ABB ACQ80-04 Series Hardware Manual
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ABB ACQ80-04 Series Hardware Manual

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ABB DRIVES FOR WATER
ACQ80-04 drives (0.75 to 160 kW, 1.0 to 215
hp)
Hardware manual

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Summary of Contents for ABB ACQ80-04 Series

  • Page 1 — ABB DRIVES FOR WATER ACQ80-04 drives (0.75 to 160 kW, 1.0 to 215 Hardware manual...
  • Page 3 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 © 2019 ABB. All Rights Reserved. 3AXD50000170661 Rev A EFFECTIVE: 2019-02-19...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ................Use of warnings and notes ..............General safety in installation, start-up and maintenance ........Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ..............Additional instructions and notes ............
  • Page 6 6 Table of contents Moving the drive .................. Unpacking and examining delivery, frames R0…R2 ........Unpacking and examining delivery, frames R3...R4 ......... Unpacking and examining delivery, frames R5 ..........Unpacking and examining delivery, frames R6…R8 ........Installing the drive ................Installing the drive vertically, frames size R0…R2 ........
  • Page 7 Connection procedure, frames R5…R8 ............ Motor cable ................. Input power cable ................DC connection ..................Connecting the control cables ..............Default control connections of ABB standard macro ........Connection diagram ................Terminal sizes ................Notes ..................Switches .................... PNP configuration for digital inputs ............
  • Page 8 8 Table of contents Option modules ................... To install a front option ................ Front option slot 1 ................To remove a front option ..............Wiring the modules ................Reinstalling covers ................Reinstalling cover, frames size R0…R2 ........... Reinstalling covers, frame size R3, R4 ............ Reinstalling side plates and covers, frames size R5…R8 .......
  • Page 9 Table of contents 9 Circuit breakers ................... Dimensions, weights and free space requirements .......... Standard frame size (R0-R8) ..............Thermal losses, cooling data and noise ............Terminal and lead-through data for the power cables ........Terminal and lead-through data for the control cables ........Electrical power network specification ............
  • Page 10 10 Table of contents Connection principle (R3…R8) .............. Connection with internal power supply ..........Connection with external power supply ..........Wiring examples (R3…R8) ..............Wiring with internal power supply ............Wiring with external power supply ............Activation switch ................Cable types and lengths ..............Grounding of protective shields .............

  • Page 11: Safety Instructions

    Safety instructions 11 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.

  • Page 12: General Safety In Installation, Start-Up And Maintenance

    12 Safety instructions 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. •...
  • Page 13 Safety instructions 13 • 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".

  • Page 14: Electrical Safety In Installation, Start-Up And Maintenance

    14 Safety instructions 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.

  • Page 15: Optical Components

    Safety instructions 15 • 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.
  • Page 16 16 Safety instructions See the electrical planning instructions of the drive, and standard IEC/EN 61800-5-1, 4.3.5.5.2.

  • Page 17: Additional Instructions For Permanent Magnet Motor Drives

    Safety instructions 17 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.

  • Page 19: Introduction To The Manual

    Introduction to the manual 19 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.

  • Page 20: Quick Installation And Commissioning Flowchart

    20 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame of your drive: R0…R8. Type designation la- bel (page 34) Plan the installation: select the cables, etc. Planning the electrical installa- tion (page 51) Check the ambient conditions, ratings and required cooling air flow. Technical data (page 111) Unpack and check the drive.

  • Page 21: Terms And Abbreviations

    Introduction to the manual 21 Task Commission the drive ACQ80-04 standard control pro- gram firmware manual (3AXD50000170654 [English]) Terms and abbreviations Term/ Description Abbreviation ACS-AP-x Assistant control panel ACS-BP-S Basic control panel BIO-01 Optional I/O extension module underneath the fieldbus adapter module Control board Circuit board in which the control program runs DC link...

  • Page 22: Related Documents

    You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative.
  • Page 23 Introduction to the manual 23 ACQ80-04 manuals www.abb.com/drives/documents for all manuals on the internet.

  • Page 25: Operation Principle And Hardware Description

    Operation principle and hardware description 25 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle, layout, type designation label and type designation information. It also shows a general diagram of power connections and control interfaces.

  • Page 26: Layout

    26 Operation principle and hardware description The figure below shows the simplified main circuit diagram of the drive. T1/U T2/V T3/W Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter. Inverter.
  • Page 27 Operation principle and hardware description 27 Installation point (4) EMC filter grounding screw (EMC). R0…R2: on the left side of drive. Cover plate Input voltage connection (L1, L2, L3). Cover plate screw Motor connection (T1/U, T2/V, T3/W) and PV Control panel input terminal connection (UDC+, UDC-).

  • Page 28: Frame Size R3

    28 Operation principle and hardware description ￭ Frame size R3 Installation point (4) EMC filter grounding screw (EMC). Cover plate Input voltage connection (L1, L2, L3), motor connection (T1/U, T2/V, T3/W) and PV input Cover plate screw terminal connection (R-, UDC+). Control panel PE connection (power line) Control panel connection...

  • Page 29: Frame R4

    Operation principle and hardware description 29 ￭ Frame R4…R8 The layout of a frame R6 drive is presented below. The frame sizes R7…R8 is similar but have a different structure. Installation point (2 points on the top and 2 points Voltage dependent resistor ground screw (VAR), on the bottom of the frame body) arranged below the control tray.

