ABB ACQ80-04 Series Installation manual

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ABB DRIVES FOR WATER
ACQ80-04 standard control program
Quick installation and start-up guide
to do
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List of related manuals
You can find manuals and other product documents in PDF format on the Internet. See
section Document library on the Internet on the inside of the back cover. For manuals
not available in the Document library, contact your local ABB representative.
The code below opens an online listing of the manuals applicable to the product:
Drive hardware manuals and guides Code (English)
ACQ80-04 drives (0.75 to 160 kW) hardware manual 3AXD50000170661
Drive firmware manuals and guides
ACQ80-04 drives quick installation and start-up guide (frames
R0...R8)
3AXD50000170647
ACQ80-04 primary control program firmware manual 3AXD50000170654
Option manuals and guides
ACS-BP-S basic control panel user manual 3AXD50000032527
ACX-AP-x assistant control panels user’s manual 3AUA0000085685
CDPI-0x communication adapter module user's manual 3AXD50000009929
DPMP-01 mounting platform for ACS-AP control panel 3AUA0000100140
DPMP-02/03 control panel mounting platform kit installation
guide
3AUA0000136205
FPBA-01 PROFIBUS DP adapter module user's manual 3AFE68573271
FENA-01/-11/-21 Ethernet adapter module user's manual 3AUA0000093568
FECA-01 EtherCAT adapter module user's manual 3AFE68573360
FCAN-01 CANopen adapter module user's manual 3AFE68615500
FOCH du/dt filters hardware manual 3AFE68577519
FSCA-01 RS-485 adapter module user's manual 3AUA0000109533
Tool and maintenance manuals and guides
Drive composer PC tool user's manual 3AUA0000094606
Converter module capacitor reforming instructions 3BFE64059629
NETA-21 remote monitoring tool user's manual 3AUA0000096939
NETA-21 remote monitoring tool installation and startup guide 3AUA0000096881
2019 ABB All Rights Reserved.
3AXD50000170647 Rev A
EN
EFFECTIVE: 2018-02-01
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EN - Quick installation and
start-up guide
This guide briefly instructs how to install and start-up the ACQ80-04 drive of all frame
sizes (R0...R8). For complete information, see ACQ80-04 hardware and firmware
manuals.
General considerations
Obey the safety instructions
Reform the capacitors
Reform the capacitors if the drive is stored for a year or more.
The manufacturing time can be determined from the serial number on type
designation label which is attached to the drive. The serial number format
MYYWWRXXXX represents the month, year and the week.
YY: 13, 14, 15, … for 2013, 2014, 2015, …
WW: 01, 02, 03, … for week 1, week 2, week 3, …
For information on reforming the capacitors, see Converter module capacitor
reforming instructions (3BFE64059629 [English]).
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur:
• If you are not a qualified electrician, do not do electrical installation work.
• Do not work on the drive, motor cable or motor when main power is applied. If
the drive is already connected to the input power, wait for 5 minutes after
disconnecting the input power.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits.
• Use the lifting eyes of the drive when you lift the drive. Do not tilt the drive. The
drive is heavy and its center of gravity is high. An overturning drive can cause
physical injury.
• Make sure that debris from drilling, cutting and grinding does not enter the drive
when installing.
• Make sure that the floor below the drive and the wall where the drive is installed
are non-flammable.
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Select the power cables
Size the power cables according to local regulations to carry the nominal current
given on the type designation label of your drive. See Ratings on page 53.
Ensure the cooling
The maximum ambient temperature without derating is 40 °C (+104 °F). No
condensation or frost is allowed. For more information on the ambient temperature,
see ACQ80-04 drives (0.75 to 160 kW) hardware manual (3AXD50000044998
[English]).
Protect the drive and input power cable
If you use gG fuses, make sure that the operating time of the fuse is below
0.5 seconds. Follow the local regulations.
Dual supply mode
The solar pump drive operates in dual supply mode either with a three phase input
supply from the grid or with DC input supply from photovoltaic array. A four-pole
changeover switch enables switching between the two supply modes. At a given time
only one supply (Photovoltaic array or grid supply) can provide power to the drive.
