Random Recipes

ABB industrial drives Delivered in PDF format on a manuals CD with the drive module. Delivered as a printed copy with the drive module. Delivered as a printed copy with the option. 3AUA0000055155 Rev A 5 Table of contents List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Safety instructions What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planning the cabinet placement on a cable channel . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 7 Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Typical power cable sizes (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Continuous motor cable shield or enclosure for equipment in the motor cable . . . . . 61 Implementing thermal overload and s hort-circuit protection . . . . . . . . . . . . . . . . . . . . . . 62 Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . 62 Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . 62 Protecting the drive and the input power and motor cables against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . 65 Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Connecting a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . 68 Considering the PELV on instal Grounding the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Connecting the control unit to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 External power supply for the JCU Control Unit (X POW) . . . . . . . . . . . . . . . . . . . 83 DI5 (XDI:5) as a thermistor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Start interlock (XDI:A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Routing the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 8. Installation checklist What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 9 12. Technical data What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Fuse tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Ultrarapid (aR) fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 10 14. Example circuit diagrams What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 15. du/dt filters and sine filters What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 When is du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . 131 Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Further information Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Grounding These instructions are intended for all who are re sponsible for the grounding of the drive. WARNING! Ignoring the following instructions can cause physical injury, death, Do not lift by the lower part of the frame. Do not tilt! „Fiber optic cables„Printed circuit boardsSafe start-up and operation Introduction to the manual 17 What this chapter contains This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delive ry, installing and commissioning the drive. The flowchart refers to chapters/section s in this manual and to other manuals. 18 Introduction to the manual Operation principle and hardware description describes the drive module. Planning the cabinet installation Introduction to the manual 19 Unpack and check the units. Check that all necessary optional modules and equipment are present and correct. Only intact units may be started up. Mechanical installation (page If the drive module has been non-operational for more than one year, the converter DC link capacitors need to be reformed. Ask ABB for instructions. Check the installation site. Ambient conditions (page 116 20 Introduction to the manual Terms and abbreviations Term/AbbreviationExplanation used in inverters due to their easy controllability and high switching frequency. I/OInput/Output JCUThe control unit of the drive module. The external I/O control signals are connected to the JCU, or optiona l I/O extensions mounted on it. JINTMain circuit board JMU-xxThe memory unit attached to the control unit of the drive RFIRadio-frequency interference Operation principle and hardware description 21 What this chapter contains This chapter describes the operating principl e and construction of the drive module in short. The ACQ850-04 is a drive module for control ling asynchronous AC induction motors for water and waste water applications. The degree of protection of the drive module is IP00. The module must be installed into a cabinet by the customer. 22 Operation principle and hardware description The main circuit of the drive module is shown below. This table describes the operation of the main circuit in short. ComponentDescription RectifierConverts the three-phase AC voltage to DC voltage. Capacitor bankEnergy storage which stabilizes the intermediate circuit DC voltage. InverterConverts the DC voltage to AC voltage and vice versa. The motor operation is controlled by switching the IGBTs. Motor output AC supply Capacitor bank R- UDC+ UDC- ACQ810-04 Operation principle and hardware description 23 „LayoutThe components of the standard unit are shown below. Front cover Pedestal Motor cable terminals Input cable terminals Alternative output cable terminals (when no vertical busbars are used) Fastening points Fastening points Additional holes for fastening the cable (JCU) Lifting lug Control cable clamp