ABB ACS880-37 User manual

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ABB INDUSTRIAL DRIVES
ACS880-37 drives (45…400 kW, 60…450 hp)
Hardware manual

ACS880-37 drives (45…400 kW,
60…450 hp)
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
9. Start-up
3AXD50000035159 Rev G
EN
EFFECTIVE: 2020-03-25

Table of contents
1 Safety instructions
15Contents of this chapter ...........................................................................
15Use of warnings and notes .......................................................................
16General safety in installation, start-up and maintenance ....................................
17Electrical safety in installation, start-up and maintenance ...................................
17Electrical safety precautions ..................................................................
19Measuring the voltage .........................................................................
22Additional instructions and notes .............................................................
23Optical components ........................................................................
23Printed circuit boards .......................................................................
23Grounding .......................................................................................
24General safety in operation .......................................................................
25Additional instructions for permanent magnet motor drives .................................
25Safety in installation, start-up, maintenance ................................................
25Safety in operation .............................................................................
2 Introduction to the manual
27Contents of this chapter ...........................................................................
27Target audience ....................................................................................
27Categorization by frame size and option code .................................................
28Quick installation, commissioning and operation flowchart ..................................
28Terms and abbreviations ..........................................................................
29Related manuals ...................................................................................
3 Operation principle and hardware description
31Contents of this chapter ...........................................................................
31Operation principle .................................................................................
32Single-line circuit diagram of the drive ......................................................
32Single-line diagram of R8 ..................................................................
33Single-line diagram of R11 ................................................................
34Block diagram of the drive with brake options +D150 and +D151 ......................
35Line-side converter .............................................................................
35AC voltage and current waveforms ......................................................
35Charging .....................................................................................
35Motor-side converter ...........................................................................
36Cabinet layout ......................................................................................
36Cabinet layout of R8 ...........................................................................
39Cabinet layout of R11 ..........................................................................
43Brake chopper cubicle option (+D150) ......................................................
44Overview of power and control connections ...................................................
44Connection overview of R8 ...................................................................
45Connection overview of R11 ..................................................................
46External control cable connection terminals (other than control unit terminals) .......
46Connection terminals of R8 ...............................................................
47Connection terminals of R11 ..............................................................
Table of contents 5

48Door switches and lights ..........................................................................
49Main disconnecting device (Q1) ..............................................................
49Other devices on the door .....................................................................
49Control panel ....................................................................................
49Control by PC tools ............................................................................
50Descriptions of options ............................................................................
50Degree of protection ...........................................................................
50Definitions ....................................................................................
50IP22 (UL Type 1) ............................................................................
50IP42 (UL Type 1 Filtered) (option +B054) ...............................................
50IP54 (UL Type 12) (option +B055) .......................................................
50Marine construction (option +C121) .........................................................
51Cooling air intake through bottom of cabinet (option +C128) ............................
51UL Listed (option +C129) ......................................................................
51Channeled air outlet (option +C130) .........................................................
51CSA Approved (option +C134) ...............................................................
51Plinth height (options +C164 and +C179) ..................................................
51Seismic design (option +C180) ...............................................................
51Empty cubicles on right (options +C196…C198) ..........................................
51Empty cubicles on left (options +C199…C201) ............................................
52Resistor braking (options +D150 and +D151) ..............................................
52du/dtfilter (option +E205) .....................................................................
52Sine filter (option +E206) ......................................................................
52Common mode filter (option +E208) .........................................................
52Cabinet heater with external supply (option +G300) ......................................
52Cabinet lighting (option +G301) ..............................................................
52Terminals for external control voltage (option +G307) ....................................
53Output for motor space heater (option +G313) ............................................
53Ready/Run/Fault lights (options +G327…G329) ..........................................
53Halogen-free wiring and materials (option +G330) ........................................
53V-meter with selector switch (option +G334) ...............................................
53A-meter in one phase (option +G335) .......................................................
53Wire markings ...................................................................................
53Standard wire markings ....................................................................
53Additional wire markings ...................................................................
54Bottom cable entry/exit (options +H350 and +H352) ......................................
54Top cable entry/exit (options +H351 and +H353) ..........................................
54Cable conduit entry (option +H358) .........................................................
54Additional terminal block X504 (option +L504) .............................................
55
Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513, +L536,
+L537) ...........................................................................................
55+L505, +2L505, +L513, +2L513 ..........................................................
55+L536, +L537 ................................................................................
56Thermal protection with Pt100 relays (options +nL506, +nL514) .......................
56Starter for auxiliary motor fan (options +M6xx) ............................................
56What the option contains ..................................................................
57Description ...................................................................................
57Type designation label ............................................................................
58Type designation key ..............................................................................
58Basic codes .....................................................................................
58Option codes (plus codes) ....................................................................
6 Table of contents

