ABB ACQ80-04-037kW-4 User manual

—

ABB DRIVES FOR WATER

ACQ80-04 drives (0.75 to 160 kW, 1.0 to 215

hp)

Hardware manual

ACQ80-04 drives (0.75 to 160 kW, 1.0

to 215 hp)

Hardware manual

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation

EN

EFFECTIVE: 2019-02-19

Table of contents

1 Safety instructions

11Contents of this chapter ..........................................................................

11Use of warnings and notes ......................................................................

12General safety in installation, start-up and maintenance ...................................

14Electrical safety in installation, start-up and maintenance ..................................

14Electrical safety precautions .................................................................

14Additional instructions and notes ............................................................

15Optical components .......................................................................

15Printed circuit boards ......................................................................

15Grounding ......................................................................................

17Additional instructions for permanent magnet motor drives ................................

17Safety in installation, start-up, maintenance ...............................................

17Safety in operation ............................................................................

2 Introduction to the manual

19Contents of this chapter ..........................................................................

19Applicability ........................................................................................

19Target audience ...................................................................................

19Purpose of the manual ...........................................................................

19Categorization by frame (size) ..................................................................

20Quick installation and commissioning flowchart ..............................................

21Terms and abbreviations .........................................................................

22Related documents ...............................................................................

3 Operation principle and hardware description

25Contents of this chapter ..........................................................................

25Operation principle ................................................................................

26Layout ..............................................................................................

26Frames R0...R2 ................................................................................

28Frame size R3 .................................................................................

29Frame R4…R8 .................................................................................

29Overview of power and control connections ..................................................

30External control connecting terminal, Frame size R0…R2 ..............................

31External control connecting terminal, Frame size R3...R5 ..............................

32External control connection terminals, frames R6…R8 ..................................

33Control panel ......................................................................................

34Type designation label ...........................................................................

35Locations of the labels on the drive .........................................................

36Type designation key .............................................................................

4 Mechanical installation

39Contents of this chapter ..........................................................................

39Safety ...........................................................................................

40Checking the installation site ....................................................................

41Required tools .....................................................................................

Table of contents 5

41Moving the drive ..................................................................................

42Unpacking and examining delivery, frames R0…R2 ........................................

42Unpacking and examining delivery, frames R3...R4 .........................................

43Unpacking and examining delivery, frames R5 ...............................................

44Unpacking and examining delivery, frames R6…R8 ........................................

46Installing the drive ................................................................................

46Installing the drive vertically, frames size R0…R2 ........................................

47Installing the drive vertically, frame size R3...R4 .........................................

48Installing the drive vertically, frames size R5…R8 ........................................

49Installing the drive vertically side by side ..................................................

49Installing the drive horizontally side by side ...............................................

5 Planning the electrical installation

51Contents of this chapter ..........................................................................

51Selecting the supply disconnecting device ....................................................

51European Union ...............................................................................

52Other regions ..................................................................................

52Checking the compatibility of the motor and drive ...........................................

52Selecting the power cables ......................................................................

52General rules ...................................................................................

52Typical power cable sizes ....................................................................

53Alternative power cable types ...............................................................

54Recommended power cable types ......................................................

54Power cable types for limited use .......................................................

54Not allowed power cable types ..........................................................

54Motor cable shield .............................................................................

55Conduit ......................................................................................

55Armored cable / shielded power cable ..................................................

55Selecting the control cables .....................................................................

55Shielding ........................................................................................

56Signals in separate cables ...................................................................

56Signals allowed to be run in the same cable ..............................................

56Relay cable .....................................................................................

56Control panel cable ...........................................................................

56Drive composer PC tool cable ...............................................................

57Routing the cables ............................................................................

57General guidelines, IEC ...................................................................

58General guidelines, North America ......................................................

59Continuous motor cable shield or enclosure for equipment on the motor cable ...

59Separate control cable ducts .............................................................

59Implementing thermal overload and short-circuit protection ............................

59Protecting the input cabling and the drive upon a short-circuit ......................

59Protecting the motor and motor cable in short-circuits ...............................

59Protecting the drive and the power cables against thermal overload ..............

60Protecting the motor against thermal overload ........................................

60Protecting the drive against ground faults .....................................................

60Residual current device compatibility ......................................................

60Implementing the Emergency stop function ...............................................

60Implementing the Safe torque off function ....................................................

60Implementing the undervoltage control (power-loss ride-through) ........................

61Using a contactor between the drive and the motor .........................................

61Implementing a bypass connection .........................................................

6 Table of contents

61Example bypass connection .................................................................

62Switching the motor power supply from drive to direct-on-line ......................

63Switching the motor power supply from direct-on-line to drive ......................

