ABB ACS880-07 User manual

ABB industrial drives
Hardware manual
ACS880-07 drives (560 to 2800 kW)

Hardware manual
ACS880-07 drives (560 to 2800 kW)
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
9. Start-up
© 2017 ABB Oy. All Rights Reserved. 3AUA0000143261 E
EN
EFFECTIVE: 2017-06-05

Table of contents
1 Safety instructions
15Contents of this chapter ...........................................................................
15Use of warnings and notes .......................................................................
16General safety in installation, start-up and maintenance ....................................
19Electrical safety in installation, start-up and maintenance ...................................
19Electrical safety precautions ..................................................................
19Additional instructions and notes .............................................................
20Grounding .......................................................................................
21Additional instructions for permanent magnet motor drives .................................
21Safety in installation, start-up, maintenance ................................................
21Safety in operation .............................................................................
2 Introduction to the manual
23Contents of this chapter ...........................................................................
23Target audience ....................................................................................
23Contents of the manual ...........................................................................
24Categorization by frame size and option code .................................................
25Quick installation, commissioning and operation flowchart ..................................
26Terms and abbreviations ..........................................................................
26Related manuals ...................................................................................
3 Operation principle and hardware description
29Contents of this chapter ...........................................................................
29Operation principle .................................................................................
30Overview circuit diagram of the drive ........................................................
3112-pulse connection (option +A004) .....................................................
32Cabinet line-up and layout examples ...........................................................
32Frame 1×D8T + 2×R8i .........................................................................
34Frame 2×D7T + 2×R8i (12-pulse connection, option +A004) ............................
36Frame 2×D8T + 3×R8i .........................................................................
38Frame 3×D8T + 4×R8i (with main breaker, option +F255) ...............................
40Auxiliary control cubicle (ACU) layout .......................................................
42Overview of power and control connections ...................................................
43Door switches and lights ..........................................................................
44Main disconnecting device (Q1.1) ...........................................................
44Auxiliary voltage switch (Q21) ................................................................
44Grounding (earthing) switch (Q9.x), optional ...............................................
44Other devices on the door .....................................................................
44Control panel ....................................................................................
45Control by PC tools .........................................................................
45Descriptions of options ............................................................................
45Degree of protection ...........................................................................
45Definitions ....................................................................................
45IP22 (standard) ..............................................................................
46IP42 (option +B054) ........................................................................
46IP54 (option +B055) ........................................................................
Table of contents 5

46Cooling air intake through bottom of cabinet (option +C128) ............................
46Channeled air outlet (option +C130) .........................................................
46Marine construction (option +C121) .........................................................
46UL Listed (option +C129) ......................................................................
46CSA Approved (option +C134) ...............................................................
47Plinth height (options +C164 and +C179) ..................................................
47Seismic design (option +C180) ...............................................................
47Empty cubicles (options +C199…C201) ....................................................
47Resistor braking (options +D150 and +D151) ..............................................
47EMC filters (option + E202) ...................................................................
47Sine filter (option +E206) ......................................................................
47Cabinet heater with external supply (option +G300) ......................................
48Cabinet lighting (option +G301) ..............................................................
48Terminals for external control voltage (option +G307) ....................................
48Output for motor space heater (option +G313) ............................................
48Supply connection by busbars (option +G317) ............................................
48Ready/Run/Fault lights (options +G327…G329) ..........................................
48Halogen-free wiring and materials (option +G330) ........................................
48V-meter with selector switch (option +G334) ...............................................
49A-meter in one phase (option +G335) .......................................................
49Additional wire markings (options +G340 and +G342) ...................................
49Standard wire markings ....................................................................
49Additional wire markings ...................................................................
49Bottom cable entry/exit (options +H350 and +H352) ......................................
50Top cable entry/exit (options +H351 and +H353) ..........................................
50Cable conduit entry (option +H358) .........................................................
50Common motor terminal cubicle (option +H359) ..........................................
50Common output terminal (option +H366) ...................................................
51Additional terminal block X504 (option +L504) .............................................
51
Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513, +L536,
+L537) ...........................................................................................
51+L505, +2L505, +L513, +2L513 ..........................................................
52+L536, +L537 ................................................................................
52Thermal protection with Pt100 relays (options +nL506) ..................................
53Starter for auxiliary motor fan (options +M602…M610) ..................................
53What the option contains ..................................................................
53Description ...................................................................................
54Type designation label ............................................................................
54Type designation key ..............................................................................
4 Mechanical installation
59Contents of this chapter ...........................................................................
59Examining the installation site ...................................................................
60Necessary tools ....................................................................................
60Checking the delivery .............................................................................
61Moving and unpacking the drive .................................................................
61Moving the drive in its packaging ............................................................
61Lifting the crate with a forklift ..............................................................
62Lifting the crate with a crane ..............................................................
63Moving the crate with a forklift ............................................................
63Removing the transport package ............................................................
6 Table of contents