Note: Use two poles of the changeover switch in series to ensure that the voltage
applied across each pole is half of the full DC voltage.
Grid supply
Photovoltaic
array
4-pole
change
over switch
To drive U1, V1, W1
Solar pump
drive
Motor and
pump
To drive DC connection
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Install the drive
You can install the drive:
• to a DIN installation rail with integrated lock. Applies to frames R0...R2 only.
or
• with screws to a suitable surface (wall or assembly plate). Applies to all frames
R0...R8.
Required tools for installing the drive
To install the drive mechanically, you will need the following tools:
• A drill and suitable drill bits
• Screwdriver (Standard, Phillips head, and Torx) and wrench with a set of suitable
bits and sizes (as appropriate for the installation hardware used). See Standard
frame sizes (R0...R8) on page 58.
• A tape measure and spirit level
• Personal protective equipment.
Installing a drive to the DIN installation rail (frames R0...R2 only)
1. On the top center of the drive move the locking part to the left.
2. Push and hold the locking button down.
3. Put the top tabs on the drive onto the top edge of the DIN rail.
4. Put the drive against the bottom edge of the DIN installation rail.
5. Release the locking button.
6. Move the locking part to the right.
7. Make sure the drive is installed correctly.
Removing drive from the DIN installation rail (frames R0...R2 only)
To remove the drive, open the locking part using a flat-head screwdriver.
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Installing a drive with screws (frames R0...R8)
All drives of frames R0...R8 can be installed on the wall with screws. See details of
Standard frame sizes (R0...R8) on page 58.
WARNING! The drive module (frames R6...R8) is heavy (45 to 70 kg). Use a
suitable lifting device. Do not lift the module manually. Make sure that the wall
and the fixing devices can carry the weight. See data in the table below.
1. Mark the mounting hole locations using the mounting template included in the
package. See the mounting dimensions in the table below.
2. Drill the mounting holes.
3. Tighten the screws into the mounting holes.
4. Position the drive onto the screws on the wall.
5. Tighten the mounting screws.
× 4
c
a
d
e
b
1
Frame
s
R0 R1 R2 R3 R4 R5 R6 R7 R8
Screws M5 M6 M8
mm
a 191 473 619 581 531 583 65
8
b - 612 571 623 70
1
c 50 75 148 160 213 245 26
3
d75 200
e 75 200 300
kg
Weight 4.47 4.5
7
7.5
4
14.8
6
23.0 28 45 55 70
a
c
b
e
d
x 4
(R5...R8
only)
2 3 4
5
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See the example below of the mounting screws in frame R0.
Frames R5...R8 only:
6. Remove the front cover with fastening screws (6a), move the cover to the top
side (6b) and then up (6c).
7. Attach the cable entry box to the drive frame.
8. Tighten the box screws: two at the top and four at the bottom.
6b
6a 6a
6c
78
8
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Check the insulation of the input and motor cables and the
motor
• Check the insulation of the input cable according to local regulations before
connecting it to the drive.
• Check the insulation of the motor cable and motor before connecting it to the
drive.
• Measure the insulation resistance between each phase conductor and the
Protective Earth conductor using a measuring voltage of 1000 V DC. The
insulation resistance of an ABB motor must exceed 100 Mohm (reference value at
25 °C or 77 °F). For the insulation resistance of other motors, see the
manufacturer’s instructions.
Note: Moisture inside the motor casing will reduce the insulation resistance. If
moisture is suspected, dry the motor and repeat the measurement.
ohm
M
3~
U1
V1
W1 PE
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Connect the power cables
Connection diagram
1 For alternatives, see ACQ80-04 hardware manual.
2 Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b)
if the conductivity of the shield does not meet the requirements for the PE conductor.
3 360-degree grounding is recommended if shielded cable is used.Ground the other end
of the input cable shield or PE conductor at the distribution board.
4 360-degree grounding is required.
5 PV input terminals. UDC-, UDC+ in frames R0…R2 and R-, UDC+ in frame R3. DC
connection (UDC+, UDC-) in frames R4…R8.