plate Drive module Fastening points Cables going to the JCU Control Unit and APOW board are coiled on the top of the module. Control panel 24 Operation principle and hardware description The control unit layout is shown below (cover assembly and protective coverings of the slots removed). Slots 1 for optional I/O extensions Slot 2 for optional fieldbus adapter Relay outputs +24VD Digital inputs Digital input/outputs Analog inputs Analog outputs Drive-to-drive link Control panel / PC connection Memory unit (JMU) connection External 24V power input Safe torque off connection Operation principle and hardware description 25 „Alternative output busbar configurationsThe motor busbars can be fastened on the left-hand long side of the module and DC busbars on the right-hand side. Alternatively, the motor can be fastened on the right-hand long side of the module and DC busbars on the left-hand side. The output busbars can also be fastened on the short back side of the module. For more information, contact your local ABB representative. Control unit variants Output busbars on the short side of the module Control unit without control panel and panel holder (+0J400) a) When covers are removed Control unit with control panel (standard) Control unit without front 26 Operation principle and hardware description „Component placementThe component layout stickers of the drive m odule are shown below. Th e stickers show all possible components. Not all of them are pr esent in each delivery or described here. Components that need to be changed regularly are listed below: 64601423 DesignationComponent Y41Cooling fan C201-C214Capacitors Operation principle and hardware description 27 „Power connections and control interfacesThe diagram shows the power connections and control interfaces of the drive. Control unit (JCU) Control panel or PC 3-phase power supply For information on default connections, see page For specifications, see page 114 * programmable. FIO-11 (Analog I/O extension) FIO-21 (Analog and digital I/O extension) FIO-31 (Digital I/O extension with four relays) Slot 2 (Fieldbus adapter) FDNA-0x (DeviceNet) du/dt or sine filter (optional, see page 2) See page 104. External power inputXPOW *Relay outputs (2pcs)XRO1…2 24V DC outputXD24 *Digital inputs (5pcs +DIIL)XDI *Digital input/outputs (2pcs)XDIO *Analog inputsXAI *Analog outputsXAO Drive-to-drive linkXD2D Safe torque offXSTO L2 L3 UDC+ R+ UDC- 28 Operation principle and hardware description „Cables for connecting the control unit to the drive module and control panel The cables connecting the drive module and c ontrol panel to the control unit are shown below. See section Connecting the control unit to the drive module , page for the actual connections. The drive contains the following printed circuit boards as standard: main circuit board (JINT) control and I/O board (JCON) inside the JCU Control Unit adapter board (JRIB) connected to the JCON board input bridge control board (AINP) input bridge protection board (AIBP) which includes snubbers for the thyristors and power supply board (APOW) gate driver control board (AGDR) diagnostics and panel interface board (JDPI) Type designation label The type designation label includes an IEC and NE MA rating, CE, “C-tick”, C-UL US, and CSA markings, a type designation and a serial number, which allow individual recognition of each unit. The first digit of the serial num ber refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week respectively. The remaining 3 m ( 118 in.) 3 m (118 in.) 2100 mm (83 in.) Drive module Protective tube Shield JCU Control Unit Category 5e cable 300 mm (12 in.) 4 . 5 ( 0 . 1 8 ” ) 0 ( 3 . 1 5 ” ) Operation principle and hardware description 29 number. The type designation label is located on the front cover. An example label is shown below. Type designation key The type designation contains information on t he specifications and configuration of the drive module. The first digits from left ex press the basic confi guration eg, ACQ810-04- 477A-4. The optional selections are given thereafter, separated by plus signs eg, +L519. The main selections are described below. Not all selections are available for all types. For ACQ810-04 Ordering Information (00588241), available on request. SelectionAlternatives Product seriesACS850 product series Type04 Drive module. When no options ar e selected: IP00 (UL open type), top entry, side exit, JCU drive control un it with front cover, control panel holder and control panel, EMC filter for Category C3, common mode filter, Standard pump cont rol program, Safe torque off function, coated boards, pedestal with output on the long side, output busbar set for motor, base and wall mounting brackets, Quick start-up guide (multilingual) and CD containing all manuals. Size Refer to the rating tables, page 105 Voltage range (nominal rating in bold) 4380…480VAC + options Filter0E200No EMC filter Control panel and control unit 0J400No control panel and panel holder J410Control panel with door mounting kit. Includes control panel mounting Type designation, see section Type designation key below. Serial number Ratings 30 Operation principle and hardware description Planning the cabinet installation 31 The installation must always be designed and made according to applicable local assume any liability whatso ever for any installation which breaches the local laws and/or other regulations. 