64Moving the unpacked drive cabinet ..........................................................
64Lifting the cabinet with a crane ...........................................................
65Moving the cabinet on rollers .............................................................
65Moving the cabinet on its back ............................................................
66Final placement of the cabinet ............................................................
66Fastening the cabinet to the floor and wall or roof (non-marine units) .....................
66General rules ....................................................................................
67Fastening methods .............................................................................
67Alternative 1 – Clamping ......................................................................
68Alternative 2 – Using the holes inside the cabinet .........................................
68Fastening the cabinet to the floor and roof/wall (marine units) ..............................
69Joining shipping splits together ..................................................................
72Miscellaneous ......................................................................................
72Cable duct in the floor below the cabinet ...................................................
72Arc welding ......................................................................................
72Air inlet through the bottom of cabinet (option +C128) ...................................
73Air outlet duct on the cabinet roof (option +C130) .........................................
74Calculating the required static pressure difference ....................................
5 Guidelines for planning the electrical installation
75Contents of this chapter ...........................................................................
75Limitation of liability ................................................................................
75Selecting the supply disconnecting device .....................................................
75Selecting the main contactor or breaker ........................................................
76Examining the compatibility of the motor and drive ...........................................
76Protecting the motor insulation and bearings ..............................................
76Requirements table ............................................................................
79Availability of du/dt filter and common mode filter by drive type .....................
79Additional requirements for explosion-safe (EX) motors ..............................
79
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ ......................................................................................
79Additional requirements for braking applications .......................................
79Additional requirements for ABB high-output and IP23 motors ......................
80Additional requirements for non-ABB high-output and IP23 motors .................
81Additional data for calculating the rise time and the peak line-to-line voltage .....
81Additional note for sine filters .............................................................
82Selecting the power cables .......................................................................
82General rules ....................................................................................
82Typical power cable sizes .....................................................................
83Alternative power cable types ................................................................
83Recommended power cable types .......................................................
84Power cable types for limited use ........................................................
84Not allowed power cable types ...........................................................
84Power cable shield .............................................................................
85Additional US requirements ...................................................................
85Conduit .......................................................................................
85Armored cable / shielded power cable ...................................................
85Planning the resistor braking system ...........................................................
85Selecting the control cables ......................................................................
85Shielding .........................................................................................
86Signals in separate cables ....................................................................
86Signals allowed to be run in the same cable ...............................................
Table of contents 7

86Relay cable type ................................................................................
86Control panel cable length and type .........................................................
86Routing the cables .................................................................................
87Separate control cable ducts .................................................................
87Continuous motor cable shield or enclosure for equipment on the motor cable ......
87Implementing thermal overload and short-circuit protection .................................
87Protecting a drive and input power cable in short-circuits ................................
88Protecting the motor and motor cable in short-circuits ....................................
88Protecting the drive and the power cables against thermal overload ...................
88Protecting the motor against thermal overload .............................................
88Protecting the drive against ground faults ......................................................
88Residual current device compatibility ........................................................
89Implementing the emergency stop function ....................................................
89Implementing the Safe torque off function .....................................................
89Implementing the Prevention of unexpected start-up function ..............................
89
Implementing the functions provided by the FSO-xx safety functions module (option
+Q972 or +Q973) ..................................................................................
90Implementing the Power-loss ride-through .....................................................
90Units with main contactor (option +F250) ...................................................
90Implementing a bypass connection .............................................................
91Supplying power for the auxiliary circuits .......................................................
91Using power factor compensation capacitors with the drive .................................
91Implementing a safety switch between the drive and the motor ............................
91Protecting the contacts of relay outputs ........................................................
92Connecting a motor temperature sensor to the drive I/O ....................................
93Drive I/O, I/O extension and encoder interface modules .................................
6 Electrical installation
95Contents of this chapter ...........................................................................
95Warnings ............................................................................................
95Checking the insulation of the assembly .......................................................
95Drive ..............................................................................................
95Input cable .......................................................................................
95Motor and motor cable .........................................................................
96Custom brake resistor assembly .............................................................
96Checking the compatibility with IT (ungrounded) systems ...................................
96Attaching the device stickers to the cabinet door .............................................
96Checking the settings of transformers T21, T101 and T111 .................................
97T21 and T101 tap settings (400…500 V units) .............................................
97T21 and T101 tap settings (690 V units) ....................................................
98T111 tap settings ...............................................................................
99Connecting the control cables ...................................................................
99Control cable connection procedure .........................................................
100Grounding the outer shields of the control cables at the cabinet lead-through ....
102Routing the control cables inside the cabinet ...........................................
103Connecting to the inverter control unit (A41) ...........................................
104Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) .......
104
Connecting the emergency stop push buttons (options +Q951, +Q952, +Q963,
+Q964, +Q978,+Q979) ....................................................................
104Wiring the starter for auxiliary motor fan (options +M602…+M610) .................
105Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513 and +2L513) .
106Wiring the Pt100 relays (option +nL506) ................................................
8 Table of contents