6 Use a separate grounding cable if the shield does not meet the requirements of
IEC 61439-1, there is no symmetrically constructed grounding conductor in the cable.
Note:
If there is a symmetrically constructed grounding conductor on the motor cable in addition to
the conductive shield, connect the grounding conductor to the grounding terminal at the drive
and motor ends.
Do not use an asymmetrically constructed motor cable for motors above 30 kW. Earthing at
the motor increases bearing current and power consumption, damages the motor bearing and
even the motor.
L1 L2 L3 T1/U T2/V T3/W
UDC+
R+
R-
L1 L2 L3(PE) (PE)PE
ACQ80-04
PE
U1
V1 W1
3 ~ M
1
2a
2b
3
6
4
UDC -
Photovoltaic (PV) input
terminals
5
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Connection procedure: frames R0...R2
WARNING! If the drive is connected to an IT (non-grounded) system or to a
corner-grounded TN system, disconnect the EMC filter grounding screw and
varistor (VAR) grounding screw.
1. Remove the front cover. Loosen the retaining screw with a screwdriver, and lift the
cover from bottom outwards.
2. Strip the motor cable.
3. Ground the motor cable shield under the grounding clamp.
4. Twist the motor cable shield into a bundle and put yellow-green insulation tape on
it, fit a cable lug, and connect it to the grounding terminal.
5. Connect the phase conductors of the motor cable to the terminals of T1/U, T2/V
and T3/W. Tighten the screws to the torque given in table below.
6. Strip the input power cable.
7. Twist the input power cable shield into a
bundle and put yellow-green insulation
tape on it, fit a cable lug, and connect it to
the grounding terminal.
8. If the drive is connected to both grid and
PV source, connect the grid phase
conductors of input power cable to L1, L2
and L3 terminals. Tighten the screws to
the torque given in the table in step 5.
9. Connect the PV input terminals to UDC+
and UDC-. Tighten the screws to the
torque given in the table in step 5.
10. Ground the motor cable at the motor end.
7
8
9
Connections Frame Tightening torque
in Nm (lbf·ft)
T1/U, T2/V,
T3/W
L1, L2, L3
UDC+, UDC-
R0...R1 0.5...0.6 (0.4)
R2 1.2...1.5
(0.9...1.1)
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Connection procedure: frames R3...R4
WARNING! If the drive is connected to an IT (non-grounded) system or to a
corner-grounded TN system, disconnect the EMC filter grounding screw and
varistor (VAR) grounding screw.
1. Remove the front cover. Loosen the retaining screw with
screwdriver (1a) and lift the cover from the bottom
outwards (1b).
2. Strip the motor cable.
3. Ground the motor cable shield under the grounding clamp.
4. Twist the motor cable shield into a bundle and put yellow-green
insulation tape on it, fit a cable lug, and connect it to the
grounding terminal.
5. Connect the phase conductors of the motor cable to the
terminals of T1/U, T2/V and T3/W. Tighten the screws to the torque given in table
below:
6. Strip the input power cable.
7. Twist the input power cable shield into a bundle and put yellow-green insulation
tape on it, fit a cable lug, and connect it to the grounding terminal.
8. Connect the phase conductors of the input power cable to L1, L2 and L3
terminals. Tighten the screws to the torque given in step 5.
9. For R3, connect the PV input terminals to UDC+ and R-. Tighten the screws to the
torque given in step 5.
1a
1b
1b
5
8
Connections Frame Tightening torque
in Nm (lbf·ft)
T1/U, T2/V,
T3/W
L1, L2, L3,
UDC+, R-
R3 2.5...4.5 (1.8...3.3)
T1/U,
T2/V,T3/W
L1, L2, L3
R4 4.0 (3.0)
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10. Install the grounding shelf for the control cables (included with the mounting
screws in a plastic bag in the delivery) onto the grounding shelf for the power
cables.
11. Ground the motor cable shield at the motor end.
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Connection procedure: frames R5...R8
WARNING! If the drive is connected to an IT (non-grounded) system or to a
corner-grounded TN system, disconnect the EMC filter grounding screw and
varistor (VAR) grounding screw.
