ABB ACS880-207 Hardware Manual
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ABB ACS880-207 Hardware Manual

Industrial drives, igbt supply units
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Summary of Contents for ABB ACS880-207

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-207 IGBT supply units Hardware manual...
  • Page 3 ACS880-207 IGBT supply units Hardware manual Table of contents 3. Electrical installation 5. Start-up 3AUA0000130644 Rev D Original instructions EFFECTIVE: 2020-12-22...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter ................Applicability ..................Safety instructions ................. Target audience ..................Categorization by frame size and option code ..........Use of component designations ..............Terms and abbreviations ................Related documents ................
  • Page 6 6 Table of contents Type designation labels ................Type designation label of the supply unit ........... Type designation labels of the supply module and LCL filter module ....Type designation keys ................Type designation key of the cabinet-installed IGBT supply unit ......Type designation key of the IGBT supply module ........
  • Page 7 Table of contents 7 6 Maintenance Contents of this chapter ................Maintenance intervals ................Maintenance timers and counters ............... Cabinet ....................Cleaning the interior of the cabinet ............Cleaning the door air inlets (IP22 and IP42) ..........Replacing the inlet door filters (IP54) ............Replacing the outlet (roof) filters (IP54) .............
  • Page 8 8 Table of contents Derating ..................Surrounding air temperature derating ............ Altitude derating ................Derating for output voltage boosting ............. Fuses ....................Main circuit AC fuses ................Main circuit DC fuses ................Fuses on CVAR board ................. LCL filters ................... Dimensions ..................

  • Page 9: Introduction To The Manual

    Contents of this chapter This chapter gives basic information on the manual. Applicability The manual is applicable to the cabinet-installed ACS880-207 IGBT supply units that form a part of an ACS880 multidrive system. Safety instructions Obey all safety instructions delivered with the drive.

  • Page 10: Categorization By Frame Size And Option Code

    The unit size can be identified from the basic code visible on the type designation label, for example, ACS880-207-0420A-3 where 0420A is the unit size. The option codes of the unit are listed after the plus sign. Section...

  • Page 11: Related Documents

    ACS880 multidrive cabinets and modules electrical planning instructions 3AUA0000102324 ACS880 multidrive cabinets mechanical installation instructions 3AUA0000101764 Supply unit manuals ACS880-207 IGBT supply units hardware manual 3AUA0000130644 ACS880 IGBT supply control program firmware manual 3AUA0000131562 ACS880 multidrives, Optimal grid control (option +N8053) supplement...
  • Page 12 Lifter for air-cooled drive modules user's guide 3AXD50000332588 Manuals for I/O extension modules, fieldbus adapters, safety options etc. You can find manuals on the Internet. See www.abb.com/drives/documents. For manuals not available in the document library, contact your local ABB representative.

  • Page 13: Operation Principle And Hardware Description

    Operation principle and hardware description 13 Operation principle and hardware description Contents of this chapter This chapter describes the operation basics and the hardware of the IGBT supply unit (ACS880-207).

  • Page 14: Operation Principle

    14 Operation principle and hardware description Operation principle IGBT supply unit rectifies three-phase AC current to direct current for the intermediate DC link of the drive. The intermediate DC link supplies the inverters that run the motors. There can be one inverter unit only (single drives) or several inverter units (multidrives) connected to the intermediate circuit.

  • Page 15: Overview Diagram Of The Drive

    Operation principle and hardware description 15 Overview diagram of the drive The following figure shows a single-line diagram of a drive with an IGBT supply unit. Auxiliary voltage transformer ([T21], option +G344) Auxiliary voltage switch [Q21] Main switch-disconnector ([Q1], option +F253) (standard, always with +F250) AC fuses [F1] Main contactor ([Q2], option +F250) (standard, always with +F253) Charging switch fuse [Q3]...

  • Page 16: Layout Drawing Of An Igbt Supply Unit 1×R8I (Limited Scope Version)

    16 Operation principle and hardware description Layout drawing of an IGBT supply unit 1×R8i (limited scope version) Limited scope means simplified version of a low power multidrive (400V and 500V) with less options and configurations. Includes only max 980A DSU, max 810A IGBT supply units and R1i-R7i inverter units.

  • Page 17: Overview Drawing Of A Drive

    Overview drawing of a drive Operation principle and hardware description 17 his drawing shows an example of a drive with an IGBT supply unit and an in Cables enter the cabinet through the bottom. Charging switch [Q3] Overview drawing of a drive This drawing shows an example of a drive with an IGBT supply unit and an inverter unit.