  • Page 30: External Control Connecting Terminal, Frame Size R0

    30 Operation principle and hardware description ￭ External control connecting terminal, Frame size R0…R2 The figure below explains the external control connecting terminal layout of Frame size R0. Layout of the external control connection terminals is identical in frames R1…R2 but the location of the control board with the terminals is different in frames R3.

  • Page 31: External Control Connecting Terminal, Frame Size R3

    Operation principle and hardware description 31 ￭ External control connecting terminal, Frame size R3...R5 The figure below explains the external control connecting terminal layout of Frame size R3. Description Analog input and output Auxiliary voltage output Digital input Safety torque cancellation Modbus built-in fieldbus X6…X8 Relay output 1...Relay output 3...

  • Page 32: External Control Connection Terminals, Frames R6

    32 Operation principle and hardware description ￭ External control connection terminals, frames R6…R8 The layout of the external control connection terminals of frames R6…R8 is shown below. Description Analog input and output Auxiliary voltage output Digital input Safety torque cancellation Modbus built-in fieldbus X6…X8 Relay output 1...Relay output 3...

  • Page 33: Control Panel

    Operation principle and hardware description 33 Control panel The drive supports these control panels: • ACS-AP-S • ACS-AP-I • ACS-AP-W • ACS-BP-S • RDUM-01 blank panel with RJ-45 connector. For information on assistant and basic control control panel, see ACS-AP-X assistant control panels user’s manual (3AUA0000085685 [English]) /ACS-BP-S basic control panel’s user’s manual (3AXD50000032527 [English]).

  • Page 34: Type Designation Label

    34 Operation principle and hardware description Type designation label The type designation label includes IEC ratings, appropriate markings and the type designation and serial number, which allow identification of each drive. The type designation label is located on the left side of the drive, see section Layout (page 26).

  • Page 35: Locations Of The Labels On The Drive

    Operation principle and hardware description 35 Description S/N: Serial number of format MYYWWXXXX, where Manufacturer 16, 17, 18, … for 2016, 2017, 2018, … 01, 02, 03, … for week 1, week 2, week 3, … XXXXX: Integer starting every week from 0001 ￭...

  • Page 36: Type Designation Key

    36 Operation principle and hardware description Operation principle and hardware description 37 Type designation key The type designation contains information on the specifications and configuration of the gnation key drive. You can find the type designation on the type designation label attached to the drive. The first digits from the left express the basic configuration, for example, ACQ80-04-04kW0-4.
  • Page 37 Operation principle and hardware description 37 CODE DESCRIPTION K473 FENA-11 Ethernet (EtherNet/IP™, Modbus/TCP, PROFINET) K469 FECA-01 EtherCAT K458 FSCA-01 Modbus/RTU K475 FENA-21 2-port Ethernet (EtherNet/IP™, Modbus/TCP, PROFINET) Cables J431 BCBL-01 USB to RJ45 PC connectivity cable (RS485) Full set of printed manuals in selected language. R700 English 3AXD10000651180...

  • Page 39: Mechanical Installation

    Mechanical installation 39 Mechanical installation 39 Mechanical installation Mechanical installation Contents of this chapter Contents of this chapter The chapter tells how to check the installation site, unpack, check the delivery and The chapter tells how to check the installation site, unpack, check the delivery and install install the drive mechanically.

  • Page 40: Checking The Installation Site

    40 Mechanical installation • Do not install the drive upside down. This can cause damage to the equipment. 40 Mechanical installation Checking the installation site Checking the installation site The drive must be placed in a cabinet and installed on the wall. Drives of frame sizes R0...R2 The drive must be placed in a cabinet and installed on the wall.

  • Page 41: Required Tools

    11.8 11.8 11.8 Mechanical installation 41 • Vertically side by side • Vertically side by side Vertical installation side by side - Frame Vertical installation side by side - c = 0 Free space Frame size Free space Size Above (a) Below (b) Between (c) Above (a)

  • Page 42: Unpacking And Examining Delivery, Frames R0

    42 Mechanical installation Unpacking and examining delivery, frames R0…R2 The figure below shows the drive package and its contents. Make sure that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type.

  • Page 43: Unpacking And Examining Delivery, Frames R5

    Mechanical installation 43 Unpacking and examining delivery, frames R3...R4 Mechanical installation 43 The figure below shows the drive package and its contents. Make sure that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type.

  • Page 44: Unpacking And Examining Delivery, Frames R6

    44 Mechanical installation Cable box package. Stopper Drive Cover protecting film In the option box Straps • Multilingual quick installation and start-up guide Pallet • User's manual (if ordered with a plus code) Control panel selected in the order (in a separate •...
  • Page 45 Mechanical installation 45 9 10 11 Cable box. Power and control cable grounding In the option tray shelves in a plastic bag, assembly drawing. • Multilingual quick installation and startup guide • User’s manual (if ordered with a plus code) Drive with factory installed options.

  • Page 46: Installing The Drive

    Installing the drive 46 Mechanical installation Installing the drive vertically, frames size R0…R2 Installing the drive Mechanical installation 47 The figures show frame R0 as an example. ￭ Installing the drive vertically, frames size R0…R2 1. Mark the hole locations with the mounting template included in the package. Installing the drive not leave the mounting template behind the drive.