32 Planning the cabinet installation 1aAir inlet for the drive module 1bAir inlet for the other equipment 2aAir outlet for the drive module 2bAir outlet for the other equipment 2cAir outlet for the drive module and the other equipment, an extra exhaust fan 3Drive control panel (control panel door mounting kit, +J410). The control panel is connected to the JCU Control IP54 IP22 Roof air flow viewed from top Planning the cabinet installation 33 „Layout examples, door openLayout examples for IP22 and See also section Required free space around the drive module , page WARNING! Never use the module without the pedestal. IP54 IP54 IP22 Air flow to the roof Air flow through the drive module 34 Planning the cabinet installation WARNING! Do not fasten the cabinet by electr ic welding if the drive module is already installed inside circuits in the cabinet. Screw sizeTorque M53.5 N·m (2.6 lbf·ft) M69 N·m (6.6 lbf·ft) M820 N·m (14.8 lbf·ft) M1040 N·m (29.5 lbf·ft) M1270 N·m (52 lbf·ft) M16180 N·m (133 lbf·ft) Planning the cabinet installation 35 The carrying structure on a cable channel Cables Cable channel 36 Planning the cabinet installation 360° high frequency grounding of the motor cable shields at their entries is recommended. The grounding can be implement ed by a knitted wire mesh screening as shown below. 360° high frequency grounding of the control cable shields is recommended at their entries. The shields can be grounded by means of conductive shielding cushions pressed against the cable shie ld from both directions: Cable ties Bare cable shield Lead-through plate Cable Shielding cushion (conductive) Cable Bare cable shield Cabinet bottom plate Planning the cabinet installation 37 Planning the grounding of the ca EMC sleeve Lead-through plate Strip this part of the cable Cable shield Base plate PE terminal of the cabinet or drive module Strain relief Recommended for control cables To power terminals Example cable lead-through 38 Planning the cabinet installation Planning the cabinet installation 39 „Prevention the air recirculat Air flow out Air flow in max. 40°C (104°F) Drive module Drive module Horizontal air baffle Vertical air baffle Drive cubicle from above Drive cubicle from side A - A 40 Planning the cabinet installation „Free space at top with high air in 300 mm (11.81 in.) (7.87 in.) Air baffles not required if the drive module touches the 200 mm 300 mm (11.81 in.) Air baffles Planning the cabinet installation 41 „Free space at the side a The figure below shows the required free space in a unit with motor busbars connected to the left-hand side of the module. The required free space when no vertical busbars are 1)When cables are connected to the output busbars of the pedestal 100 mm (3.94 in.) free space around the busbars is required for cooling. 2)When cables connected to the vertical output busbar terminals 50 mm (1.97 in.) free space around the busbar terminals is required for cooling. 3)The required free space in front of the unit depends on the gratings in the cabinet door: 0 mm (0 in.) 150 mm (5.91 in.) 100 mm (3.94 in.) 50 mm (1.97 in.) Air inlet side 3) 3) 42 Planning the cabinet installation Planning the placement of the control panel Note the following alternatives when planning the placement of the control panel: The control panel can be snapped on the control unit. See page Mechanical installation 43 Mechanical installation What this chapter contains This chapter describes how to insta ll the drive module into a cabinet. 44 Mechanical installation WARNING! The drive module is heavy 200kg (441lb). Lift it by the upper part only using the lifting lugs attached to the top of the unit. The lower part will be deformed from lifting. Do not remove the pedestal before lifting. Do not tilt the The centre of gravity of the unit is high. The unit will overturn from a tilt of about 6 degrees. An overturning unit can cause physical injury. Checking the installation site The material below the drive must be non- flammable and strong enough to carry the weight of the drive. Technical data for the allowed operating conditions. Do not lift by the lower part of the frame. Do not tilt! Mechanical installation 45 Moving and unpacking the unit 3 4 5 Part no.Description Drive module with factory installed options and multilingual residual voltage warning sticker Output cable terminals with fastening screws 46 Mechanical installation Attaching the warning stickers Attach the residual voltage warning sticker of the local language onto the drive module front cover. 1.Fasten the grounding terminals to the long side plates of the pedestal with screws. 