ABB ACQ80-04 Series User manual

—
ABB DRIVES FOR WATER
ACQ80-04 drives
Hardware manual

ACQ80-04 drives
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation – IEC
© 2022 ABB Oy. All rights reserved. 3AXD50000170661 Rev B
EN
EFFECTIVE: 2022-02-15

Table of contents
1 Safety instructions
11Contents ofthis chapter .......................................................................
11Use ofwarnings andnotes ....................................................................
12General safety in installation, start-up and maintenance ...............................
14Electrical safety in installation, start-up and maintenance .............................
14Electrical safetyprecautions ..............................................................
14Additional instructionsand notes ........................................................
15Printed circuitboards ...................................................................
15Grounding .....................................................................................
16General safetyin operation ...................................................................
16Additional instructions for permanent magnet motor drives .........................
16Safety in installation, start-up, maintenance ..........................................
17Safety inoperation ..........................................................................
2 Introduction to the manual
19Contents ofthis chapter .......................................................................
19Applicability .......................................................................................
19Target audience ..................................................................................
19Categorization byframe size .................................................................
20Quick installation and commissioning flowchart .........................................
21Terms andabbreviations ......................................................................
21Related manuals .................................................................................
3 Operation principle and hardware description
23Contents ofthis chapter .......................................................................
23Operation principle .............................................................................
24Simplified maincircuit diagram ..........................................................
24Product variants .................................................................................
25Layout ..............................................................................................
26Control connections ............................................................................
26Standard unit(with RIIO-01) ...............................................................
27Base unit .......................................................................................
27Option modules ..................................................................................
28Control paneloptions ..........................................................................
28Drive labels ........................................................................................
28Type designationlabel ......................................................................
28Software informationlabel ................................................................
28Type designationkey ...........................................................................
29Basic code .....................................................................................
29Option codes ..................................................................................
4 Mechanical installation
31Contents ofthis chapter .......................................................................
31Installation alternatives ........................................................................
31Examining theinstallation site ...............................................................
Table of contents 5

32Required tools ....................................................................................
32Unpacking thedelivery .........................................................................
33Installing thedrive ...............................................................................
33To installthe drivewith screws ...........................................................
33To installthe driveto aDIN installationrail ............................................
5 Guidelines for planning the electrical installation
35Contents ofthis chapter .......................................................................
35Limitation ofliability ............................................................................
35Selecting the main supply disconnecting device .........................................
35European Unionand UnitedKingdom ...................................................
36Other regions .................................................................................
36DC solarPV powersupply ..................................................................
36Selecting themain contactor .................................................................
36Other regions .................................................................................
36Checking the compatibility of the motor and drive ......................................
37Selecting thepower cables ....................................................................
37General guidelines ...........................................................................
37Typical powercable sizes ..................................................................
37Power cabletypes ............................................................................
37Preferred powercable types ...........................................................
38Alternate powercable types ...........................................................
39Not allowedpower cabletypes ........................................................
39Power cableshield ...........................................................................
40Selecting DCpower cables ....................................................................
41Grounding requirements .......................................................................
41Additional groundingrequirements –IEC ..............................................
42Additional grounding requirements – UL (NEC) .......................................
42Selecting thecontrol cables ...................................................................
42Shielding .......................................................................................
42Signals inseparate cables ..................................................................
42Signals thatcan berun inthe samecable ..............................................
42Relay cable .....................................................................................
43Control panelto drivecable ...............................................................
43PC toolcable ..................................................................................
43Routing thecables ..............................................................................
43General guidelines– IEC ....................................................................
44
Continuous motor cable shield/conduit or enclosure for equipment on the
motor cable ...................................................................................
44Separate controlcable ducts ..............................................................
44Implementing short-circuit and thermal overload protection .........................
44Protecting the drive and input power cable in short-circuits ......................
44Protecting the motor and motor cable in short-circuits ............................
45
Protecting the drive, and the input power and motor cables against thermal
overload ........................................................................................
45Protecting the motor against thermal overload ......................................
45
Protecting the motor against overload without thermal model or temperature
sensors .........................................................................................
45Implementing a motor temperature sensor connection ................................
46Protecting thedrive againstground faults ................................................
46Residual currentdevice compatibility ...................................................
46Earth connection (grounding) recommendation ......................................
6 Table of contents