  • Page 47: Installing The Drive Vertically, Frame Size R3

    48 Mechanical installation Mechanical installation 47 4. Position the drive onto the screws on the wall. Tighten the screws in the wall 4. Position the drive onto the screws on the wall. Tighten the screws in the wall securely. securely. Mechanical installation 47 Installing the drive Installing the drive vertically, frames size...

  • Page 48: Installing The Drive Vertically, Frames Size R5

    48 Mechanical installation Mechanical installation 49 Installing the drive vertically, frame size R3...R4 1. Mark the hole locations with the mounting template included in the package. Do not leave the mounting template behind the drive. The drive dimensions and hole locations are also shown in the drawings, see chapter Dimension drawings page 149.

  • Page 49: Installing The Drive Vertically Side By Side

    11.8 11.8 300 11.8 300 11.8 300 11.8 300 11.8 300 11.8 300 300 11.8 300 11.8 300 11.8 11.8 11.8 7.9 200 7.9 200 7.9 200 × 4 × 4 × 4 Mechanical installation 49 2. Drill the mounting holes. 2.

  • Page 51: Planning The Electrical Installation

    Planning the electrical installation 51 Planning the electrical installation Contents of this chapter This chapter contains instructions for planning the electrical installation of the drive, for example, for checking the compatibility of the motor and drive, selecting cables, protections, and cable routing. Note: The installation must always be designed and made according to applicable local laws and regulations.

  • Page 52: Other Regions

    52 Planning the electrical installation ￭ Other regions The disconnecting device must conform to the applicable local safety regulations. Checking the compatibility of the motor and drive Use an AC induction motor or permanent magnet motor with the drive. Several induction motors can be connected to the drive at a time but only one permanent magnet motor can be connected to the drive at a time.

  • Page 53: Alternative Power Cable Types

    Planning the electrical installation 53 Drive type Frame size ACQ80-04 Cu cable type Cu cable type AI cable type AI cable type AWG/kcmil AWG/kcmil 3-phase U = 400 V (380…480 V) 0kW75-4 3×1.5 + 1.5 01kW1-4 3×1.5 + 1.5 01kW5-4 3×1.5 + 1.5 02kW2-4 3×1.5 + 1.5...

  • Page 54: Recommended Power Cable Types

    54 Planning the electrical installation Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as the shield. The shield must meet the requirements of IEC 61439-1, see General rules (page 52). Check with local/state/country electrical codes for allowance. Symmetrical shielded cable with three phase conductors and a concentric PE conductor as the shield.

  • Page 55: Conduit

    shield conductivity must be at least 1/10 of the phase conductor conductivity. The requirements are easily met with a copper or aluminum shield. The minimum requirement of the motor cable shield of the drive is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire.

  • Page 56: Signals In Separate Cables

    (330 ft). If multiple drives are connected, the total length of the panel bus must not exceed 100 m (330 ft). The cable type tested and approved by ABB is used in control panel option kits. Suitable cables are CAT 5e unshielded or shielded twisted pair cables.

  • Page 57: Routing The Cables

    Planning the electrical installation 57 ￭ Routing the cables General guidelines, IEC • Route the motor cable away from other cables. Motor cables of several drives can be run in parallel installed next to each other. • Install the motor cable, input power cable and control cables on separate trays. •...

  • Page 58: General Guidelines, North America

    58 Planning the electrical installation General guidelines, North America The following illustrates general guidelines for routing power and motor cabling in conduit. Ensure the installation of your application is in accordance with national and local codes. • Do not run input power cable and motor cable in the same conduit. •...

  • Page 59: Continuous Motor Cable Shield Or Enclosure For Equipment On The Motor Cable

    Planning the electrical installation 59 Continuous motor cable shield or enclosure for equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...

  • Page 60: Protecting The Motor Against Thermal Overload

    60 Planning the electrical installation protection is tuned for the total motor load. It may not trip due to an overload in one motor circuit only. Protecting the motor against thermal overload According to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected.

  • Page 61: Using A Contactor Between The Drive And The Motor

    Planning the electrical installation 61 Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate. See also section (page 61). When you have selected to use vector control mode and motor ramp stop, open the contactor as follows: 1.

  • Page 62: Switching The Motor Power Supply From Drive To Direct-On-Line

    62 Planning the electrical installation Main switch for the drive Drive main contactor on/off control Bypass circuit breaker Motor power supply selection (drive or direct-on- line) Drive main contactor Start when the motor is connected direct-on-line Bypass contactor Stop when the motor is connected direct-on-line Drive output contactor Drive Switching the motor power supply from drive to direct-on-line...

  • Page 63: Switching The Motor Power Supply From Direct-On-Line To Drive

    Planning the electrical installation 63 Switching the motor power supply from direct-on-line to drive 1. Stop the motor with S42. 2. Switch the motor power supply from direct-on-line to the drive with S40. 3. Close the main contactor of the drive with switch S11 (-> turn to position ST for two seconds and leave at position 1).

  • Page 65: Electrical Installation

    Electrical installation 65 Electrical installation Contents of this chapter The chapter describes how to check the insulation of the assembly and the compatibility with IT (ungrounded) and corner-grounded TN systems. It then shows how to connect the power and control cables, install optional modules and connect a PC. Warnings WARNING! Obey the instructions in chapter...

