ABB ACS880-37 User manual

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ABB INDUSTRIAL DRIVES
ACS880-37 drives (160 to 3200 kW)
Hardware manual

ACS880-37 drives (160 to 3200 kW)
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
9. Start-up
3AXD50000020437 Rev C
EN
Original instructions
EFFECTIVE: 2021-01-18

Table of contents
1 Safety instructions
15Contents of this chapter ...........................................................................
15Use of warnings and notes .......................................................................
16General safety in installation, start-up and maintenance ....................................
18Electrical safety in installation, start-up and maintenance ...................................
18Electrical safety precautions ..................................................................
20Additional instructions and notes .............................................................
20Optical components ........................................................................
21Printed circuit boards .......................................................................
21Grounding .......................................................................................
22General safety in operation .......................................................................
22Additional instructions for permanent magnet motor drives .................................
22Safety in installation, start-up, maintenance ................................................
23Safety in operation .............................................................................
2 Introduction to the manual
25Contents of this chapter ...........................................................................
25Target audience ....................................................................................
25Categorization by frame size and option code .................................................
26Use of component designations .................................................................
26Quick installation, commissioning and operation flowchart ..................................
27Terms and abbreviations ..........................................................................
28Related manuals ...................................................................................
3 Operation principle and hardware description
29Contents of this chapter ...........................................................................
29Supply unit ..........................................................................................
30AC voltage and current waveforms ..........................................................
30Charging .........................................................................................
30Inverter unit .........................................................................................
31Overview circuit diagram of the drive ...........................................................
32Cabinet line-up and layout examples ...........................................................
32Frame 1×R8i+1×R8i ...........................................................................
34Frame 2×R8i+2×R8i ...........................................................................
36Frame 3×R8i+3×R8i (with main breaker, option +F255) ..................................
38Auxiliary control cubicle (ACU) layout .......................................................
40Overview of power and control connections ...................................................
41Door switches and lights ..........................................................................
42Main disconnecting device (Q1.1) ...........................................................
42Auxiliary voltage switch [Q21] ................................................................
42Grounding (earthing) switch [Q9], optional .................................................
42Other devices on the door .....................................................................
43Control panel ....................................................................................
43Control by PC tools .........................................................................
Table of contents 5

44Descriptions of options ............................................................................
44Degree of protection ...........................................................................
44Definitions ....................................................................................
44IP22 (UL Type 1) ............................................................................
44IP42 (UL Type 1 Filtered) (option +B054) ...............................................
44IP54 (UL Type 12) (option +B055) .......................................................
44Marine construction (option +C121) .........................................................
45Cooling air intake through bottom of cabinet (option +C128) ............................
45UL Listed (option +C129) ......................................................................
45Channeled air outlet (option +C130) .........................................................
45CSA Approved (option +C134) ...............................................................
45Plinth height (options +C164 and +C179) ..................................................
45Seismic design (option +C180) ...............................................................
45Empty cubicles on left (options +C199…C201) ............................................
46EMC filter (option +E202) .....................................................................
46du/dtfilter ........................................................................................
46Sine filter (option +E206) ......................................................................
46Cabinet heater with external supply (option +G300) ......................................
46Cabinet lighting (option +G301) ..............................................................
46Terminals for external control voltage (option +G307) ....................................
47Output for motor space heater (option +G313) ............................................
47Supply connection by busbars (option +G317) ............................................
47Ready/Run/Fault lights (options +G327…G329) ..........................................
47Halogen-free wiring and materials (option +G330) ........................................
47V-meter with selector switch (option +G334) ...............................................
47A-meter in one phase (option +G335) .......................................................
47Wire markings ...................................................................................
47Standard wiring .............................................................................
48Additional wire markings ...................................................................
48Voltage measurement with BAMU auxiliary measurement unit (option +G442) ......
48Common mode filter temperature monitoring (option +G453) ...........................
49Bottom cable entry/exit (options +H350 and +H352) ......................................
49Top cable entry/exit (options +H351 and +H353) ..........................................
49Cable conduit entry (option +H358) .........................................................
49Common motor terminal cubicle (option +H359) ..........................................
49Common output terminals (option +H366) ..................................................
50Additional terminal block X504 (option +L504) .............................................
50
Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513, +L536,
+L537) ...........................................................................................
50+L505, +2L505, +L513, +2L513 ..........................................................
50+L536, +L537 ................................................................................
51Thermal protection with Pt100 relays (options +nL506, +nL514) .......................
51Starter for auxiliary motor fan (options +M6xx) ............................................
51What the option contains ..................................................................
52Description ...................................................................................
53Type designation label ............................................................................
53Type designation key ..............................................................................
54Option codes ....................................................................................
4 Mechanical installation
59Contents of this chapter ...........................................................................
59Examining the installation site ...................................................................
6 Table of contents

