit
216
The Safe Torque off Function
217
Contents of this Chapter
217
Description
217
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations
218
Wiring
219
Activation Switch
219
Cable Types and Lengths
219
Grounding of Protective Shields
219
Dual-Channel Connection with Internal Power Supply
220
Single-Channel Connection of Activation Switch
221
Multiple Drives
222
Internal Power Supply
222
External Power Supply
223
Operation Principle
224
Start-Up Including Validation Test
225
Competence
225
Validation Test Reports
225
Validation Test Procedure
225
Use
227
Maintenance
229
Competence
229
Fault Tracing
230
Safety Data
231
Terms and Abbreviations
232
TÜV Certificate
233
Declarations of Conformity
234

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