2.Fasten the cable lug terminals to the busbars with screws. Side view (cable lug terminals fastened) WARNING! See the next page for the screw sizes and tightening torques! Mechanical installation 47 M10 Tightening torques: M10: 30...44 N·m (22...32 lbf·ft) M12: 50...75 N·m (37...55 lbf·ft) 2 2 2 M10x M10x25 WARNING! Fasten the output busbars to the insu lating supports with M10x20 screws when no cable lug terminal is connected, but with M10x25 screws when a cable lug terminal is connected as well. Screwing an M10x25 screw wit hout a cable lug terminal through the busbar into the insulating support will break the insulating support. M10x20 M10x25 M10x25 Cable lug terminal Insulating support 48 Mechanical installation WARNING! Place the module on a solid base . The fastening brackets are not strong enough to carry the weight of the module on their own. Tightening torque: 5 N·m (3.7 lbf·ft) Mechanical installation 49 Installing the drive control unit The drive control unit can be fastened on a mounting plate through the fastening holes in its back or by using a DIN rail. The followin g drawings show the control unit with front cover but units without covers are installed in the same way. „Mounting through the fastening holes1.Fasten the fastening screws in the wall. 2.Lift the unit onto the screws. 3aua0000038989 50 Mechanical installation „Vertical DIN rail mounting 1.Fasten the latch (A) to the back of the control unit with four screws. 2.Click the control unit to the rail as shown below (B). Horizontal DIN rail mounting 1.Fasten the latches (A) to the back of the control unit with four screws. 2.Click the control unit to the rail as shown below (B). 3aua0000038989 B 3aua0000038989 A B Planning the electrical installation 51 installation What this chapter contains This chapter contains the instructions that you must follow when selecting the motor, cables, protections, cable routing and way of operation for the drive system. The installation must always be designed and made according to applicable local assume any liability whatso ever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover. Install a hand-operated input disconnecting devi ce (disconnecting means) between the AC power source and the drive. The disconnecti ng device must be of a type that can be locked to the open position for installation and maintenance work. 52 Planning the electrical installation nology. Regardless of frequency, the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time. The pulse voltage can almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the term additional stress on the motor and motor cable insulation. Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings, which can gradually erode the bearing races and rolling elements. Optional du/dt filters protect motor insulation system and reduce bearing currents. Common mode filters mainly reduce bearing currents. insulated N-end (non-drive end) bearings protect the motor bearings. See section Checking the compatibility of the motor and drive below for the required filters and N-end bearings to be used with the drive. Select and install the cables according to the instructions given in this manual. Checking the compatibility of the motor and drive Use an AC induction motor with the drive. Several induction motors can be connected to the drive at a time. Select the motor and drive according to the rating tables in chapter Technical data 1.Check that the motor ratings lie within the allowed ranges of the drive control program: 2.motor nominal voltage is in the range of 1/2...2 · 3.motor nominal current is 1/3 ... 1 · of the drive in DTC control and 0 ... 1· Planning the electrical installation 53 5.Ensure that the motor insulation system withstands the maximum peak voltage in the motor terminals. See the Requirements table below for the required motor insulation system and drive filtering. Example: When the supply voltage is 440 V, the maximum peak voltage in the motor terminals can be approximated as follows: 440V·1.35·2 = 1190V. Check that the motor insulation system withstands this voltage. 6.Use insulated N-end (non-drive end) beari ngs and output filters from ABB according to the Requirements table below. „Requirements table The following table shows how to select the motor insulation system and when an optional ABB du/dt filter, insulated N-end (non-d filters are required. Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty. The drive is equipped with the comm on mode filter as standard. type Nominal AC line voltage Requirement for insulation system ABB du/dt filter, insulated N-end bearing and ABB common mode filter frame size IEC 315 100 kW 350kW frame size IEC 315 350 kW frame size IEC 400 and frame size NEMA500 134 hp 469hp or frame size NEMA500 469hp or frame size NEMA580 ABB motors Random- wound M2_ and 500 VStandard -+ N+ N + CMF 600 VStandard + du/dt+ du/dt + N+ du/dt + N + CMF Reinforced -+ N+ N + CMF 690 VReinforced + du/dt+ du/dt + N+ du/dt + N + CMF Form- wound HX_ and 690 VStandard n.a.