4 Mechanical installation
63Contents of this chapter ...........................................................................
63Examining the installation site ...................................................................
64Necessary tools ....................................................................................
64Examining the delivery ............................................................................
65Moving and unpacking the drive .................................................................
65Moving the drive in its packaging – Frame R8 .............................................
67Moving the drive in its packaging – Frame R11 ............................................
67Lifting the crate with a forklift ..............................................................
68Lifting the crate with a crane ..............................................................
69Moving the crate with a forklift ............................................................
69Removing the transport package ............................................................
70Moving the unpacked drive cabinet ..........................................................
70Lifting the cabinet with a crane ...........................................................
71Moving the cabinet on rollers .............................................................
71Moving the cabinet on its back ............................................................
72Final placement of the cabinet ............................................................
73Installing the IP54 roof (option +B055) .........................................................
73Frame R8 ........................................................................................
74Frame R11 .......................................................................................
75Attaching the cabinet to the floor and wall or roof .............................................
75General rules ....................................................................................
76Attaching the cabinet (non-marine units) ...................................................
76Alternative 1 – Clamping ...................................................................
77Alternative 2 – Using the holes inside the cabinet .....................................
78Attaching the cabinet (marine units) .........................................................
79Miscellaneous ......................................................................................
79Cable duct in the floor below the cabinet ...................................................
79Arc welding ......................................................................................
79Air inlet through the bottom of cabinet (option +C128) ...................................
80Air outlet duct on the cabinet roof (option +C130) .........................................
80Calculating the required static pressure difference ....................................
82Lifting lugs and bars ...............................................................................
82Certificate of conformity .......................................................................
82Declaration of Conformity .....................................................................
5 Guidelines for planning the electrical installation
85Contents of this chapter ...........................................................................
85Limitation of liability ................................................................................
85Selecting the supply disconnecting device .....................................................
86Examining the compatibility of the motor and drive ...........................................
86Protecting the motor insulation and bearings ..............................................
86Requirements table ............................................................................
89Availability of du/dtfilter and common mode filter by drive type .....................
89Additional requirements for explosion-safe (EX) motors ..............................
89
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ ......................................................................................
89Additional requirements for ABB high-output and IP23 motors ......................
89Additional requirements for non-ABB high-output and IP23 motors .................
90Additional data for calculating the rise time and the peak line-to-line voltage .....
91Additional note for sine filters .............................................................
Table of contents 7

91Selecting the power cables .......................................................................
91General guidelines .............................................................................
92Typical power cable sizes .....................................................................
92Power cable types ..............................................................................
92Preferred power cable types ..............................................................
93Alternate power cable types ...............................................................
94Not allowed power cable types ...........................................................
94Additional guidelines, North America ........................................................
95Metal conduit ................................................................................
95Power cable shield .............................................................................
96Selecting the control cables ......................................................................
96Shielding .........................................................................................
96Signals in separate cables ....................................................................
96Signals that can be run in the same cable ..................................................
96Relay cable ......................................................................................
96Control panel to drive cable ...................................................................
97PC tool cable ....................................................................................
97Routing the cables .................................................................................
97General guidelines – IEC ......................................................................
97General guidelines – North America .........................................................
98
Continuous motor cable shield/conduit or enclosure for equipment on the motor
cable ..............................................................................................
98Separate control cable ducts .................................................................
99Implementing thermal overload and short-circuit protection .................................
99Protecting the drive and input power cable in short-circuits ..............................
99Protecting the motor and motor cable in short-circuits ....................................
99Protecting the drive and the power cables against thermal overload ...................
100Protecting the motor against thermal overload .............................................
100Protecting the drive against ground faults ..................................................
100Residual current device compatibility ....................................................
100Implementing the emergency stop function ................................................
100Implementing the Safe torque off function ..................................................
100Implementing an ATEX-certified motor thermal protection ...............................
101Implementing the Prevention of unexpected start-up function ...........................
101Implementing the functions provided by the FSO-xx safety functions module ........
102Implementing the Power-loss ride-through function .......................................
102Cabinets with line contactor (option +F250) ............................................
102Implementing a bypass connection ..........................................................
102Supplying power for the auxiliary circuits ...................................................
103Using power factor compensation capacitors with the drive .............................
103Using a safety switch between the drive and the motor ..................................
103Implementing the control of a contactor between drive and motor ......................
103Protecting the contacts of relay outputs .....................................................
104Implementing a motor temperature sensor connection ...................................
105Connecting motor temperature sensor to the drive via an option module ..........
6 Electrical installation
107Contents of this chapter ...........................................................................
107Warnings ............................................................................................
107Measuring the insulation ..........................................................................
107Measuring the insulation of the drive ........................................................
107Measuring the insulation of the input power cable ........................................
8 Table of contents