60Necessary tools ....................................................................................
60Examining 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 ............................................................
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 ............................................................
67Attaching the cabinet to the floor and wall or roof .............................................
67General rules ....................................................................................
68Attaching the cabinet (non-marine units) ...................................................
68Alternative 1 – Clamping ...................................................................
69Alternative 2 – Using the holes inside the cabinet .....................................
69Alternative 3 – Cabinets with plinth options +C164 and +C179 ......................
70Attaching the cabinet (marine units) .........................................................
71Joining cabinet sections together ................................................................
73Miscellaneous ......................................................................................
73Cable duct in the floor below the cabinet ...................................................
73Arc welding ......................................................................................
73Air inlet through the bottom of cabinet (option +C128) ...................................
74Air outlet duct on the cabinet roof (option +C130) .........................................
75Calculating the required static pressure difference ....................................
76Lifting lugs and bars ...............................................................................
76Certificate of conformity .......................................................................
76Declaration of Conformity .....................................................................
5 Guidelines for planning the electrical installation
79Contents of this chapter ...........................................................................
79Limitation of liability ................................................................................
79Selecting the supply disconnecting device .....................................................
79Selecting the main contactor or breaker ........................................................
80Examining the compatibility of the motor and drive ...........................................
80Protecting the motor insulation and bearings ..............................................
80Requirements table ............................................................................
83Availability of du/dtfilter and common mode filter by drive type .....................
83Additional requirements for explosion-safe (EX) motors ..............................
83
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ ......................................................................................
83Additional requirements for braking applications .......................................
83Additional requirements for the regenerative and low harmonics drives ...........
83Additional requirements for ABB high-output and IP23 motors ......................
83Additional requirements for non-ABB high-output and IP23 motors .................
84Additional data for calculating the rise time and the peak line-to-line voltage .....
85Additional note for sine filters .............................................................
85Selecting the power cables .......................................................................
85General guidelines .............................................................................
86Typical power cable sizes .....................................................................
Table of contents 7

86Power cable types ..............................................................................
86Preferred power cable types ..............................................................
87Alternate power cable types ...............................................................
88Not allowed power cable types ...........................................................
88Power cable shield .............................................................................
89Selecting the control cables ......................................................................
89Shielding .........................................................................................
89Signals in separate cables ....................................................................
89Signals that can be run in the same cable ..................................................
89Relay cable ......................................................................................
89Control panel to drive cable ...................................................................
90PC tool cable ....................................................................................
90Routing the cables .................................................................................
90General guidelines – IEC ......................................................................
91
Continuous motor cable shield/conduit or enclosure for equipment on the motor
cable ..............................................................................................
91Separate control cable ducts .................................................................
91
Protecting the drive, input power cable, motor and motor cable in short circuit situations
and against thermal overload ....................................................................
91Protecting the input cabling and the drive upon a short-circuit ..........................
91Protecting the motor and motor cable in short-circuits ....................................
91Protecting the drive and the power cables against thermal overload ...................
92Protecting the motor against thermal overload .............................................
92Protecting the motor against overload without thermal model or temperature sensors .
92Protecting the drive against ground faults ......................................................
92Residual current device compatibility ........................................................
93Implementing the emergency stop function ....................................................
93Implementing the Safe torque off function .....................................................
93Implementing the Prevention of unexpected start-up function ..............................
93Implementing an ATEX-certified motor thermal protection ...................................
94Implementing the functions provided by the FSO-xx safety functions module ............
94Implementing the power loss ride-through function ...........................................
95Implementing a bypass connection .............................................................
95Supplying power for the auxiliary circuits .......................................................
95Using power factor compensation capacitors with the drive .................................
96Using a safety switch between the drive and the motor ......................................
96Implementing the control of a contactor between drive and motor .........................
96Protecting the contacts of relay outputs ........................................................
97Implementing a motor temperature sensor connection ......................................
98Connecting motor temperature sensor to the drive via an option module .............
6 Electrical installation
99Contents of this chapter ...........................................................................
99Warnings ............................................................................................
99Measuring the insulation ..........................................................................
99Measuring the insulation of the drive ........................................................
99Measuring the insulation of the motor and motor cable ..................................
100Compatibility check - IT (ungrounded) earthing system ......................................
100Attaching the device stickers to the cabinet door .............................................
100Checking the settings of transformers T21, T101 and T111 .................................
101T21 and T101 tap settings (400…500 V units) .............................................
101T21 and T101 tap settings (690 V units) ....................................................
8 Table of contents