+ N + CMF 500 kW: + N + 500 kW: + N + CMF + du/dt Old* form- wound HX_ and modular 690 VCheck with the motor manufacturer. + du/dt with voltages over 500V + N + CMF Random- wound HX_ and 0 V 500 VEnamelled wire with fiber glass taping + N + CMF 690 V+ du/dt + N + CMF 54 Planning the electrical installation *manufactured before 1.1.1998 **For motors manufactured before 1.1.1998, check for ad ditional instructions with the motor manufacturer. The abbreviations used in the table are defined below. Explosion-safe (EX) motors The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors. Non-ABB motors Random- wound and form- wound 420 VStandard: = 1300V -+ N or CMF+ N + CMF 500 VStandard: + du/dt+ du/dt + N + du/dt + N + CMF + du/dt + CMF Reinforced: = 1600 V, 0.2 microsecond -+ N or CMF+ N + CMF 600 VReinforced: = 1600V + du/dt+ du/dt + N+ du/dt + N + CMF + du/dt + CMF Reinforced: = 1800V -+ N or CMF+ N + CMF 690 VReinforced: = 1800V + du/dt+ du/dt + N+ du/dt + N + CMF Reinforced: = 2000 V, 0.3 microsecond -N + CMFN + CMF Abbr.Definition 350kW frame size IEC 315 350 kW frame size IEC 400 134 hp and frame size NEMA500 134 hp 469hp or frame size NEMA500 469hp or frame size NEMA580 Planning the electrical installation 55 High-output motors and IP 23 motors For motors with higher rated output than what is stated for the particular frame size in EN50347 (2001) and for IP23 motors, the requirements of ABB random-wound moto r series (for example M3AA, M3AP, M3BP) are given below. For non-ABB motor types, see the Requirements table above. Apply the requirements of range 100 kW 350kW to motors with 100 kW. Apply the requirements of range 350kW to motors within the range 100 kW 350kW . In other cases, consult the motor manufacturer. HXR and AMA motors All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR machines manufactured in Helsinki starting 1.1.1998 have form-wound windings. ABB motors of types other than M2_, M3_, HX_ and AM_ Use the selection criteria given for non-ABB motors. Calculating the rise time and the peak line-to-line voltage The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length. The requ irements for the motor insulation system given in the requirements table 200kW 200 kW 140 hp140 hp 268hp 268hp ABB motors Random- wound 500 VStandard -+ N+ N + CMF 600 VStandard + du/dt+ du/dt + N+ du/dt + N + CMF Reinforced -+ N+ N + CMF 690 VReinforced + du/dt+ du/dt + N+ du/dt + N + CMF Without du/dt filter Cable length (m) du/dt -(1/ 100200300 100200300 0.0 0.5 1.0 1.5 2.0 2.5 3.0 Cable length (m) With du/dt filter ------------ -(1/ 5.5 56 Planning the electrical installation Sine filters Sine filters protect the motor insulati on system. Therefore, du/dt filter ca n be replaced with a sine filter. The peak phase-to-phase voltage with the si ne filter is approximately 1.5 · „General rulesDimension the input power and motor cables according to local regulations Dimension the cable to carry th e drive load current. See chapter Technical data for the rated currents. Select a cable rated for at least 70 C maximum permissible temperature of conductor in continuous use. For US, see Additional US requirements, page The inductance and impedance of the PE conductor/cable (grounding wire) must be rated according to permissible touch voltag e appearing under fault conditions (so that the fault point voltage will not rise excessively when a ground fault occurs). 600 VAC cable is accepted for up to 500 VAC 16S 3516 35 SS/2 Planning the electrical installation 57 „Typical power cable sizes The table below gives copper and aluminium cable types for different load currents. Cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one on top of the other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (EN60204-1 and IEC60364-5-52/2001). For other conditions, dimension the cables according to local safe ty regulations, appropriate input voltage and the load current of the drive. Typical power cable sizes (US) Cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40°C (104°F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or earth (directly buried). For other conditions, dimension the cables according to local safety regu lations, appropriate input voltage and the load current of the drive. Copper cables with concentric copper shield Aluminium cables with concentric copper shield Max. load current Cable type Max. load Cable type 2742 × (3×70)3022 × (3×120) 3342 × (3×95)3482 × (3×150) 3862 × (3×120)3982 × (3×185) 4462 × (3×150)4702 × (3×240) 5102 × (3x185)5223 × (3×150) 6022 × (3×240)5973 × (3×185) 5793 × (3×120)7053 × (3×240) 6693 × (3×150) 7653 × (3×185) 9033 × (3×240) 3BFA 01051905 C Copper cables with concentric copper shield Max. load current Cable type AWG/kcmil 273350 MCM or 2 × 2/0 295400 MCM or 2 × 2/0 334500 MCM or 2 × 3/0 370600 MCM or 2 × 4/0 or 3 × 1/0 405700 MCM or 2 × 4/0 or 3 × 2/0 4492 × 250 MCM or 3 × 2/0 5022 × 300 MCM or 3 × 3/0 5462 × 350 MCM or 3 × 4/0 5902 × 400 MCM or 3 × 4/0 6692 × 500 MCM or 3 × 250 MCM 7392 × 600 MCM or 3 × 300 MCM 8102 × 700 MCM or 3 × 350 MCM 8843 × 400 MCM or 4 × 250 MCM 10033 × 500 MCM or 4 × 300 MCM 11093 × 600 MCM or 4 × 400 MCM 12143 × 700 MCM or 4 × 500 MCM 58 Planning the electrical installation „Alternative power cable typesThe power cable types that can be used with the drive are represented below. To effectively suppress radiated and conduc ted radio-frequency emissions, the cable shield conductivity must be at least 1/ 10 of the phase conductor conductivity. The Recommended and