108Measuring the insulation of the motor and motor cable ..................................
108
Compatibility with IT (ungrounded), corner-grounded delta, midpoint-grounded delta and
TT systems .........................................................................................
108EMC filter (standard drive, options +E200 or +E202) .....................................
108Ground-to-phase varistor ......................................................................
109Corner-grounded and midpoint-grounded delta systems .................................
109Attaching the device stickers to the cabinet door .............................................
109Settings the voltage range of auxiliary voltage transformers ................................
110Connecting the power cables ....................................................................
110Connection diagram ............................................................................
110Connection diagram of frame R8 .........................................................
111Connection diagram of frame R11 ........................................................
112Layout of power cable connection terminals and cable entries ..........................
112Frame R8 ....................................................................................
113Frame R11 ...................................................................................
114Layout of power cable connection terminals (option +C129) .........................
115External resistor cable connection terminals and cable entries ......................
115Connection procedure (IEC) ..................................................................
117Connection procedure (North America) .....................................................
120Grounding the motor cable shield at the motor end .......................................
120Connecting the control cables ...................................................................
120Routing the control cables inside the cabinet ..............................................
120Routing the control cables inside the cabinet ...........................................
120Frame R8 ....................................................................................
123Frame R11 ...................................................................................
127Connecting the external control cables to the drive control unit .........................
127Connecting a PC ...................................................................................
129Installing option modules .........................................................................
129
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface
modules ..........................................................................................
129Installation of an FSO-xx safety functions module beside the ZCU-12 control unit ...
130Installation of an FSO-xx safety functions module onto ZCU-14 ........................
131Safety functions module FSO-xx beside the ZCU-14 control unit .......................
132Installation of an FSPS-21 safety functions module .......................................
7 Control units of the drive
133Contents of this chapter ...........................................................................
133General ..............................................................................................
134ZCU-12 layout ......................................................................................
135ZCU-14 layout ......................................................................................
136Default I/O diagram of the drive control unit (ZCU-1x) .......................................
138Additional information on the connections .....................................................
138External power supply for the control unit (XPOW) .......................................
138DI6 as a PTC sensor input ....................................................................
138AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input .............................
139DIIL input ........................................................................................
139The XD2D connector ..........................................................................
140Safe torque off (XSTO) ........................................................................
140FSO-xx safety functions module connection (X12) ........................................
141Connector data .....................................................................................
143ZCU-1x ground isolation diagram ............................................................
Table of contents 9

8 Installation checklist of the drive
145Contents of this chapter ...........................................................................
145Checklist .............................................................................................
9 Start-up
147Contents of this chapter ...........................................................................
147Start-up procedure .................................................................................
10 Fault tracing
151Contents of this chapter ...........................................................................
151LEDs .................................................................................................
151Warning and fault messages .....................................................................
11 Maintenance
153Contents of this chapter ...........................................................................
153Maintenance intervals .............................................................................
155Cabinet ..............................................................................................
155Cleaning the interior of the cabinet ..........................................................
155Cleaning the door air inlets (IP22 and IP42) ...............................................
156Replacing the inlet door filters (IP54) ........................................................
156Cleaning the roof outlet filters (IP54) ........................................................
156Replacing the outlet (roof) filters (IP54) .....................................................
157Cleaning the heatsink .............................................................................
157Power connections ................................................................................
157Retightening the power connections ........................................................
157Fans ..................................................................................................
158Replacing the cabinet “door fan” .............................................................
159Replacing the internal cabinet cooling fans (frame R8) ...................................
161Replacing the drive module main fan (frame R8) ..........................................
161Replacing the drive module main fans (frame R11) .......................................
163Replacing the LCL filter module fan (frame R11) ..........................................
164Replacing the auxiliary cooling fan of the drive module (frame R8) ....................
165Replacing the auxiliary cooling fans of the drive module (frame R11) ..................
167
Frame R8: Replacing the IP54 (UL Type 12) roof fan and chopper (option +D150)
cubicle fan G101.2 .............................................................................
168Frame R11 with options +B055 and +C128: Replacing the roof fan ....................
169Frame R11 with option +B055: Replacing the roof fan ...................................
169Replacing the brake chopper (option +D150) cubicle fan ................................
170Replacing the sine filter cooling fan ..........................................................
171Replacing the drive module (frame R8) ........................................................
171Required tools ..................................................................................
171Replacing the drive module (frame R8) .....................................................
180Replacing the drive and LCL filter modules (frame R11) .....................................
180Required tools ..................................................................................
180Safety ............................................................................................
180Module handling ............................................................................
182Replacing the drive module (frame R11) ....................................................
191Replacing the LCL filter module ..............................................................
193Capacitors ...........................................................................................
193Reforming the capacitors ......................................................................
10 Table of contents