1. Remove the front cover.
2. Remove the shroud on the power cable terminals by releasing the clips and lifting
the shroud up from the sides with a screwdriver.
3. Knock out holes in the shroud for the cables to be installed.
4. Frame R8 only: If you install parallel cables, also knock out holes in the lower
shroud for the cables to be installed.
5. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable.
6. Strip the motor cable.
7. Slide the cables through the holes of the lead-through plate and attach the
grommets to the holes (the motor cable to the right and the input power cable to
the left).
8. Ground the motor cable shield under the grounding clamp.
1
2
4Frame 8
3
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9. Twist the motor cable shield into a bundle and put yellow-green insulation tape on
it, fit a cable lug, and connect it to the grounding terminal. See figure below.
10. Connect the phase conductors of the motor cable to the terminals of T1/U, T2/V
and T3/W. See figure below. Tighten the screws to the torque given in table below.
Frame R8 only:
• If you connect only one conductor to the connector, we recommend that you
put it under the upper pressure plate.
• The connectors are detachable but we do not recommend that you detach
them. If you do, detach and reinstall the connectors as follows.
11. Strip the power cable.
12. Ground the motor cable shield under the grounding clamp.
13. Twist the motor cable shield into a bundle and put yellow-green insulation tape on
it, fit a cable lug, and connect it to the grounding terminal.
14. Connect the phase conductors of the power cable to the terminals of L1, L2 and
L3. Tighten the screws to the torque given. See step 10.
Frame Tightening torque in Nm (lbf·ft)
T1/U, T2/V, T3/W, L1, L2, L3 PE,
R5 5.6 (4.1) 2.2 (1.6)
R6 30 (22.1) 9.8 (7.2)
R7, R8 40 (29.5)
10
9
77
13
14
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15. Frame R8 only:If you installed parallel cables, install the second grounding shelf
for the parallel power cables (15a). Repeat steps 11...14 (15b).
16. Install the grounding shelf of the control cables.
17. Reinstall the shroud on the power terminals.
18. Secure the cables outside the unit mechanically.
19. Ground the motor cable shield at the motor end. For minimum radio frequency
interference, ground the motor cable shield 360 degrees at the lead-through of
the motor terminal box.
M5×25
M5×12
15a
15b
15a
15b
1716
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DC connection
The UDC+ and UDC- terminals in frames R4…R8 are for connecting photovoltaic
(PV) panels.
Note: For R6...R8, PV array input terminals must be connected through external pre-
charging circuit. For details on charging unit, contact your local ABB representative.
Connect the control cables
See section Default I/O connections (ABB standard macro) on page 17 for the default
I/O connections of the ABB standard macro. For other macros, see ACQ80-04
firmware manual (3AXD50000042620 [English]).
Connect the cables as described under in ACQ80-04 firmware manual
(3AXD50000042620 [English]).
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Default I/O connections (ABB standard macro)
X1 Reference voltage and analog inputs
1SCR Signal cable shield (screen)
2AI1 Open for configuration1)
3AGND Analog input circuit, common
4+10V 10 V DC reference voltage
5AI2 Open for configuration2)
6AGND Analog input circuit, common
7AO1 Output frequency, 0…20 mA 9):
see
13.12
8AO2 Motor current9):
see
13.22
9AGND Analog output circuit common
X2, X3 Aux. voltage output and programmable digital inputs
10 +24V Aux. voltage output +24 VDC, max. 250 mA3)
11 DGND Aux. voltage output common
12 DCOM Digital input common for all
13 DI1 Start (0) /Stop (1): see 79.11
8)
14 DI2 Open for configuration
15 DI3 Open for configuration
16 DI4 Open for configuration
17 DI5 Open for configuration
18 DI6 Open for configuration
X6, X7, X8 Relay outputs
19 RO1C Ready Run 9): see
10.24
250 V AC / 30 V DC
2 A
20 RO1A
21 RO1B
22 RO2C Running 9): see
10.27
250 V AC / 30 V DC
2 A
23 RO2A
24 RO2B
25 RO3C Fault (-1) 9): see
10.30
250 V AC / 30 V DC
2 A
26 RO3A
27 RO3B
X5 Built-in fieldbus
29 B+
Internal Modbus RTU (EIA-485)
30 A-
31 DGND
(Frame R0~R2)
S100 TERM&BIAS Termination resistor and bias resistor switch
(Frame R3~R8)
S100 TERM Termination resistor switch
S200 BIAS Bias resistor switch
X4 Safety torque off
R0~R2 R3~R8
33 - OUT1 Safety torque off function. Factory connection.