106Wiring the Pt100 relays (option +nL514) ................................................
107
Powering the heating and lighting equipment (options +G300, +G301 and
+G313) .......................................................................................
108Wiring ground fault monitoring for IT ungrounded systems (option +Q954) .......
109
Connecting the motor cables (units without common motor terminal cubicle or sine output
filter) ..................................................................................................
109Motor connection diagram (without option +H366) ........................................
110Motor connection diagram (with option +H366) ............................................
111Procedure .......................................................................................
111Removing the inverter module(s) .........................................................
115Removing and reinstalling the fan carriage of an inverter module ...................
117Connecting the motor cables ..............................................................
119Re-installing the fan carriage of an inverter module ...................................
119Re-inserting the inverter module into the cubicle ......................................
119
Connecting the motor cables (units with common motor terminal cubicle or sine output
filter) ..................................................................................................
119Output busbars .................................................................................
120Connection diagram ............................................................................
120Procedure .......................................................................................
121Connecting an external brake resistor assembly ..........................................
121Connecting the input power cables ..............................................................
121Connection diagram, 6-pulse units ..........................................................
122Connection diagram, 12-pulse units .........................................................
122Layout of the input cable connection terminals and lead-throughs .....................
122Connection procedure .........................................................................
124Connecting a PC ...................................................................................
125Panel bus (Control of several units from one control panel) .................................
126Installing option modules .........................................................................
126
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface
modules ..........................................................................................
126Mechanical installation of an FSO-xx safety functions module ..........................
127Wiring of optional modules ....................................................................
7 Control units of the drive
129What this chapter contains .......................................................................
129General ..............................................................................................
130Control unit layout and connections .........................................................
132Default I/O diagram of the supply control unit (A51) ......................................
133Default I/O diagram of the inverter control unit (A41) .....................................
134External power supply for the control unit (XPOW) .......................................
134DI6 as a PTC sensor input ....................................................................
134AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input .............................
135DIIL input ........................................................................................
135Drive-to-drive link (XD2D) .....................................................................
136Safe torque off (XSTO, XSTO OUT) .........................................................
136FSO-xx safety functions module connection (X12) ........................................
136SDHC memory card slot .......................................................................
136Connector data .....................................................................................
139Ground isolation diagram .....................................................................
8 Installation checklist
141Contents of this chapter ...........................................................................
Table of contents 9

141Warnings ............................................................................................
141Checklist .............................................................................................
9 Start-up
143Contents of this chapter ...........................................................................
143Start-up procedure .................................................................................
10 Fault tracing
147Contents of this chapter ...........................................................................
147LEDs .................................................................................................
147Warning and fault messages .....................................................................
11 Maintenance
149Contents of this chapter ...........................................................................
149Maintenance intervals .............................................................................
151Cabinet ..............................................................................................
151Cleaning the interior of the cabinet ..........................................................
151Cleaning the door air inlets (IP22 and IP42) ...............................................
151Cleaning the door air inlets (IP54) ...........................................................
152Cleaning the outlet (roof) filters (IP54) ......................................................
152Replacing the outlet (roof) filters (IP54) .....................................................
152Power connections and quick connectors ......................................................
152Retightening the power connections ........................................................
153Fans ..................................................................................................
153Replacing the cooling fan in the auxiliary control cubicle .................................
153Replacing the cooling fan(s) in the incoming cubicle .....................................
154Replacing a roof fan (IP54/UL type 12) .....................................................
155Replacing a supply module (D7T) cooling fan .............................................
156Replacing a supply module (D8T) or inverter module (R8i) cooling fan ................
157Replacing the circuit board compartment fan ..............................................
160Supply and inverter modules .....................................................................
160Replacing a frame D7T supply module .....................................................
163Replacing a frame D8T supply module .....................................................
167Cleaning the heatsink ..........................................................................
168Activating the reduced run of the inverter unit .............................................
170Returning the module ......................................................................
170Capacitors ...........................................................................................
170Reforming the capacitors ......................................................................
171Fuses ................................................................................................
171Replacing the AC and DC fuses in cabinet .................................................
172Replacing the supply module DC fuses (D7T and D8T) ..................................
174Control panel .......................................................................................
174Replacing the control panel battery ..........................................................
174Cleaning .........................................................................................
175Control units ........................................................................................
175BCU control unit types .........................................................................
175Replacing the memory unit ...................................................................
175Replacing the BCU control unit battery .....................................................
12 Technical data
177Contents of this chapter ...........................................................................
10 Table of contents