  • Page 66: Input Power Cable

    Protective Earth conductor. Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, consult the manufacturer’s instructions.

  • Page 67: Ground-To-Phase Varistor

    Electrical installation 67 Do not install the drive with the internal EMC filter connected on a corner-grounded TN system, otherwise the drive will be damaged. Note: When the internal EMC filter is disconnected, the drive EMC compatibility is considerably reduced. See section EMC compatibility and motor cable length (page 125).

  • Page 68: Frames R4

    68 Electrical installation 2. Open the front cover, if not already opened. For R0...R2, see Connection procedure: frames R0…R2 (page 72) and for R3 see section Connection procedure, frames R3...R4 (page 76). 3. To disconnect the internal EMC filter, remove the EMC grounding screw. 4.
  • Page 69 2. Open the cover, if not already opened. For frames R4…R6, see page 82. For frames R6…R8, see page 86. frames R6…R8, see page 86. 3. To disconnect the internal EMC filter, remove the two EMC screws. 3. To disconnect the internal EMC filter, remove the two EMC screws. 4.

  • Page 70: Connecting The Power Cables

    76 Electrical installation 70 Electrical installation R6...R8 R6…R8 Connecting the power cables ￭ Connection diagram For alternatives, see section Selecting the supply disconnecting device (page 51). Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity of the shield does not meet the requirements for the PE conductor (see Selecting the power cables (page...
  • Page 71 Electrical installation 71 Use a separate grounding cable if the shield does not meet the requirements of IEC 61439-1 (see lecting the power cables (page 52)) and there is no symmetrically constructed grounding conductor in the cable (see Motor cable shield (page 54)).

  • Page 72: Connection Procedure: Frames R0

    72 Electrical installation ￭ Connection procedure: frames R0…R2 78 Electrical installation 78 Electrical installation WARNING! WARNING! If the drive is connected on an IT (ungrounded) system, make sure that the EMC Connection procedure, frames R0…R2 Filter and Varistor (VAR) is disconnected. See EMC filter (page 66).

  • Page 73: Input Power Cable

    Electrical installation 79 Electrical installation 73 3. Connect the motor cable as follows: 3. Connect the motor cable as follows: • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable (3a). •...

  • Page 74: Finalization

    80 Electrical installation 80 Electrical installation 5. Connect the input power cable as follows: 74 Electrical installation 5. Connect the input power cable as follows: • Connect the twisted shield of the cable to the grounding terminal (5a). • Connect the twisted shield of the cable to the grounding terminal (5a). •...
  • Page 75 Finalization 10. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the lead-through of the motor terminal box. Electrical installation 75...

  • Page 76: Connection Procedure, Frames R3

    78 Electrical installation 78 Electrical installation Connection procedure, frames R0…R2 76 Electrical installation Connection procedure, frames R0…R2 1. Remove the front cover as follows: 1. Remove the front cover as follows: • Loosen the retaining screw with a screwdriver (1a). ￭...

  • Page 77: Note

    3. Connect the motor cable as follows: If the power cable is temporarily removed from the grounding shelf, connect the motor and input power cables except the 360 degree grounding, and then reinstall the grounding shelf. Electrical installation 77 • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable (4a).

  • Page 78: Finalization

    84 Electrical installation 84 Electrical installation 78 Electrical installation 5. Connect the input power cable as follows: 5. Connect the input power cable as follows: • Ground the shield 360 degrees by tightening the clamp of the power cable • Ground the shield 360 degrees by tightening the clamp of the power cable grounding •...
  • Page 79 screws in a plastic bag in the delivery) onto the grounding shelf for the power Finalization cables. 11. Install the grounding shelf for the control cables (included with the mounting screws in a plastic bag in the delivery) onto the grounding shelf for the power Electrical installation 79 cables.

  • Page 80: Connection Procedure, Frames R5

    Connection procedure, frames R6…R8 WARNING! If the drive will be connected on an IT (ungrounded) sys 80 Electrical installation make sure you have disconnected the EMC filter and ground-to-phas See page 71. If the drive will be connected on a corner-grounded TN syste ￭...

  • Page 81: Input Power Cable

    Note: Frame R8 only: Tighten the screws to the torque given in the figure (9b). • If you connected the connector to only one conductor, ABB recommends to put the conductor under the upper pressure plate. • The connectors are detachable, but ABB recommends not to detach them. If you do, detach and reinstall the connectors as follows.
  • Page 82 • The connectors are detachable but we do not recommend that you detach them. • The connectors are detachable but we do not recommend that you detach them. If you do, detach and reinstall the connectors as follows. If you do, detach and reinstall the connectors as follows. Input power cable Input power cable 82 Electrical installation...
  • Page 83 Electrical installation 89 Electrical installation 89 Electrical installation 83 Terminals L1, L2 and L3 Terminals L1, L2 and L3 • Remove the combi screw that attaches the connector to its terminal post, and • Remove the combi screw that attaches the connector to its terminal post, and pull the connector off.

  • Page 84: Dc Connection

    For details on pre-charging unit, contact your local ABB representative. Connecting the control cables Connect the cables as described in section Control cable connection procedure R0…R8 (page 90). See the below default I/O connections of ABB standard macro. See other macro connections in the firmware manual.