46Implementing theEmergency stopfunction ..............................................
47Implementing theSafe torqueoff function ...............................................
47Implementing the control of a contactor between drive and motor .................
47Protecting thecontacts ofrelay outputs ..................................................
6 Electrical installation – IEC
49Contents ofthis chapter .......................................................................
49Warnings ..........................................................................................
49Required tools ....................................................................................
50Measuring theinsulation resistance- IEC ..................................................
50Measuring the insulation resistance of the drive .....................................
50Measuring the insulation resistance of the input power cable ....................
50Measuring the insulation resistance of the motor and motor cable ..............
50Grounding systemcompatibility check– IEC ..............................................
51EMC filter ......................................................................................
51Ground-to-phase varistor ..................................................................
51
Compatibility of EMC filter and ground-to-phase varistor with the grounding
system ..........................................................................................
52Disconnecting the EMC filter or ground-to-phase varistor .........................
52Guidelines for installing the drive to a TT system ....................................
53Identifying the grounding system of the electrical power network ...............
54Connecting the power cables – IEC (shielded cables) ...................................
54Connection diagram .........................................................................
54Connection procedure ......................................................................
55Connecting thecontrol cables- IEC .........................................................
55Control cableconnection procedure .....................................................
56Additional information on the control connections ..................................
56Embedded EIA-485fieldbus connection ............................................
57PNP configurationfor digitalinputs .................................................
57NPN configurationfor digitalinputs .................................................
58Connection examples of two-wire and three-wire sensors .....................
58AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor interface .
60AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs ......
60Safe torqueoff ............................................................................
61Auxiliary voltageconnection ..................................................................
61Installing options ................................................................................
61Installing afront option ....................................................................
7 Installation checklist
63Contents ofthis chapter .......................................................................
63Checklist ...........................................................................................
8 Maintenance
65Contents ofthis chapter .......................................................................
65Maintenance intervals ..........................................................................
65Description ofsymbols .....................................................................
66Recommended maintenance intervals after start-up ................................
66Functional safetycomponents ...............................................................
67Cleaning theheatsink ...........................................................................
67Replacing thecooling fans ....................................................................
67Replacing thecooling fan,frames R1and R2 ...........................................
Table of contents 7

69Replacing thecooling fan,frame R3 .....................................................
70Capacitors ........................................................................................
70Reforming thecapacitors ..................................................................
9 Technical data
71Contents ofthis chapter .......................................................................
71Electrical ratings .................................................................................
71IEC ratings .....................................................................................
72Definitions .....................................................................................
72How to calculate required PV voltage and ISC .........................................
72Definitions .................................................................................
73Sizing ...........................................................................................
73Output derating .................................................................................
74Surrounding airtemperature derating ..................................................
74Altitude derating .............................................................................
74Switching frequencyderating .............................................................
75Fuses (IEC) ........................................................................................
75AC fuses ........................................................................................
75gG fuses ....................................................................................
75gR fuses ....................................................................................
76DC fuses(gG) .................................................................................
77MOV .............................................................................................
78DC EMIfilter ...................................................................................
78Reverse polaritydiodes .....................................................................
78Alternate short-circuitprotection ...........................................................
79Dimensions andweights .......................................................................
80Free spacerequirements ......................................................................
80Thermal losses,cooling dataand noise ....................................................
80Terminal datafor thepower cables .........................................................
81Terminal datafor thecontrol cables ........................................................
81Choke andsine filter ............................................................................
82Electrical powernetwork specification .....................................................
82Motor connectiondata .........................................................................
82Motor cablelength ...........................................................................
82Operational functionality and motor cable length ................................
83EMC compatibilityand motorcable length ............................................
84Control connectiondata .......................................................................
84Energy efficiencydata (ecodesign) ..........................................................
85Protection classes ...............................................................................
85Ambient conditions .............................................................................
86Materials ...........................................................................................
86Disposal ...........................................................................................
86Applicable standards ...........................................................................
87Markings ...........................................................................................
87EMC compliance (IEC/EN 61800-3:2004 + A1:2012) ......................................
87Definitions .....................................................................................
88Category C1 ...................................................................................
88Category C2 ...................................................................................
89Category C4 ...................................................................................
90Disclaimers .......................................................................................
90Generic disclaimer ...........................................................................
90Cybersecurity disclaimer ...................................................................
8 Table of contents