shield Shield A separate PE conductor is required if the conductivity of the cable shield is 50% of the conductivity of the phase conductor. A four-conductor system: three phase conductors and a protective conductor Shield Not allowed fo r motor cables phase conductor cross section larger than 10mm (motors 30 kW [40 hp]). Not allowed for motor cables Copper wire screen Helix of copper tape or copper wire Cable core Inner insulation Planning the electrical installation 59 Double-shielded twisted pair cable Single-shielded twisted pair 60 Planning the electrical installation „Relay cable type 90 ° min 500 mm (20 in.) Input power cable Control cables min 200 mm (8 in.) min 300 mm (12 in.) Motor cable Power cable Planning the electrical installation 61 „Separate control cable ducts motor cable 24 V Lead 24V and 230V (120V) control cables in separate ducts inside the cabinet. Not allowed unless the 24V cable is insulated for 230V (120V) or insulated with an insulation sleeving for 230V (120V). (120 V) (120 V) 62 Planning the electrical installation „Protecting the drive and input power cable in short-circuits Protect the drive and input cable with fuses or a circuit breaker as follows: 1.Size the fuses according to instructions given in chapter Technical data. The fuses will protect the input cable in short-circuit si tuations, restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive. 2.Circuit breakers which have been tested by ABB with the drive can be used. Fuses must be used with other circuit breakers. Co ntact your local ABB representative for the approved breaker types and suppl y network characteristics. The protective characteristics of circui t breakers depend on the type, construction and WARNING! Due to the inherent operating principle and construction of circuit breakers, independent of the manufacturer, hot ionized gases may escape from the breaker enclosure in case of a short-circuit. To ensure safe use, special attention must be paid to the installation and placement of the breakers. Follow the manufacturer’s instructions. Circuit breakers must not be used without fuses in the USA. and motor cable in short-circuits The drive protects the motor cable and motor in a short-circuit situation when the motor cable is dimensioned according to the nominal current of the drive. No additional protection devices are needed. The drive protects itself and the input and mo tor cables against thermal overload when the cables are dimensioned according to the nomi nal current of the drive. No additional thermal protection devices are needed. ~ Distribution board Input cable ~ Drive module Planning the electrical installation 63 WARNING! If the drive is connected to multiple motors, a separate thermal overload switch or a circuit breaker must be used for protecting each cable and motor. These devices may require a separate fuse to cut off the short-circuit current. „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 overl 64 Planning the electrical installation The drive supports the Safe torque off function according to standards EN61800-5-2:2007; EN954-1:1997; IEC/EN60204-1:1997; EN61508:2002 and EN1037:1996. The Safe torque off function disables the c ontrol voltage of the power semiconductors of the drive output stage, thus preventing the inverter from generating the voltage required to rotate the motor (see diagram below). By usi ng this function, short- time operations (like cleaning) and/or maintenance work on non-electrical parts of the machinery can be performed without switching off the power supply to the drive. WARNING! The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive. Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply. It is not recommended to stop the drive by using the Safe torque off function. If a running drive is stopped by using the Safe to rque off function, the drive will stop by coasting. If this causes danger or is not acceptable, the drive and machinery must be stopped using the appropriate stopping mode before using the Safe torque off function. +24 V Control UDC- ACQ810-04 Output stage (1phase shown) Safe torque off connection on JCU Notes: • The contacts of the activation switch must open/close within 200 ms of each other. • The maximum cable length Planning the electrical installation 65 WARNING! Do not connect power factor compensation capacitors or harmonic If there are power factor compensation capacitors in parallel with the three phase input of the drive: 1.Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may trip or even damage the drive. 2.If capacitor load is increased/decreased step by step when the AC drive is connected to the power line, ensure that the connection steps are low enough not to cause voltage transients that would trip the drive. 3.Check that the power factor compensation un it is suitable for use in systems with AC drives ie, harmonic generating loads. In such systems, the compensation unit should typically be equipped with a blocki ng reactor or harmonic filter. When you have selected to use the default motor control mode (DTC) and motor coast stop in the drive, open the contactor as follows: 1.Give a stop command to the drive. 