  • Page 85: Default Control Connections Of Abb Standard Macro

    Electrical installation 85 EN - Quick installation and start-up guide 17 Default control connections of ABB standard macro ￭ Connection diagram Default I/O connections (ABB standard macro) Reference voltage and analog inputs Signal cable shield (screen) Open for configuration 1…10 kohm...

  • Page 86: Notes

    86 Electrical installation • Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft) Notes Current [0(4)…20 mA, R < 500 ohm] or voltage [ 0(2)…10 V, R > 200 kohm] input as selected with parameter 12.15 AI1 unit selection. Current [0(4)…20 mA, R = 100 ohm] or voltage[ 0(2)…10 V, R >...

  • Page 87: Npn Configuration For Digital Inputs

    PNP configuration for digital inputs PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP configuration are Internal and external +24 V power supply connections for PNP configuration are shown in the figure below. Electrical installation 87 shown in the figure below.

  • Page 88: Connection Examples Of Two-Wire And Three-Wire Sensors

    88 Electrical installation 8 AO2 Analog output 2. Default output 0…20 mA. 500 ohm Analog common ground. Internally connected 9 AGND to chassis through a 2 Mohm resistor. 8 AO2 Analog output 2. Default output 0…20 mA. 1 kohm 1 kohm Analog common ground.

  • Page 89: Di5 As Frequency Input

    98 Electrical installation Electrical installation 89 DI5 as frequency input See section Digital inputs DI1…DI6 on page for which digital input can be used DI5 as frequency input as a frequency input in the drive.For setting the parameters for the digital frequency See section Digital inputs DI1…DI6 (page 126) for which digital input can be used as a...

  • Page 90: Control Cable Connection Procedure R0

    90 Electrical installation Control cable connection procedure R0…R8 WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and perform the steps in section Electrical safety precautions (page 14) before you start the work.

  • Page 91: R0...R2

    and101 (R6…R8). 10. Connect the conductors to the appropriate terminals of the control board and tighten to 0.5…0.6 N·m (0.4 lbf·ft). Electrical installation 91 11. Tie all control cables to the provided cable tie mounts. Note: Note: • Leave the other ends of the control cable shields unconnected or ground them •...

  • Page 92: R3...R5

    le shields unconnected or ground them with a few nanofarads, eg, 3.3 nF / 630 V. ly at both ends if they are in the same drop between the end points. 92 Electrical installation ose to the terminals as possible. Twisting turbances caused by inductive coupling.

  • Page 93: Option Modules

    Electrical installation 101 Electrical installation 93 ￭ R6...R8 R6…R8 0.5...0.6 N·m (0.4 lbf·ft) 0.5...0.6 N·m (0.4 lbf·ft) M4×20 Option modules You can install the following optional modules: Module Option slot Applicable frames I/O extension - BIO-01 Front option slot 1 R0...R2 Fieldbus (In R0...R2 frames, fieldbus Front option slot1...

  • Page 94: Front Option Slot

    94 Electrical installation Before you start the work, stop the drive and do the steps in section Electrical safety precautions (page 14). Front option slot 1 By default, RIIO-01 module is provided in ACS560 standard R0...R2 drives. You can remove the RIIO-01 module and can install BIO-01 and/or fieldbus adapter module (+fxxx).

  • Page 95: To Remove A Front Option

    Electrical installation 95 ￭ To remove a front option 1. Loosen the locking screw. 2. Pull the locking tab out to unlock the option module. 3. Pull the option module to disconnect and remove it. Note: The option module can be tightly in position. Electrical installation 103 ￭...

  • Page 96: Reinstalling Side Plates And Covers, Frames Size R5

    Reinstalling covers, frame size R3, R4 1. Reinstall the module cover. Put the tabs on the cover top in their counterparts on the housing and then press the cover. (1a.1b). 96 Electrical installation 2. Tighten the two retaining screws with a screwdriver. ￭...
  • Page 97 (3AUA0000094606 [English]). • Use a USB to RJ45 converter BCBL-01 (3AXD50000032449) with RDUM-01 (3AXD50000040850). You can order it from ABB. Note: Panel keys cannot be used when a USB data cable is connected to the panel. For information on the Drive composer PC tool, refer to Drive composer PC tool user's...

  • Page 99: Installation Checklist Of The Drive

    Installation checklist of the drive 99 Installation checklist of the drive Contents of this chapter This chapter contains a checklist of the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person.
  • Page 100 100 Installation checklist of the drive Make sure that … The input power cable has been connected to the appropriate terminals, the phase order is right, and the terminals have been tightened. (Pull on the conductors to check.) There is an adequately sized protective earth (ground) conductor between the motor and the drive, and the conductor has been connected to appropriate terminal, and the terminal has been tightened.

  • Page 101: Maintenance And Hardware Diagnostics

    For more information, consult your local ABB Service representative (www.abb.com/searchchannels). Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. Note: Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 102: Recommended Annual Maintenance Actions By The User

    Recommended maintenance action by the user The table below shows the intervals for the preventive maintenance tasks allowed for the customer. For other maintenance tasks, consult your local ABB Service representative, or see the complete maintenance schedule on the Internet.

  • Page 103: Heatsink

    * Ambient temperature constantly over 40 °C, especially dusty or humid ambient conditions, cyclic heavy load, or continuous rated (full) load. To maintain the best possible performance and reliability of the drive, inspect the drive annually. Contact ABB Service at least once in three years for replacement of aging components.