10 Dimension drawings
91Contents ofthis chapter .......................................................................
92Frame R0 ..........................................................................................
92Frame R0(front& side)- IP20 ..............................................................
93Frame R0(bottom& rear)- IP20 ...........................................................
94Frame R1 ...........................................................................................
94Frame R1(front& side)- IP20 ..............................................................
95Frame R1(bottom& rear)- IP20 ...........................................................
96Frame R2 ..........................................................................................
96Frame R2(front& side)- IP20 ..............................................................
97Frame R2(bottom& rear)- IP20 ...........................................................
98Frame R3 ..........................................................................................
98Frame R3(front& side)- IP20 ..............................................................
99Frame R3(bottom& rear)- IP20 ...........................................................
100Recommendedcabinet design ...............................................................
100Cabinet assemblydrawings ...............................................................
102Module mountingplate detaildrawing .................................................
103Supporting Cclamp detaildrawing ......................................................
104EMI filterlayout diagram .......................................................................
104EMI filterlayout -Horizontal position ...................................................
105EMI filterlayout -Vertical position .......................................................
11 The Safe torque off function
107Contents ofthis chapter .......................................................................
107Description .......................................................................................
108
Compliance with the European Machinery Directive and the UK Supply of Ma-
chinery (Safety)Regulations ...............................................................
109Wiring ..............................................................................................
109Connection principle ........................................................................
109Single ACQ80-04 drive, internal power supply .....................................
110Single ACQ80-04 drive, external power supply ....................................
110Wiring examples ..............................................................................
110Single ACQ80-04 drive, internal power supply .....................................
111Single ACQ80-04 drive, external power supply ....................................
112Multiple ACQ80-04 drives, internal power supply .................................
113Multiple ACQ80-04 drives, external power supply ................................
113Activation switch .............................................................................
113Cable typesand lengths ....................................................................
114Grounding ofprotective shields ..........................................................
115Operation principle .............................................................................
116Start-up includingvalidation test ............................................................
116Competence ...................................................................................
116Validation testreports ......................................................................
116Validation testprocedure ..................................................................
118Use ..................................................................................................
119Maintenance ......................................................................................
119Competence ...................................................................................
120Fault tracing ......................................................................................
121Safety data ........................................................................................
121Terms andabbreviations ...................................................................
122TÜV certificate ................................................................................
Table of contents 9

123Declarations ofconformity ................................................................
12 BIO-01 I/O extension module
125Contents ofthis chapter .......................................................................
125Safety instructions ..............................................................................
125Hardware description ..........................................................................
125Product overview .............................................................................
126Layout ..........................................................................................
126Mechanical installation .........................................................................
126Terminal configuration .........................................................................
126Electrical installation ...........................................................................
127Start-up ............................................................................................
127Technical data ....................................................................................
Further information
10 Table of contents

Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install,
start-up, operate and do maintenance work on the drive. If you ignore the safety
instructions, injury, death or damage can occur.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or death, or damage to the
equipment. They also tell you how to prevent the danger. Notes draw attention to a
particular condition or fact, or give information on a subject.
The manual uses these warning symbols:
WARNING!
Electricity warning tells about hazards from electricity which can cause injury
or death, or damage to the equipment.
WARNING!
General warning tells about conditions other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
1
Safety instructions 11

