ABB ACS880-37LC-0390A-7 User manual

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ABB INDUSTRIAL DRIVES
ACS880-37LC drives
Hardware manual

ACS880-37LC drives
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
9. Start-up
3AXD50000251407 Rev B
EN
Original instructions
EFFECTIVE: 2022-04-20

Table of contents
1 Safety instructions
15Contents of this chapter ...........................................................................
15Use of warnings and notes .......................................................................
16General safety in installation, start-up and maintenance ....................................
18Work on the liquid cooling system ...........................................................
19Electrical safety in installation, start-up and maintenance ...................................
19Electrical safety precautions ..................................................................
20Additional instructions and notes .............................................................
21Optical 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 ..........................................................................
27Related 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 2×R8i+2×R8i line-up ..................................................................
33Frame 2×R8i+2×R8i layout ...................................................................
34100 kA input cubicle (option +F274) .........................................................
35Overview of power and control connections ...................................................
36Door switches and lights ..........................................................................
36Main disconnecting device [Q1] ..............................................................
36Auxiliary voltage switch [Q21] ................................................................
36Grounding (earthing) switch [Q9], optional .................................................
37Other devices on the door .....................................................................
37Control panel ....................................................................................
37Control by PC tools .........................................................................
Table of contents 5

38Descriptions of options ............................................................................
38Degree of protection ...........................................................................
38Definitions ....................................................................................
38Marine construction (option +C121) .........................................................
38UL Listed (option +C129) ......................................................................
38Plinth height (options +C164 and +C179) ..................................................
38Resistor braking (options +D150 and +D151) ..............................................
39du/dtfilter ........................................................................................
39Common mode filter (option +E208) .........................................................
39Cabinet heater with external supply (option +G300) ......................................
39Cabinet lighting (option +G301) ..............................................................
39Terminals for external control voltage (option +G307) ....................................
39Output for motor space heater (option +G313) ............................................
40Halogen-free wiring and materials (option +G330) ........................................
40V-meter with selector switch (option +G334) ...............................................
40Wire markings ...................................................................................
40Standard wiring .............................................................................
41Additional wire markings ...................................................................
41Voltage measurement with BAMU auxiliary measurement unit (option +G442) ......
42Bottom cable entry/exit (options +H350 and +H352) ......................................
42Top cable entry/exit (options +H351 and +H353) ..........................................
42Common motor terminal cubicle (option +H359) ..........................................
42
Thermal protection with PTC relays (options +L505, +2L505, +L513, +2L513, +L536,
+L537) ...........................................................................................
42+L505, +2L505, +L513, +2L513 ..........................................................
43+L536, +L537 ................................................................................
43Thermal protection with Pt100 relays (options +nL506, +nL514) .......................
44Starter for auxiliary motor fan (options +M600…M610) ..................................
44What the option contains ..................................................................
44Description ...................................................................................
45Type designation label ............................................................................
45Type designation key ..............................................................................
46Option codes ....................................................................................
4 Mechanical installation
51Contents of this chapter ...........................................................................
51Examining the installation site ...................................................................
51Necessary tools ....................................................................................
52Examining the delivery ............................................................................
53Moving and unpacking the drive .................................................................
53Moving the drive in its packaging ............................................................
53Lifting the crate with a forklift ..............................................................
54Lifting the crate with a crane ..............................................................
55Moving the crate with a forklift ............................................................
55Removing the transport package ............................................................
56Moving the unpacked drive cabinet ..........................................................
56Lifting the cabinet with a crane ...........................................................
57Moving the cabinet on rollers .............................................................
57Moving the cabinet on its back ............................................................
58Final placement of the cabinet ............................................................
59Attaching the cabinet to the floor and wall or roof .............................................
59General rules ....................................................................................
6 Table of contents