63Protecting the contacts of relay outputs .......................................................

6 Electrical installation

65Contents of this chapter ..........................................................................

65Warnings ...........................................................................................

65Required tools .....................................................................................

65Checking the insulation of the assembly ......................................................

65Drive .............................................................................................

66Input power cable .............................................................................

66Checking the insulation of the motor and motor cable ...................................

66Checking the compatibility with IT (ungrounded) and corner-grounded TN systems ...

66EMC filter .......................................................................................

67Ground-to-phase varistor .....................................................................

67Frames R0…R3 ...............................................................................

68Frames R4…R8 ...............................................................................

70Connecting the power cables ...................................................................

70Connection diagram ..........................................................................

72Connection procedure: frames R0…R2 ....................................................

72Motor cable .................................................................................

73Input power cable ..........................................................................

74Finalization ..................................................................................

76Connection procedure, frames R3...R4 ....................................................

76Motor cable .................................................................................

77Note: .........................................................................................

77Input power cable ..........................................................................

78Finalization ..................................................................................

80Connection procedure, frames R5…R8 ....................................................

80Motor cable .................................................................................

81Input power cable ..........................................................................

84DC connection .....................................................................................

84Connecting the control cables ..................................................................

85Default control connections of ABB standard macro ........................................

85Connection diagram ..........................................................................

85Terminal sizes ..............................................................................

86Notes ........................................................................................

86Switches ............................................................................................

86PNP configuration for digital inputs ............................................................

87NPN configuration for digital inputs ............................................................

87Connection for obtaining 0…10 V from analog output 2 (AO2) ............................

88Connection examples of two-wire and three-wire sensors .................................

89DI5 as frequency input ...........................................................................

89AI1 and AI2 as Pt100 sensor inputs (X1) ......................................................

89Safe torque off (X4) ...............................................................................

90Control cable connection procedure R0…R8 .................................................

91R0...R2 ..........................................................................................

92R3...R5 ..........................................................................................

93R6...R8 ..........................................................................................

Table of contents 7

93Option modules ...................................................................................

93To install a front option ........................................................................

94Front option slot 1 ..........................................................................

95To remove a front option .....................................................................

95Wiring the modules ............................................................................

95Reinstalling covers ................................................................................

95Reinstalling cover, frames size R0…R2 ...................................................

95Reinstalling covers, frame size R3, R4 ....................................................

96Reinstalling side plates and covers, frames size R5…R8 ...............................

96Connecting a PC ..................................................................................

7 Installation checklist of the drive

99Contents of this chapter ..........................................................................

99Checklist ...........................................................................................

8 Maintenance and hardware diagnostics

101Contents of this chapter ..........................................................................

101Maintenance intervals ............................................................................

101Description of symbols .......................................................................

102Recommended annual maintenance actions by the user ...............................

102Recommended maintenance action by the user .........................................

103Heatsink ............................................................................................

103Fans ................................................................................................

104Replacing the cooling fan, frames size R0…R4 ..........................................

104Replacing the main cooling fan, frame R5 .................................................

105Replacing the main cooling fan, frames size R6…R8 ...................................

106Replacing the auxiliary cooling fan, frames R6...R8 .....................................

107Capacitors .........................................................................................

107Reforming the capacitors .....................................................................

107Control panel ......................................................................................

107Cleaning the control panel ...................................................................

107Replacing the battery in the control panel .................................................

108LEDs ................................................................................................

108Drive LEDs (R3~R8) ..........................................................................

108Control panel LEDs ...........................................................................

9 Technical data

111Contents of this chapter ..........................................................................

111Ratings .............................................................................................

111IEC ratings .....................................................................................

112Definitions ......................................................................................

112Sizing ............................................................................................

113Derating ............................................................................................

113Ambient temperature derating, IP20 ........................................................

114Switching frequency derating ................................................................

115Altitude derating ...............................................................................

115Fuses (IEC) ........................................................................................

115uR and aR fuse ................................................................................

116gG fuses ........................................................................................

117gR fuses ........................................................................................

118DC fuses ........................................................................................

8 Table of contents

119Circuit breakers ...................................................................................

120Dimensions, weights and free space requirements ..........................................

120Standard frame size (R0-R8) ...................................................................

121Thermal losses, cooling data and noise .......................................................

122Terminal and lead-through data for the power cables .......................................

123Terminal and lead-through data for the control cables ......................................

124Electrical power network specification .........................................................

124Motor connection data ...........................................................................

125EMC compatibility and motor cable length ................................................

126Control connection data ..........................................................................

130Auxiliary circuit power consumption ............................................................

131Efficiency ...........................................................................................

131Degree of protection ..............................................................................

131Ambient conditions ...............................................................................