  • Page 18: Layout Drawings Of The Cubicles In The Supply Unit

    18 Operation principle and hardware description Layout drawings of the cubicles in the supply unit This section contains layout drawings of cubicles that are included in a supply unit: auxiliary control cubicle, incoming cubicle and supply module cubicle. The components, layout and size of the cubicles vary depending on the supply unit size and options.
  • Page 19 Operation principle and hardware description 19 Control unit (BCU) T130 24 V DC power supply for cabinet lighting (option +G301) Reserved space for customer-defined equipment At the backside of the assembly plate: Auxiliary voltage transformer (option +G344). Note: Connections are accessible from front. (Terminal block is at the lower part of cubicle.) T101 At the backside of the assembly plate: Auxiliary voltage transformer, IP54 roof fans...

  • Page 20: Layout Drawings Of Incoming Cubicles

    20 Operation principle and hardware description Layout drawings of incoming cubicles ￭ This section shows examples of the incoming cubicle layouts. The input power cables are connected to the incoming cubicle and it contains the main switching and disconnecting devices. The components, layout, size and appearance vary depending on the supply unit size and selected options.
  • Page 21 Operation principle and hardware description 21 Earthing/grounding switch handle ([Q9], option +F259) Auxiliary voltage switch handle Selector switch for V meter (option +G334) Grounding busbar [PE] Input power cable terminals [L1…L3] Main switch-disconnector [Q1] Grounding/earthing switch ([Q9], option +F259) Main AC fuses [F1…3] Main contactor ([Q2], option +F250) Auxiliary voltage switch [Q21] Cubicle cooling fan...

  • Page 22: Layout Drawing Of A 600 Mm Incoming Cubicle

    22 Operation principle and hardware description Layout drawing of a 600 mm incoming cubicle These layout drawings show a 600 mm wide incoming cubicle. Options used with this cubicle are bottom cable entry (options +H350 and +H367) and main switch-disconnector (option +F253).
  • Page 23 Operation principle and hardware description 23 Selector switch for V meter (option +G334) Grounding [PE] busbar Input power cable terminals [L1…L3] Main switch-disconnectors [Q1.1, Q1.2] Main AC fuses [F1.1…F2.3] Charging contactor [Q4] Auxiliary voltage switch [Q21] Cubicle cooling fans Charging switch handle Charging switch [Q3] Main contactor [Q2] Charging resistors...

  • Page 24: Layout Drawing Of A 1000 Mm Incoming Cubicle

    24 Operation principle and hardware description Layout drawing of a 1000 mm incoming cubicle These layout drawings show a 1000 mm wide incoming cubicle with cabling through the bottom (option +H350). Door closed Door open Auxiliary voltage switch handle Earthing/grounding switch handle ([Q9], option +F259) Charging switch handle Auxiliary voltage switch [Q21] Grounding [PE] busbar...

  • Page 25: Layout Drawing Of A Supply Module Cubicle 2×R8I

    Operation principle and hardware description 25 Layout drawing of a supply module cubicle 2×R8i ￭ These layout drawings show the supply module cubicle. The cubicle contains IGBT supply module(s) and LCL filter module(s). Door open Door closed Supply module LCL filter module DC fuses AC fuses Module cooling fan...

  • Page 26: Layout Drawings Of Supply And Lcl Filter Modules

    26 Operation principle and hardware description Layout drawings of supply and LCL filter modules IGBT supply module (frame R8i) ￭ This figure shows the layout of the R8i module. R8i module, front R8i module, back DC busbars Handle LEDs and fiber optic connectors Fan (standard speed-controlled fan shown;...

  • Page 27: Lcl Filter Module (Type Blcl-1X-X For Frame 1×R8I)

    Operation principle and hardware description 27 LCL filter module (type BLCL-1x-x for frame 1×R8i) ￭ LCL filter module, front LCL filter module, back Input (AC) connection Output (AC) connection Terminal block [X55] (power supply for module heating element, option +C183; direct-on-line fan supply, option +C188) (ready-connected) Handle Wheels...

  • Page 28: Lcl Filter Module (Type Blcl-2X-X For Frame R8I Multiples)

    28 Operation principle and hardware description LCL filter module (type BLCL-2x-x for frame R8i multiples) ￭ LCL filter module, front LCL filter module, back Input (AC) connection Output (AC) connection Terminal block [X55] (power supply for module heating element, option +C183; direct-on-line fan supply, option +C188) (ready-connected) Handle Wheels...

  • Page 29: Overview Of Power And Control Connections

    Operation principle and hardware description 29 Overview of power and control connections Input power connections of the IGBT supply unit are terminals L1, L2 and L3 located in the lower part of the incoming cubicle. Power cables enter the cabinet via lead-throughs on the floor of the cubicle as standard.