  • Page 104: Replacing The Cooling Fan, Frames Size R0

    increases the life span of the fan. Replacement fans are available from the manufacturer. Do not use other than specified spare parts. 104 Maintenance and hardware diagnostics Replacing the cooling fan, frames size R0…R4 Replacement fans are available from the manufacturer. Do not use other than specified spare parts.

  • Page 105: Replacing The Main Cooling Fan, Frames Size R6

    electrical work on page before you start the work. 2. Lift the fan assembly upwards from the front edge (2a) and remove the assembly (2b). Maintenance and hardware diagnostics 105 3. Unplug fan power supply wires from the drive. 4. Install the new fan assembly in reverse order. 4.

  • Page 106: Replacing The Auxiliary Cooling Fan, Frames R6

    4. Unplug fan power supply wires from the drive. 5. Lift the fan mounting plate off. 6. Remove the fan from the mounting plate. 106 Maintenance and hardware diagnostics 7. Install the new fans in reverse order. ￭ Replacing the auxiliary cooling fan, frames R6...R8 WARNING! Obey the instructions in chapter Safety instructions (page...

  • Page 107: Capacitors

    For information on reforming the capacitors, see Converter module capacitor reforming instructions (3BFE64059629 [English]), available on the Internet (go to http://www.abb.com and enter the code in the Search field). Control panel ￭...

  • Page 108: Leds

    Note: The battery is NOT required for any control panel or drive functions, except the clock. 1. Remove the control panel from the drive. See section Control panel on page 34. 108 Maintenance and hardware diagnostics 2. To remove the battery, use a coin to rotate the battery cover on the back of the control panel.
  • Page 109 Maintenance and hardware diagnostics 109 Control panel LED, at the left edge of the control panel LED off LED lit and steady LED blinking/flickering Panel has no Green Drive functioning normally. Green Blinking: power. Active warning in the drive Connection between the drive and control panel may be faulty Flickering: or lost, or the panel and drive...

  • Page 111: Technical Data

    Technical data 111 Technical data Contents of this chapter The chapter contains the technical specifications of the drive, for example ratings, sizes and technical requirements as well as provisions for fulfilling the requirements for CE, UL and other approval marks. Ratings ￭...

  • Page 112: Definitions

    200.98 132kW-4 418.2 239.38 160kW-4 3AXD10000715646.xls A 1) External charging circuit is required for these frame sizes. For details on charging unit, contact your local ABB representative. See definitions and notes in section Definitions (page 112). ￭ Definitions Nominal voltage Nominal input current (rms) at 40 °C (104 °F)

  • Page 113: Derating

    Technical data 113 Note: The nominal values of I apply to the ambient temperature of 40°C (104°F). Derating is needed above this temperature. Derating The load capacity (I ; note that I is not derated) decreases for certain situations, as defined below.

  • Page 114: Switching Frequency Derating

    114 Technical data तकनीकी डे ट ा Frame R0 1.00 0.95 0.95 0.90 0.85 0.80 50 °C 55 °C -15 °C 104 °F 131 °F 5 °F Frames R1...R3 1.00 0.95 0.90 0.90 0.85 0.80 50 °C 55 °C -15 °C 60 °C 104 °F 131 °F...

  • Page 115: Altitude Derating

    Technical data 115 Frame size Derating factor of the min. switch frequency 2kHz 4kHz 8kHz 12kHz 0.65 0.48 0.73 0.55 0.71 0.55 0.97 0.83 0.66 0.98 0.88 0.96 0.81 Not applicable 3AXD10000715646.xls ￭ Altitude derating In altitudes 1000…4000 m (3300…13120 ft) above sea level, the derating is 1% for every 100 m (330 ft).

  • Page 116: Gg Fuses

    ￭ gG fuses Drive type Input cur- gG (IEC 60269) Minimum ACQ80-04- rent short cir- Rated cur- Rated ABB designa- IEC 60269 cuit cur- rent I voltage tion type size rent 3 phases U = 400 V (380...480 V) 0kW75-4...

  • Page 117: Gr Fuses

    Technical data 117 Drive type Input cur- gG (IEC 60269) Minimum ACQ80-04- rent short cir- Rated cur- Rated ABB designa- IEC 60269 cuit cur- rent I voltage tion type size rent 05kW5-4 20.2 2500 OFAF000H25 07kW5-4 27.2 4500 OFAF000H32 011kW-4 40.0...

  • Page 118: Dc Fuses

    118 Technical data Drive type Input cur- gG (IEC 60269) Minimum ACQ80-04- rent short cir- Rated cur- Rated ABB desig- IEC 60269 cuit cur- rent I voltage nation type size rent 011kW-4 40.0 3600 170M2699 015kW-4 33.0 1450 170M1565 18kW5-4 39.0...

  • Page 119: Circuit Breakers

    Technical data 119 Circuit breakers The table below lists MCB circuit breakers that can be used with the drive. Type MCBs ACQ80-04- ABB type Max. short- Tmax Tmax rat- Electronic SACE ordering circuit frame XT / release code for breaker...