2.Open the contactor. 66 Planning the electrical installation Alternative 2: When you have selected to use the default motor control mode (DTC) and motor ramp stop in the drive, open the contactor as follows: 1.Give a stop command to the drive. 2.Wait until the drive decelerates the motor to zero speed. 3.Open the contactor. Alternative 3: When you have selected to use the scalar motor control mode in the drive, open the contactor as follows: 1.Give a stop command to the drive. 2.Open the contactor. WARNING! When you have the default motor control mode (DTC) in use, never open the output contactor while the drive rotates the motor. The DTC motor control operates extremely fast, much faster than it takes for the contactor to open its contacts. When the contactor starts opening while the drive rotates the motor, the DTC will try to maintain the load current by im mediately increasing the drive output voltage to Planning the electrical installation 67 An example bypass con nection is shown below. WARNING! Never connect the supply power to the drive output terminals U2, V2 and W2. Line voltage applied to the output can result in permanent damage to the unit. Protecting the contacts of relay outputs Inductive loads (relays, contactors, motors ) cause voltage transients when switched off. The relay contacts on the JCU Control Unit are protected with varistors (250V) against overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads with noise attenuating circuits (varistors, RC filter s (AC) or diodes (DC)) in order to minimize the EMC emission at switch-off. If not suppressed, the disturbances may connect capacitively or inductively to other conducto rs in the control cable and form a risk of malfunction in other parts of the system. SwitchDescription S11Drive main contactor on/off control S40Motor power supply selection (drive or direct on line) S41Start when motor is connected on S42Stop when motor is connected direct on line 68 Planning the electrical installation Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs. WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non- conductive or conductive but not connected to the protective earth. To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital inputs of the drive can be implemented in three alternate ways: Considering the PELV on in stallation sites above 2000 WARNING! Do not use a voltage greater than 48 V for the relay outputs of the fulfilled if a relay output is used with a voltage greater than 48 V. 230 VAC 230 VAC Relay output RC filter Diode Relay output Relay output Planning the electrical installation 69 See page 70 Planning the electrical installation Electrical installation 71 Electrical installation What this chapter contains This chapter instructs in the cabling of the drive. Warnings WARNING! Only qualified electricians are allo wed to carry out the work described in this chapter. Follow the 72 Electrical installation „Motor and motor cableCheck the insulation of the motor and motor cable as follows: 1.Check that the motor cable is disconnected from the drive output terminals U2, V2 and W2. 2.Measure the insulation resistance between each phase conductor and the Protective Earth conductor using a measuring voltage of 500VDC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25°C or 77°F). For the insulation resistance of other motors, plea se consult the manufacturer’s instructions. Moisture inside the motor casing will reduce the insulation resistance. If moisture is suspected, dry the motor and repeat the measurement. Electrical installation 73 „Connection diagram 1.For alternatives, see section Selecting the supply di sconnecting device (d on page 2.If shielded cable is used (not required but recommend ed) and the conductivity of the shield is 50% of the conductivity of the phase conductor, use a se parate PE cable (2) or a cable with a grounding 3.as 2) OUTPUT V1W1 V2W2 UDC L1L2L3 (PE)(PE) ACQ810-04 5) 74 Electrical installation „Input cable connection procedureConnect the input cable phase conductors to the drive module terminals U1, V1 and W1 and the PE conductor to the PE terminal. Connect t he twisted shield of the input cable to the PE terminal even if it is not used as the PE conductor. The protective covering on top of the dr ive module prevents dust from borings and grindings from entering the module when installing. The covering is used because electrically conductive dust inside the unit may cause damage or malfunctioning. WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature. Electrical installation 75 „Motor cable connection procedure1.Connect the twisted shield of the motor cable to the grounding terminal with a cable 2.Connect the phase conductors to the cable lug terminals U2, V2 and W2. 360 degrees grounding 76 Electrical installation or by twisting the shield as follows: flattened width 1/5 · length. DCconnection r common DC configurations of a number of drives, allowing regenerative energy from on e drive to be utilized by the other drives in motoring mode. Contact your local ABB r epresentative for further instructions.