102T111 tap settings ...............................................................................
103Connecting the control cables ...................................................................
103Control cable connection procedure .........................................................
103Grounding the outer shields of the control cables at the cabinet entry .............
105Routing the control cables inside the cabinet ...........................................
105Connecting control cabling ................................................................
106Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) .......
107
Connecting the emergency stop push buttons (options +Q951, +Q952, +Q963,
+Q964, +Q978,+Q979) ....................................................................
107Wiring the starter for auxiliary motor fan (options +M6xx) ............................
107Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513 and +2L513) .
108Wiring the Pt100 relays (option +nL506) ................................................
109Wiring the Pt100 relays (option +nL514) ................................................
110
Powering the heating and lighting equipment (options +G300, +G301 and
+G313) .......................................................................................
110Wiring ground fault monitoring for IT ungrounded systems (option +Q954) .......
111
Connecting the motor cables (units without common motor terminal cubicle or sine output
filter) ..................................................................................................
111Motor connection diagram (without option +H366) ........................................
112Motor connection diagram (with option +H366) ............................................
113Procedure .......................................................................................
113Removing the inverter module(s) .........................................................
116Removing the fan carriage of an inverter module ......................................
118Connecting the motor cables ..............................................................
121Re-installing the fan carriage of an inverter module ...................................
121Re-inserting the inverter modules into the cubicle .....................................
122
Connecting the motor cables (units with common motor terminal cubicle or sine output
filter) ..................................................................................................
122Output busbars .................................................................................
122Connection diagram ............................................................................
122Procedure .......................................................................................
123Connecting an external brake resistor assembly ..............................................
124Connecting the input power cables ..............................................................
124Connection diagram ............................................................................
124Layout of the input cable connection terminals and cable entries .......................
124Connection procedure .........................................................................
127Connecting a PC ...................................................................................
127Panel bus (Control of several units from one control panel) .................................
130Installing option modules .........................................................................
130
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface
modules ..........................................................................................
130Installation of an FSO-xx safety functions module onto BCU ............................
132Wiring of option modules ......................................................................
7 Control units of the drive
133Contents of this chapter ...........................................................................
133General ..............................................................................................
134BCU-x2 layout ......................................................................................
136Default I/O diagram of the supply control unit .................................................
138Default I/O diagram of the inverter control unit (A41) .........................................
139Additional information on the connections .....................................................
139External power supply for the control unit (XPOW) .......................................
Table of contents 9

139DI6 as a PTC sensor input ....................................................................
140AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input .............................
140DIIL input ........................................................................................
141The XD2D connector ..........................................................................
141Safe torque off (XSTO, XSTO OUT) .........................................................
141FSO-xx safety functions module connection (X12) ........................................
141SDHC memory card slot .......................................................................
142Connector data .....................................................................................
144BCU-x2 ground isolation diagram ............................................................
8 Installation checklist
145Contents of this chapter ...........................................................................
145Checklist .............................................................................................
9 Start-up
147Contents of this chapter ...........................................................................
147Start-up procedure .................................................................................
149Switching off the drive .............................................................................
10 Fault tracing
151Contents of this chapter ...........................................................................
151Control unit LEDs ..................................................................................
151Control panel and panel platform/holder LEDs ................................................
152Warning and fault messages .....................................................................
11 Maintenance
153Contents of this chapter ...........................................................................
153Maintenance intervals .............................................................................
156Cabinet ..............................................................................................
156Cleaning the interior of the cabinet ..........................................................
156Cleaning the door air inlets (IP22 and IP42) ...............................................
157Replacing the inlet door filters (IP54) ........................................................
157Cleaning the roof outlet filters (IP54) ........................................................
157Replacing the outlet (roof) filters (IP54) .....................................................
158Power connections and quick connectors ......................................................
158Retightening the power connections ........................................................
159Fans ..................................................................................................
160Replacing R8i module cooling fan (speed-controlled version) ...........................
161Replacing R8i module cooling fan (direct-on-line version) ...............................
163Replacing the fan of the LCL filter (BLCL-1x-x) ............................................
164Replacing the fan of the LCL filter (BLCL-2x-x) ............................................
165Replacing the circuit board compartment fan ..............................................
166Replacing the cooling fan in the auxiliary control cubicle .................................
167Replacing the cooling fan in the incoming cubicle .........................................
167Replacing a roof fan (IP54/UL type 12) .....................................................
168Replacing the brake chopper and resistor cubicle fans (options +D150 and +D151) .
169Supply and inverter modules .....................................................................
169Replacing a supply or inverter module ......................................................
169Cleaning the heatsink ..........................................................................
169Activating the reduced run of the inverter unit .............................................
171Returning the module ......................................................................
10 Table of contents