General safety in installation, start-up and maintenance
These instructions are for all personnel who do work on the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
• Keep the drive in its package until you install it. After unpacking, protect the drive
from dust, debris and moisture.
• Use the required personal protective equipment: safety shoes with metal toe cap,
safety glasses, protective gloves and long sleeves, etc. Some parts have sharp
edges.
• Lift a heavy drive with a lifting device. Use the designated lifting points. See the
dimension drawings.
• Be careful when handling a tall module. The module overturns easily because it is
heavy and has a high center of gravity. Whenever possible, secure the module with
chains. Do not leave an unsupported module unattended especially on a sloping
floor.
• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors,
and brake resistors, remain hot for a while after disconnection of the electrical
supply.
• Vacuum clean the area around the drive before the start-up to prevent the drive
cooling fan from drawing the dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not enter the drive
during the installation. Electrically conductive debris inside the drive may cause
damage or malfunction.
• Make sure that there is sufficient cooling. See the technical data.
• Before you connect voltage to the drive, make sure that all covers are in place. Do
not remove the covers when voltage is connected.
• Before you adjust the drive operation limits, make sure that the motor and all
driven equipment can operate throughout the set operation limits.
• Before you activate the automatic fault reset or automatic restart functions of
the drive control program, make sure that no dangerous situations can occur.
These functions reset the drive automatically and continue operation after a fault
or supply break. If these functions are activated, the installation must be clearly
marked as defined in IEC/EN/UL 61800-5-1, subclause 6.5.3, for example, "THIS
MACHINE STARTS AUTOMATICALLY".
12 Safety instructions
3

• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors.
• If you have connected safety circuits to the drive (for example, Safe torque off or
emergency stop), validate them at start-up. See separate instructions for the
safety circuits.
• Beware of hot air exiting from the air outlets.
• Do not cover the air inlet or outlet when the drive is running.
Note:
• If you select an external source for the start command and it is on, the drive will
start immediately after fault reset unless you configure the drive for pulse start.
See the firmware manual.
• If the drive is in remote control mode, you cannot stop or start the drive with the
control panel.
• Only authorized persons are allowed to repair a malfunctioning drive.
Safety instructions 13

Electrical safety in installation, start-up and maintenance
￭Electrical safety precautions
These electrical safety precautions are for all personnel who do work on the drive,
motor cable or motor.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
Go through these steps before you begin any installation or maintenance
work.
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that re-connection is not
possible. Lock out and tag out.
• Open the main disconnecting device of the drive.
• If you have a permanent magnet motor connected to the drive, disconnect the
motor from the drive with a safety switch or by other means.
• Disconnect all dangerous external voltages from the control circuits.
• After you disconnect power from the drive, always wait 5 minutes to let the
intermediate circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a quality voltage tester.
•Before and after measuring the installation, verify the operation of the voltage
tester on a known voltage source.
• Make sure that the voltage between the drive input power terminals (L1, L2,
L3) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive output terminals (T1/U, T2/V,
T3/W) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive DC terminals (UDC+ and UDC-)
and the grounding (PE) terminal is zero.
Note: If cables are not connected to the drive DC terminals, measuring the
voltage from the DC terminal screws can give incorrect results.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation
work.
￭Additional instructions and notes
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
14 Safety instructions
3

•Make sure that the electrical power network, motor/generator, and environmental
conditions agree with the drive data.
• Do not do insulation or voltage withstand tests on the drive.
• If you have a cardiac pacemaker or other electronic medical device, keep away
from the area near motor, drive, and the drive power cabling when the drive is in
operation. There are electromagnetic fields present which can interfere with the
function of such devices. This can cause a health hazard.
Note:
• When the drive is connected to the input power, the motor cable terminals and
the DC bus are at a dangerous voltage.
After disconnecting the drive from the input power, these remain at a dangerous
voltage until the intermediate circuit capacitors have discharged.
• External wiring can supply dangerous voltages to the relay outputs of the control
units of the drive.
• The Safe torque off function does not remove the voltage from the main and
auxiliary circuits. The function is not effective against deliberate sabotage or
misuse.
Printed circuit boards
WARNING!
Use a grounding wristband when you handle printed circuit boards. Do not
touch the boards unnecessarily. The boards contain components sensitive
to electrostatic discharge.
￭Grounding
These instructions are for all personnel who are responsible for the grounding of the
drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or equipment
malfunction can occur, and electromagnetic interference can increase.
If you are not a qualified electrical professional, do not do grounding work.
• Always ground the drive, the motor and adjoining equipment. This is necessary
for the personnel safety.
•Make sure that the conductivity of the protective earth (PE) conductors is sufficient
and that other requirements are met. See the electrical planning instructions of
the drive. Obey the applicable national and local regulations.
• When using shielded cables, make a 360° grounding of the cable shields at the
cable entries to reduce electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) busbar of the power supply.
Safety instructions 15