131For R0...R2 .....................................................................................

132For R3...R8 .....................................................................................

133Materials ...........................................................................................

133Applicable standards .............................................................................

134CE marking ........................................................................................

134Compliance with the European EMC Directive ...........................................

134Compliance with the European ROHS II Directive 2011/65/EU ........................

134Compliance with the EN 61800-3:2004 + A1:2012 ..........................................

134Definitions ......................................................................................

135Category C1 ....................................................................................

135Category C2 ....................................................................................

135Category C3 ....................................................................................

136Category C4 ....................................................................................

10 Dimension drawings

137Contents of this chapter ..........................................................................

138Frame R0, IP20 ...................................................................................

139Frame R1, IP20 ...................................................................................

139Frame R2, IP20 ...................................................................................

140Frame R3, IP20 ...................................................................................

141Frame R4, IP20 ...................................................................................

142Frame R5, IP20 ...................................................................................

143Frame R6, IP20 ...................................................................................

144Frame R7, IP20 ...................................................................................

145Frame R8, IP20 ...................................................................................

11 The Safe torque off function

147Contents of this chapter ..........................................................................

147Description .........................................................................................

148Compliance with the European Machinery Directive .....................................

149Wiring ...............................................................................................

149Connection principle (R0…R2) ..............................................................

149Connection with internal power supply .................................................

149Connection with external power supply .................................................

150Wiring examples (R0…R2) ..................................................................

150Wiring with internal power supply .......................................................

150Wiring with external power supply .......................................................

Table of contents 9

151Connection principle (R3…R8) ..............................................................

151Connection with internal power supply .................................................

151Connection with external power supply .................................................

152Wiring examples (R3…R8) ..................................................................

152Wiring with internal power supply .......................................................

152Wiring with external power supply .......................................................

152Activation switch ...............................................................................

153Cable types and lengths ......................................................................

153Grounding of protective shields .............................................................

154Operation principle ................................................................................

155Start-up including acceptance test .............................................................

155Competence ...................................................................................

155Acceptance test reports ......................................................................

155Acceptance test procedure ..................................................................

157Use ..................................................................................................

158Maintenance .......................................................................................

158Competence ...................................................................................

159Fault tracing .......................................................................................

160Safety data .........................................................................................

161Abbreviations ..................................................................................

12 BIO-01 I/O extension module

163Contents of this chapter ..........................................................................

163Safety instructions ................................................................................

163BIO-01 product overview ........................................................................

164Layout ...........................................................................................

164Mechanical installation ...........................................................................

165Electrical installation ..............................................................................

166Start-up .............................................................................................

166Technical data .....................................................................................

166Control connection data ......................................................................

167Dimensions .....................................................................................

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, etc.

• Lift a heavy drive with a lifting device. Use the designated lifting points. See the dimension

drawings.

• Secure the drive cabinet to the floor to prevent it from toppling over. The cabinet has a

high center of gravity. When you pull out heavy components or power modules, there

is a risk of overturning. Secure the cabinet also to the wall when necessary.

• 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.

• Make sure that there is sufficient cooling. See the technical data.

• Before you adjust the drive operation limits, make sure that the motor and all driven

equipment can operate throughout the set operation limits.

12 Safety instructions

3

• 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

61800-5-1, subclause 6.5.3, for example, "THIS MACHINE STARTS AUTOMATICALLY".

• 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.

• Validate any safety circuits (for example, Safe torque off or emergency stop) in start-up.

See separate instructions for the safety circuits.

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.

• Depending on the wiring and parametrization of the drive, the stop key on the control

panel may not stop the drive.

• 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 electrician, 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. Lock and tag.

• 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.

• Make sure that re-connection is not possible.

• Disconnect any external power sources from the control circuits.

• After you disconnect 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 multimeter with an impedance of at least 1 Mohm.

• Make sure that the voltage between the drive input power terminals and the

grounding (PE) busbar is close to 0 V.

• If you have a permanent magnet motor connected to the drive, make sure that the

voltage between the drive output terminals and the grounding (PE) busbar is close

to 0 V.

6. Ask the person in control of the electrical installation work for a permit to 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 electrician, do not do electrical installation or maintenance

work.

• Do not install the drive if the electrical power network, motor/generator, or environmental

conditions do not agree with the drive data.

• Do not do insulation or voltage withstand tests on the drive.

Note:

• The motor cable terminals of the drive are at a dangerous voltage when the input power

is on, regardless of whether the motor is running or not.

• When the input power is on, the drive DC bus is at a dangerous voltage.

14 Safety instructions

3

• 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.

Optical components

WARNING!

Obey these instructions. If you ignore them, damage to the equipment can occur.