  • Page 120: Dimensions, Weights And Free Space Requirements

    120 Technical data Dimensions, weights and free space requirements Frame size Dimensions and weight IP20 Weight 14.9 28.3 42.4 Standard frame size (R0-R8)

  • Page 121: Thermal Losses, Cooling Data And Noise

    Technical data 121 Symbols IP20 Height of front side Height of back side (without cable connecting box) Width Depth Frame size Free space Vertical installation Vertical installation Independent Side by side Above Below Above Below Interval See the figures in section Checking the installation site (page 40).

  • Page 122: Terminal And Lead-Through Data For The Power Cables

    122 Technical data Desig. Thermal losses Air flow Noise Frame size ACQ80-04- Main cir- Control cir- Control cir- Main circuit cuit nomin- cuit Min. cuit Max. and control al I load load circuit Max. load dB(A) 01kW1-4 63.10 01kW5-4 63.10 02kW2-4 63.10 03kW0-4...

  • Page 123: Terminal And Lead-Through Data For The Control Cables

    Technical data 123 Desig. U1. V1. W1 / U2. V2. W2 / R+. R- / DC+. DC- terminal PE terminals ACQ80- min. ( single core Max.( (single core and/ torque torque size and / multicore) multi-core ) N·m lbf·ft N·m 02kW2-4 0.2/0.2 0.5...0.6...

  • Page 124: Electrical Power Network Specification

    124 Technical data Electrical power network specification Voltage (U Input voltage range 3~ 380…480 V AC. This is indicated in the type designa- tion label as typical input voltage levels 3~ 400/480 V AC. Network type Public low voltage networks. TN (grounded), IT (ungrounded) and corner- grounded TN systems.

  • Page 125: Emc Compatibility And Motor Cable Length

    Technical data 125 Maximum recommended mo- Operational functionality and motor cable length tor cable length The drive is designed to operate with optimum performance with the following maximum motor cable lengths. Frame size Maximum motor cable length, 4 kHz Scalar control Vector control Standard drive, without external options 3AXD10000715646.xls A...

  • Page 126: Control Connection Data

    126 Technical data Frame size Maximum motor cable length, 4 kHz 1) See the terms in section Definitions (page 134). Applicable for frames R4...R8. Frames R0...R2 require external EMC filter to meet the category 2 standards. Note 2: Radiated emissions are according to C3 with an internal EMC filter. Note 3: The internal EMC filter must be connected.
  • Page 127 Technical data 127 Reference voltage output for Max. 20 mA output analog inputs +10V DC (Term. Inaccuracy: ±1% Safe torque off (STO) inputs 24 V DC logic levels: "0" < 5 V, "1" > 13 V IN1 and IN2 (Term. 37 and 38) R : 2.47 kohm STO cable Maximum cable length 300 m (984 ft) between activation switch (K) and drive...
  • Page 128 128 Technical data Grounding of frames R0…R2 X2 & X3 Slot 2 Slot 1 +24V DGND DCOM RO1C RO1A RO1B OUT1 SGND Ground *) Installed with jumpers at the factory.
  • Page 129 Technical data 129 Grounding of frames R3…R5 Slot 1 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6. X7. X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND Ground Installed with jumpers at the factory.

  • Page 130: Auxiliary Circuit Power Consumption

    130 Technical data Grounding of frames R6…R8 Slot 1 Slot 2 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6, X7, X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND 24VAC/DC+in 24VAC/DC-in Ground Jumper installed at factory Auxiliary circuit power consumption Maximum external power supply:...

  • Page 131: Efficiency

    Technical data 131 Efficiency Approximately 98% at nominal power level Degree of protection Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. All printed circuit boards are conformal coated. ￭...

  • Page 132: For R3

    132 Technical data Contamination levels No conductive dust allowed. (IEC 60721-3-3 According to IEC According to IEC According to IEC (IEC 60721-3-2 60721-3-3, chemical 60721-3-1, chemical 60721-3-2, chemical (IEC 60721-3-1 gases: Class 3C2 gases: Class 1C2 gases: Class 2C2 solid particles: Class solid particles: Class solid particles: Class 3S2.

  • Page 133: Materials

    IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.

  • Page 134: Ce Marking

    134 Technical data EN 60204-1:2006 + AC:2010 Safety of machinery. Electrical equipment of machines. Part 1: General re- quirements. Provisions for compliance: The final assembler of the machine is responsible for installing - emergency-stop device - supply disconnecting device. IEC/EN 60529:1992 + A2: 2013 Degrees of protection provided by enclosures (IP code) EN 61000-3-12:2011 Electromagnetic compatibility (EMC) - Part 3-12: Limits - Limits for harmonic...

  • Page 135: Category C1

    Technical data 135 Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment. Note: A professional is a person or organization having necessary skills in installing and/or starting up power drive systems, including their EMC aspects.

  • Page 136: Category C4

    136 Technical data 2. The drive is installed according to the instructions given in this manual. 3. For the maximum motor cable length with 4 kHz switching frequency, see section Maximum recommended motor cable length (page 125). WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises.

  • Page 137: Dimension Drawings

    Dimension drawings 137 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the ACQ80-04. The dimensions are given in millimeters and [inches].

  • Page 138: Frame R0, Ip20

    138 Dimension drawings Frame R0, IP20...

  • Page 139: Frame R1, Ip20

    Dimension drawings 139 Frame R1, IP20 Frame R2, IP20...

  • Page 140: Frame R3, Ip20

    140 Dimension drawings Frame R3, IP20...

  • Page 141: Frame R4, Ip20

    Dimension drawings 141 Frame R4, IP20...