Both circuits must be closed for the drive to
start. See Safe torque off function in the drive
hardware manual.
34 SGND OUT2
35 OUT1 SGND
36 IN1 IN1
37 IN2 IN2
X10 24 V AC/DC (frames R6~R8 only)
40 24 V AC/DC- in 24V AC/DC input, for control unit power supply
when external main power is disconnected.
41 24 V AC/DC+ in
X11 Redundant auxiliary voltage output (frames R0~R2 only)
42 +24 V Aux. voltage output +24 V DC, max. 250 mA3)
43 DGND Aux. voltage output common
44 DCOM Digital input common for all
4)
6)
Max.
500 ohm
7 )
1…10 kohm
R3~R8
4)
5)
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Terminal sizes
• Frame sizes R0…R8: 0.14…1.5 mm2(all terminals)
• Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft)
Notes
1) Current [0(4)…20 mA, Rin < 500 ohm] or voltage [ 0(2)…10 V, Rin > 200 kohm]
input as selected with parameter 12.15 AI1 unit selection.
2) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [ 0(2)…10 V, Rin > 200 kohm]
input as selected with parameter 12.25 AI2 unit selection.
3) Total load capacity of the auxiliary voltage output +24V (X2:10) =
6.0 W (250 mA / 24 V) - User can use this source for either of the I/O connections
(DI1... DI2- RO1 or DI3...DI6 - RO2~RO3).
4) Connected with jumpers at the factory.
5) Applicable for R0~R2 frames only.
6) Use shielded twisted-pair cables for digital signals.
7) Ground the outer shield of the cable 360 degrees under the grounding clamp on
the grounding shelf for the control cables.
8) Input signal
9) Output signal
For information on cable connection and drive operation, see Control Connections in
the hardware manual (3AXD50000170661).
Install optional modules, if any
See chapter Electrical installation in ACQ80-04 hardware manual.
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Check the compatibility with IT (ungrounded) system
The internal EMC filter is not suitable for use on an IT (ungrounded) system.
Disconnect the EMC filter and varistor before connecting the drive to the supply
network.
WARNING! Do not install the drive with the internal EMC filter connected on an
IT system (an ungrounded power system or a high-resistance-grounded [over
30 ohms] power system), otherwise the system will be connected to ground potential
through the EMC filter capacitors of the drive. This can cause danger, or damage the
drive.
Note:
• When the internal EMC filter is disconnected, the drive EMC compatibility is
considerably reduced.
• If you connect the drive to an IT (ungrounded) disconnect the internal EMC filter
and varistor by removing the two screws.
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Reinstall covers (frames R3...R8)
Frames Action
R3, R4 1. Reinstall the cover: Put the tabs on the cover top in their counterparts on the
housing and press the cover.
2. Tighten the retaining screw at the bottom with a screwdriver.
R5 1. Slide the cover upwards (1a) and tighten the retaining screws (1b).
2. Reinstall the module cover (2a) and press the cover at bottom. Tighten the two
retaining screws (2b) with a screwdriver.
R6...R8 1. Install the side plates (1a) of the cable box. Tighten the retaining screws (1b) with
a screw driver.
2. Slide the cover (2a) of the cable box on the module from below until the cover
snaps into place.
3. Reinstall the module cover (3a). Tighten the two retaining screws (3b) with a
screwdriver.
1a
1b
1b
2b
2a
1b
1a
2a
3a
3b
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