General safety in operation
These instructions are for all personnel that operate the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
• If you have a cardiac pacemaker or other electronic medical device, keep away
from the area near motor, drive, and the drive power cabling when the drive is in
operation. There are electromagnetic fields present which can interfere with the
function of such devices. This can cause a health hazard.
• Give a stop command to the drive before you reset a fault. If you have an external
source for the start command and the start is on, the drive will start immediately
after the fault reset, unless you configure the drive for pulse start. See the firmware
manual.
• Before you activate the automatic fault reset or automatic restart functions of
the drive control program, make sure that no dangerous situations can occur.
These functions reset the drive automatically and continue operation after a fault
or supply break. If these functions are activated, the installation must be clearly
marked as defined in IEC/EN/UL 61800-5-1, subclause 6.5.3, for example, "THIS
MACHINE STARTS AUTOMATICALLY".
Note:
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors. If you need to
start or stop the drive, use the control panel keys or commands through the I/O
terminals of the drive.
• If the drive is in remote control mode, you cannot stop or start the drive with the
control panel.
Additional instructions for permanent magnet motor
drives
￭Safety in installation, start-up, maintenance
These are additional warnings concerning permanent magnet motor drives. The other
safety instructions in this chapter are also valid.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
•Do not do work on the drive when a rotating permanent magnet motor is connected
to it. A rotating permanent magnet motor energizes the drive including its input
and output power terminals.
Before installation, start-up and maintenance work on the drive:
• Stop the drive.
• Disconnect the motor from the drive with a safety switch or by other means.
16 Safety instructions
3

•If you cannot disconnect the motor, make sure that the motor cannot rotate during
work. Make sure that no other system, like hydraulic crawling drives, can rotate
the motor directly or through any mechanical connection like felt, nip, rope, etc.
• Do the steps in section Electrical safety precautions (page 14) .
• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W).
Connect the output terminals together as well as to the PE.
During the start-up:
• Make sure that the motor cannot run overspeed, for example, driven by the load.
Motor overspeed causes overvoltage that can damage or destroy the capacitors
in the intermediate circuit of the drive.
￭Safety in operation
WARNING!
Make sure that the motor cannot run overspeed, for example, driven by the
load. Motor overspeed causes overvoltage that can damage or destroy the
capacitors in the intermediate circuit of the drive.
Safety instructions 17

18

Introduction to the manual
Contents of this chapter
The chapter describes the applicability, target audience and purpose of the manual.
The chapter contains a list of related manuals and a flowchart for installation and
commissioning.
Applicability
This manual is applicable to ACQ80-04 drives.
Target audience
This manual is intended for people who plan the installation, install, commission and
do maintenance work on the drive, or create instructions for the end user of the drive
concerning the installation and maintenance of the drive.
Read the manual before working on the drive. You are expected to know the
fundamentals of electricity, wiring, electrical components and electrical schematic
symbols.
Categorization by frame size
The drives are manufactured in frame sizes (for example, R1). The information that is
applicable only to specific frames is identified with the frame size. The frame size is
shown on the type designation label.
2
Introduction to the manual 19

Quick installation and commissioning flowchart
SeeTask
Type designation key (page 28)
Identify the frame size: R1, R2, etc.
Guidelines for planning the electrical installa-
tion (page 35)
Plan the installation.
Check the ambient conditions, ratings and required
cooling air flow.
Unpacking the delivery (page 32)
Unpack and check the delivery.
Grounding system compatibility check –
IEC (page 50)
If the supply network is not a symmetrically groun-
ded TN-S system, make sure that the drive is com-
patible with the grounding system.
Grounding system compatibility check – North
America
Installing the drive (page 33)
Install the drive.
Routing the cables (page 43)
Route the cables.
Measuring the insulation resistance - IEC (page 50)
Measure the insulation of the input cable, motor
and motor cable.
Measuring the insulation resistance - North America
Connecting the power cables – IEC (shielded
cables) (page 54)
Connect the power cables.
Connecting the power cables – North America (wir-
ing in conduits)
Connecting the control cables - IEC (page 55)
Connect the control cables.
Connecting the control cables - North America
Installation checklist (page 63)
Examine the installation.
20 Introduction to the manual