  • Page 142: Frame R5, Ip20

    142 Dimension drawings Frame R5, IP20...

  • Page 143: Frame R6, Ip20

    Dimension drawings 143 Frame R6, IP20...

  • Page 144: Frame R7, Ip20

    144 Dimension drawings Frame R7, IP20...

  • Page 145: Frame R8, Ip20

    Dimension drawings 145 Frame R8, IP20...

  • Page 147: The Safe Torque Off Function

    The Safe torque off function 147 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, to as the final actuator device of safety circuits that stop the drive in case of danger (such as an emergency stop circuit).

  • Page 148: Compliance With The European Machinery Directive

    148 The Safe torque off function Standard Name IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC requirements – Part 3-1: Immunity requirements for safety-related systems and for equipment intended to perform safety-related functions (functional safety) – General industrial applications IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems –...

  • Page 149: Wiring

    The Safe torque off function 149 Wiring For the electrical specifications of the STO connection, see the technical data of the control board. ￭ Connection principle (R0…R2) Connection with internal power supply + 24 V DC OUT1 SGND UDC+ UDC- Drive Control board Control logic...

  • Page 150: Wiring Examples (R0

    150 The Safe torque off function Drive Control board Control logic To motor Activation switch ￭ Wiring examples (R0…R2) Wiring with internal power supply OUT1 SGND Drive Safety PLC Safety relay Wiring with external power supply 24 V DC OUT1 SGND ÍN2 Drive...

  • Page 151: Connection Principle (R3

    The Safe torque off function 151 ￭ Connection principle (R3…R8) Connection with internal power supply OUT1 + 24 V DC OUT2 + 24 V DC SGND UDC+ UDC- Drive Control board Control logic To motor Activation switch Connection with external power supply 24 V DC OUT1 + 24 V DC...

  • Page 152: Wiring Examples (R3

    152 The Safe torque off function Activation switch ￭ Wiring examples (R3…R8) Wiring with internal power supply OUT1 OUT2 SGND Drive Safety PLC Safety relay Wiring with external power supply 24 V DC OUT1 OUT2 SGND Drive Safety PLC Safety relay ￭...

  • Page 153: Cable Types And Lengths

    The Safe torque off function 153 • The contacts of the switch or relay must open/close within 200 ms of each other. ￭ Cable types and lengths • Double-shielded twisted-pair cable is recommended. • Maximum cable lengths: • Frames R0…R2: 100 m (330 ft) between activation switch [K] and drive control board Frames R3…R8: 300 m (1000 ft) between activation switch [K] and drive control board...

  • Page 154: Operation Principle

    154 The Safe torque off function Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control board de-energize. 3. The control board cuts off the control voltage from the output IGBTs. 4.

  • Page 155: Start-Up Including Acceptance Test

    The Safe torque off function 155 Start-up including acceptance test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing an acceptance test. The acceptance test must be performed •...
  • Page 156 156 The Safe torque off function Action Test the operation of the STO function when the motor is running. • Start the drive and ensure the motor is running. • Open the STO circuit. The motor should stop. The drive generates an indication if one is defined for the 'running' state in parameter 31.22 (see the firmware manual).

  • Page 157: Use

    The Safe torque off function 157 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control board de-energize, and the control board cuts off the control voltage from the output IGBTs. 3.

  • Page 158: Maintenance

    If any wiring or component change is needed after start up, or the parameters are restored, follow the test given in section Acceptance test procedure (page 155). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...

  • Page 159: Fault Tracing

    See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control board for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.

  • Page 160: Safety Data

    160 The Safe torque off function Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. MTTF Frame SIL/...

  • Page 161: Abbreviations

    The Safe torque off function 161 Frames R3…R8: 2 ms (typical), 5 ms (maximum) • Fault detection time: Channels in different states for longer than 200 ms • Fault reaction time: Fault detection time + 10 ms • Indication delays: •...

  • Page 163: Bio-01 I/O Extension Module

    BIO-01 I/O extension module 163 BIO-01 I/O extension module Contents of this chapter This chapter contains a description and technical data of the optional BIO-01 I/O extension module. The chapter also contains references to the relevant other content elsewhere in the manual.

  • Page 164: Layout

    164 BIO-01 I/O extension module ￭ Layout 1. Locking tab 2. Fieldbus option module slot 3. Chassis screw 4. I/O connector Mechanical installation See section Option modules (page 93) Before you install the BIO-01 option module, make sure that the chassis screw slider is in the top position.

  • Page 165: Electrical Installation

    Electrical installation See chapter Electrical installation (page 65). If you configure the inputs, set up the wiring accordingly. The BIO-01 module has removable spring clamp terminals. Use ferrules on the multistranded cables before assembly. Sample wiring with the ABB standard macro...

  • Page 166: Start-Up

    55. If you configure the inputs, set up the 166 BIO-01 I/O extension module wiring accordingly. The BIO-01 module has removable spring clamp terminals. Use ferrules on the multistranded cables before assembly. Sample wiring with the ABB standard macro: Terminals Description Base...

  • Page 167: Dimensions

    BIO-01 I/O extension module 167 ￭ Dimensions...

  • Page 169: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 170 3AXD50000170661A © 2019 ABB. All Rights Reserved. Specifications subject to change without notice.

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