60Attaching the cabinet (non-marine units) ...................................................
60Alternative 1 – Clamping ...................................................................
61Alternative 2 – Using the holes inside the cabinet .....................................
62Attaching the cabinet (marine units) .........................................................
63Joining cabinet sections together ................................................................
68Miscellaneous ......................................................................................
68Cable duct in the floor below the cabinet ...................................................
68Arc welding ......................................................................................
69Lifting lugs and bars ...............................................................................
69Certificate of conformity .......................................................................
69Declarations of conformity ....................................................................
5 Guidelines for planning the electrical installation
73Contents of this chapter ...........................................................................
73Limitation of liability ................................................................................
73Selecting the supply disconnecting device .....................................................
73Selecting the main breaker option ...............................................................
74Examining the compatibility of the motor and drive ...........................................
74Protecting the motor insulation and bearings ..............................................
74Requirements table ............................................................................
77Availability of du/dtfilter and common mode filter by drive type .....................
77Additional requirements for explosion-safe (EX) motors ..............................
77
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ ......................................................................................
77Additional requirements for braking applications .......................................
77Additional requirements for the regenerative and low harmonics drives ...........
77Additional requirements for ABB high-output and IP23 motors ......................
77Additional requirements for non-ABB high-output and IP23 motors .................
78Additional note for sine filters .............................................................
79Selecting the power cables .......................................................................
79General guidelines .............................................................................
79Typical power cable sizes .....................................................................
79Power cable types ..............................................................................
79Preferred power cable types ..............................................................
80Alternate power cable types ...............................................................
81Not allowed power cable types ...........................................................
81Power cable shield .............................................................................
81Grounding requirements ..........................................................................
82Additional grounding requirements – IEC ...................................................
82Additional grounding requirements – UL (NEC) ...........................................
83Selecting the control cables ......................................................................
83Shielding .........................................................................................
83Signals in separate cables ....................................................................
83Signals that can be run in the same cable ..................................................
83Relay cable ......................................................................................
83Control panel to drive cable ...................................................................
83PC tool cable ....................................................................................
84Routing the cables .................................................................................
84General guidelines – IEC ......................................................................
84
Continuous motor cable shield/conduit or enclosure for equipment on the motor
cable ..............................................................................................
85Separate control cable ducts .................................................................
Table of contents 7

85
Protecting the drive, input power cable, motor and motor cable in short circuit situations
and against thermal overload ....................................................................
85Protecting the input cabling and the drive upon a short-circuit ..........................
85Protecting the motor and motor cable in short-circuits ....................................
85Protecting the drive and the power cables against thermal overload ...................
85Protecting the motor against thermal overload .............................................
86Protecting the motor against overload without thermal model or temperature sensors .
86Protecting the drive against ground faults ......................................................
86Residual current device compatibility ........................................................
86Implementing the emergency stop function ....................................................
86Implementing the Safe torque off function .....................................................
87Implementing the Prevention of unexpected start-up function ..............................
87Implementing an ATEX-certified motor thermal protection ...................................
87Implementing the functions provided by the FSO safety functions module ...............
88Implementing the power loss ride-through function ...........................................
88Implementing a bypass connection .............................................................
89Supplying power for the auxiliary circuits .......................................................
89Using power factor compensation capacitors with the drive .................................
89Using a safety switch between the drive and the motor ......................................
89Implementing the control of a contactor between drive and motor .........................
90Protecting the contacts of relay outputs ........................................................
91Implementing a motor temperature sensor connection ......................................
91Connecting a motor temperature sensor to the drive through an option module .....
6 Electrical installation
93Contents of this chapter ...........................................................................
93Warnings ............................................................................................
93Measuring the insulation ..........................................................................
93Measuring the insulation resistance of the drive ...........................................
93Measuring the insulation resistance of the motor and motor cable .....................
94Measuring the insulation resistance of the input power cable ...........................
95Connecting the control cables ...................................................................
95Control cable connection procedure .........................................................
95Grounding the outer shields of the control cables 360° at the cabinet entry .......
96Routing the control cables inside the cabinet ...........................................
97Connecting control cabling ................................................................
98Connecting the motor cables (units without common motor terminal cubicle) ............
98Motor connection diagram (without option +H366) ........................................
99Procedure .......................................................................................
102Connecting the motor cables (units with common motor terminal cubicle) ................
102Output busbars .................................................................................
102Connection diagram ............................................................................
103Procedure .......................................................................................
103Connecting an external brake resistor assembly ..............................................
104Connecting the input power cables ..............................................................
104Connection diagram ............................................................................
104Layout of the input cable connection terminals and cable entries .......................
104Connection procedure .........................................................................
107Connecting input power cables - cable entry in 100 kA input cubicle (option +F274) ...
107Connection diagram ............................................................................
107Connection procedure .........................................................................
111Connecting a PC ...................................................................................
8 Table of contents