• When you unplug the fibre optic cables, always hold the connector, not the cable itself.

• Do not touch the ends of the fibers with bare hands as the ends are extremely sensitive

to dirt.

• Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is

35 mm (1.4”).

Printed circuit boards

WARNING!

Use a grounding wrist band 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 electrician, do not do grounding work.

• Always ground the drive, the motor and adjoining equipment. This is necessary for the

personnel safety. Proper grounding also reduces electromagnetic emission and

interference.

• Make sure that the conductivity of the protective earth PE conductors is sufficient. See

the electrical planning instructions of the drive. Obey the local regulations.

• Connect the power cable shields to protective earth terminals of the drive to make sure

of personnel safety.

• Make a 360° grounding of the power and control cable shields at the cable entries to

suppress electromagnetic disturbances.

• In a multiple-drive installation, connect each drive separately to the protective earth

(PE) busbar of the power supply.

Note:

• You can use power cable shields as grounding conductors only when their conductivity

is sufficient.

• IEC/EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch current of the

drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed protective earth (PE)

connection. The minimum size of the protective earthing conductor must comply with

the local safety regulations for high protective earthing conductor current equipment.

Safety instructions 15

See the electrical planning instructions of the drive, and standard IEC/EN 61800-5-1,

4.3.5.5.2.

16 Safety instructions

3

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 and damage to the

equipment can occur.

• 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 and do the steps in section Electrical safety precautions (page 14).

• Disconnect the motor from the drive with a safety switch or by other means.

• 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.

• Measure that the installation is de-energized.

• Use a multimeter with an impedance of at least 1 Mohm.

• Make sure that the voltage between the drive output terminals and the grounding

(PE) busbar is close to 0 V.

• Make sure that the voltage between the drive input power terminals and the

grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the drive DC terminals (if any) and the grounding

(PE) terminal is close to 0 V.

• Install temporary grounding to the drive output terminals (U2, V2, W2). Connect the

output terminals together as well as to the PE.

During the start up:

• Make sure that the motor cannot be run into overspeed, eg, 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 be run into overspeed, e.g. 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 applicability, target audience and purpose of this manual. It describes

the contents of this manual and refers to a list of related manuals for more information. The

chapter also contains a flowchart of steps for checking the delivery, installing and

commissioning the drive. The flowchart refers to chapters/sections in this manual.

Applicability

The manual applies to the ACQ80-04 drives.

Target audience

The reader is expected to know the fundamentals of electricity, wiring, electrical components

and electrical schematic symbols.

The manual is written for readers worldwide. Both SI and imperial units are shown. Special

US instructions for installations in the United States are given.

Purpose of the manual

This manual provides information needed for planning the installation, installing, and servicing

the drive.

Categorization by frame (size)

The ACQ80-04 is manufactured in frames (frame sizes) R0…R8. Some instructions and

other information which only concern certain frames are marked with the symbol of the

frame (R0…R8). The frame is marked on the type designation label attached to the drive,

see section Type designation label (page 34).

2

Introduction to the manual 19

Quick installation and commissioning flowchart

SeeTask

Type designation la-

bel (page 34)

Identify the frame of your drive: R0…R8.

Planning the electrical installa-

tion (page 51)

Plan the installation: select the cables, etc.

Technical data (page 111)

Check the ambient conditions, ratings and required cooling air flow.

Mechanical installation: Unpack-

ing and examining delivery,

frames R0…R2 (page 42), Un-

packing and examining delivery,

frames R3...R4 (page 42), Un-

packing and examining delivery,

frames R5 (page 43), Unpacking

and examining delivery, frames

R6…R8 (page 44).

Unpack and check the drive.

Operation principle and hard-

ware description: Type designa-

tion label (page 34)

Electrical installation: Checking

the compatibility with IT (un-

grounded) and corner-grounded

TN systems (page 66)

If the drive will be connected to an IT (ungrounded) system, check that the

internal EMC filter and ground-to-phase varistor are not connected. If the

drive will be connected to a corner-grounded TN system, check that the in-

ternal EMC filter is not connected.

Mechanical installa-

tion (page 39)

Install the drive on a wall.

Planning the electrical installa-

tion: (page 57)

Route the cables.

Electrical installation: Checking

the insulation of the as-

sembly (page 65)

Check the insulation of the input cable and the motor and the motor cable.

Electrical installation: Connect-

ing the power cables (page 70)

Connect the power cables.

Electrical installation: Connect-

ing the control cables (page 84)

Connect the control cables.

Installation checklist:Installation

checklist of the drive (page 99)

Check the installation.

20 Introduction to the manual

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ABB ACQ80-04-037kW-4 User manual

ABB ACQ80-04-037kW-4 User manual

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