  • Page 30: Overview Of The Control Connections Of The Bcu Control Unit

    30 Operation principle and hardware description Overview of the control connections of the BCU control unit ￭ The diagram shows the control connections and interfaces of the BCU control unit. Analog and digital I/O extension modules and Control panel. fieldbus communication modules can be inserted into slots 1, 2 and 3.

  • Page 31: Supply Unit Control Devices

    Operation principle and hardware description 31 Supply unit control devices ￭ The following figure shows examples of the door control devices of the IGBT supply unit. The selection and exact location of control devices varies in different deliveries. The purpose of the devices is explained in the following sections.

  • Page 32: Door Switches And Devices For Frame R8I Cabinet

    32 Operation principle and hardware description Door switches and devices for frame R8i cabinet Auxiliary control cubicle Incoming cubicle Main switch-disconnector / breaker Auxiliary voltage switch Operating switch The ACS-AP-W control panel Emergency stop button E-stop reset button Electrical disconnect push button Ground/Earth fault indicator light (option +Q954).

  • Page 33: Main Switch-Disconnector / Main Circuit Breaker

    Operation principle and hardware description 33 Main switch-disconnector / main circuit breaker The supply unit is equipped with a main switch-disconnector ([Q1], option +F253) or a main circuit breaker in high powers ([Q1], option +F255) as standard. With this device, you can isolate the main circuit of the drive from the power line.

  • Page 34: Operating Switch

    34 Operation principle and hardware description Operating switch The operating switch [S21] is a standard device. By default, the operating switch controls the unit as follows: • The ENABLE/RUN position: The control program closes the charging contactor [Q4] and the main DC link is charged. After the DC link is charged, the main contactor [Q2] is closed and the charging contactor [Q4] opened.

  • Page 35: The Acs-Ap-W Control Panel

    Operation principle and hardware description 35 The ACS-AP-W control panel With the control panel, you can: • start and stop the supply unit • view and reset the fault and warning messages, and view the fault history • view actual signals •...

  • Page 36: Type Designation Labels

    36 Operation principle and hardware description Type designation labels Type designation label of the supply unit ￭ Each IGBT supply unit has a type designation label attached onto the inside of the cubicle door. The type designation label includes the ratings, appropriate markings, a type designation and a serial number of the unit.

  • Page 37: Type Designation Labels Of The Supply Module And Lcl Filter Module

    Operation principle and hardware description 37 Type designation labels of the supply module and LCL filter module ￭ Each IGBT supply module and LCL filter module has a type designation label attached to it. The type designation stated on the label contains information on the specifications and configuration of the unit.
  • Page 38 38 Operation principle and hardware description Description Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial number so that there are no two units with the same number.

  • Page 39: Type Designation Keys

    Operation principle and hardware description 39 Type designation keys Type designation key of the cabinet-installed IGBT supply unit ￭ Type designation describes the composition of the unit in short. The type designation is visible on the label (sticker) which is attached to the cabinet. The complete designation code is divided in subcodes: •...
  • Page 40 40 Operation principle and hardware description CODE DESCRIPTION C132 Marine type approval. Refer to ACS880 +C132 marine type-approved cabinet-built drives supplement (3AXD50000039629 [English]). C134 CSA-approved C164 100 mm plinth height C176 Door hinges on left-hand side C179 200 mm plinth height C180 Seismic design C186...
  • Page 41 Operation principle and hardware description 41 CODE DESCRIPTION 3G335 A-meter in three phases G336 Arc monitoring unit, 1 loop, Rea 101, including cable G337 Arc monitoring with current monitoring unit G343 Corrosion classification coupon in ACU (Purafil 3AUA64044052) G344 Auxiliary voltage transformer G426 Arc monitoring unit, extension for 2 loops, Rea 105, including cable G442...
  • Page 42 42 Operation principle and hardware description CODE DESCRIPTION K475 FENA-21 high performance EtherNet/IP, Modbus TCP and PROFINET adapter module K480 Ethernet switch for PC tool or control network (for max. 6 supply units) K483 Ethernet switch with optical link for PC tool or control network (for max. 6 supply units) K490 FEIP-21 Ethernet adapter module for EtherNet/IP K491...

  • Page 43: Type Designation Key Of The Igbt Supply Module

    Operation principle and hardware description 43 CODE DESCRIPTION R706 Finnish R707 French R708 Spanish R711 Russian R716 Hard copies of documentation R717 Second set of hard copies of documentation Type designation key of the IGBT supply module ￭ Type designation describes the composition of the module in short. The type designation is visible on the label (sticker) which is attached to the module.

  • Page 44: Type Designation Key Of The Filter Module

    BLCL-1x-x only: 115 V AC 1-phase fan supply G427 BLCL-2x-x only: 208 V AC 3-phase fan supply P922 Module to be installed in the ABB cabinet (included in the delivery as standard) V991 Hardware version. LCL filter modules with or without this code are interchangeable.