111Panel bus (Control of several units from one control panel) .................................
114Installing option modules .........................................................................
114
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface
modules ..........................................................................................
114Installation of an FSO safety functions module onto BCU ...............................
116Wiring of option modules ......................................................................
7 Control units of the drive
117Contents of this chapter ...........................................................................
117General ..............................................................................................
118BCU-x2 layout ......................................................................................
120Default I/O diagram of the supply control unit .................................................
123Default I/O diagram of the inverter control unit (A41) .........................................
127Additional information on the connections .....................................................
127External power supply for the control unit (XPOW) .......................................
127DI6 as a PTC sensor input ....................................................................
127AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input .............................
128DIIL input ........................................................................................
128The XD2D connector ..........................................................................
129Safe torque off (XSTO, XSTO OUT) .........................................................
129FSO safety functions module connection (X12) ...........................................
129SDHC memory card slot .......................................................................
130Connector data .....................................................................................
133BCU-x2 ground isolation diagram ............................................................
8 Installation checklist
135Contents of this chapter ...........................................................................
135Checklist .............................................................................................
9 Start-up
137Contents of this chapter ...........................................................................
137Start-up procedure .................................................................................
139Switching off the drive .............................................................................
10 Fault tracing
141Contents of this chapter ...........................................................................
141Control unit LEDs ..................................................................................
141Control panel and panel platform/holder LEDs ................................................
142Warning and fault messages .....................................................................
11 Maintenance
143Contents of this chapter ...........................................................................
143Maintenance intervals .............................................................................
143Description of symbols ........................................................................
144Recommended maintenance intervals after start-up ......................................
146Cabinet ..............................................................................................
146Cleaning the interior of the cabinet ..........................................................
146Cleaning the exterior of the drive ............................................................
147Power connections and quick connectors ......................................................
147Retightening the power connections ........................................................
Table of contents 9

147Fans ..................................................................................................
147Frame R8i fan replacement ...................................................................
149Replacing the heat exchanger fan in the filter cubicle ....................................
150Replacing the fan in the incoming cubicle ..................................................
152Replacing the fan in the auxiliary control cubicle ..........................................
152Replacing the common motor terminal cubicle fan ........................................
153Replacing the brake chopper and resistor cubicle fans (options +D150 and +D151) .
154Supply and inverter modules .....................................................................
154Assembling the service platform .............................................................
154Replacing a supply or inverter module ......................................................
155Removing the module ......................................................................
157Reinstalling the module ....................................................................
158Capacitors ...........................................................................................
158Reforming the capacitors ......................................................................
159Fuses ................................................................................................
159Replacing the AC and DC fuses in cabinet .................................................
160Replacing AC fuses - 100 kA input cubicle (option +F274) ..............................
161Control panel .......................................................................................
161Control units ........................................................................................
161BCU control unit types .........................................................................
162Replacing the memory unit ...................................................................
162Replacing the BCU control unit battery .....................................................
163Functional safety components ...................................................................
12 Internal cooling circuit
165Contents of this chapter ...........................................................................
165Applicability .........................................................................................
165Internal cooling system ............................................................................
167Connection to a cooling unit ......................................................................
167Connection to an ACS880-1007LC cooling unit ...........................................
167Connection to a custom cooling unit .........................................................
167General requirements ......................................................................
167Coolant temperature control ...............................................................
168Filling up and bleeding the internal cooling circuit ............................................
168Drive line-ups with an ACS880-1007LC cooling unit ......................................
168Drive line-ups with a custom cooling unit ...................................................
170Draining the internal cooling circuit ..............................................................
170Maintenance intervals .............................................................................
170Technical data ......................................................................................
170Coolant specification ...........................................................................
170Coolant type .................................................................................
170Temperature limits ..............................................................................
172Pressure limits ..................................................................................
172Coolant flow rate limits ........................................................................
172Cooling circuit materials .......................................................................
13 Technical data
175Contents of this chapter ...........................................................................
175Ratings ..............................................................................................
176Definitions .......................................................................................
10 Table of contents