  • Page 45: Electrical Installation

    This chapter instructs how to check the insulation of the assembly and how to install the input power cables and control cables. The information is valid for cabinet-installed ACS880-207 supply units. For more information on cable selection, protections, etc., see Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324 [English]).

  • Page 46: Electrical Safety Precautions

    46 Electrical installation Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.

  • Page 47: General Notes

    Electrical installation 47 5. Measure that the installation is de-energized. If the measurement requires removal or disassembly of shrouding or other cabinet structures, obey the local laws and regulations applicable to live working (including – but not limited to – electric shock and arc protection).

  • Page 48: Checking The Insulation Of The Assembly

    Drives with a category 2, 1st environment EMC filter (option +E202) are not suitable for use in an IT (ungrounded) supply network system. If the drive is equipped with option +E202, disconnect the filter before connecting the drive to the IT supply network. Contact ABB for instructions.

  • Page 49: Connection Diagram (Frame R8I And Multiples)

    Electrical installation 49 Note: Fuses or other protection means. Use a separate grounding PE cable or a cable with a separate PE conductor if the conductivity of the shield does not meet the requirements for the PE conductor. See Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324 [English]).
  • Page 50 50 Electrical installation WARNING! With aluminum cables, apply grease to stripped conductors before attaching them to non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions. Aluminum-aluminum contact can cause oxidation of the contact surfaces. 1. Disconnect the drive from the AC power line and make sure it is safe to start the work. See section Electrical safety precautions (page 46) 2.
  • Page 51 Electrical installation 51 Recommendation: 360 degrees grounding of the cable shield at the lead-through suppresses interference.

  • Page 52: Connection Procedure (Frame R8I And Multiples)

    7. Fasten the conductive sleeves to the cable shields with cable ties. 8. Seal the slot between the cable and mineral wool sheet (if used) with sealing compound (eg, CSD-F, ABB brand name DXXT-11, code 35080082). 9. Tie up the unused conductive sleeves with cable ties.
  • Page 53 Electrical installation 53...
  • Page 54 54 Electrical installation...

  • Page 55: Checking The Settings Of Transformers T21, T101 And T111

    Electrical installation 55 Checking the settings of transformers T21, T101 and T111 Auxiliary voltage transformer [T21, T101, T111] connections are made at the factory according to the supply voltage and desired output voltage and you do not need to change the settings during the installation.

  • Page 56: T21 And T101 Tap Settings (690 V Units)

    56 Electrical installation T21 and T101 tap settings (690 V units) ￭ T21_X1 or T101_X1 T21_X2 or T101_X2 llation without +G304 with +G304 ettings T111 tap settings ￭ 3~ input 3~ output 3~ input 3~ output...

  • Page 57: Checking The Settings Of The Cooling Fan Transformer

    Electrical installation 57 3~ input 3~ output Tap settings Terminals Supply Terminals 400 V 320/340 V voltage A1– B1– C1– (50 Hz) (60 Hz) 690 V A1, B1, C1 a1, b1, c1 a2, b2, c2 660 V A1, B1, C1 a1, b1, c1 a2, b2, c2 600 V...
  • Page 58 58 Electrical installation 5. Run the cables to the appropriate terminals. Wherever possible: • Use the existing cable trunking in the cabinet. • Use sleeving wherever the cables are laid against sharp edges. • Tie the cables to provide strain relief. •...

  • Page 59: Connection Procedure (Frame R8I And Multiples)

    Electrical installation 59 The detailed figure of step 4 has been rotated 180 degrees. Connection procedure (frame R8i and multiples) ￭ See the chapter on control units for the default I/O connections. Note that the default I/O connections can be affected by some options. See the circuit diagrams delivered with the drive for the actual wiring.

  • Page 60: Control Cable Connection Procedure

    60 Electrical installation Control cable connection procedure WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.
  • Page 61 Electrical installation 61 • Cut the shield at the midpoint of the bare part. Be careful not to cut the conductors or the grounding wire (if present). • Turn the shield inside out to expose its conductive surface. • Cover the turned shield and the stripped cable with copper foil to keep the shielding continuous.
  • Page 62 Electrical installation 99 62 Electrical installation 5. Arrange the bunches according to size from thickest to the thinnest between the EMI 5. Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions. conductive cushions. 6.

  • Page 63: Wiring The Functional Safety Options +Q951, +Q952, +Q963, +Q964 Or +Q979

    Electrical installation 63 Notes: • Do not ground the outer shield of the cable here since it is grounded at the cable entry. • Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling. At the other end of the cable, leave the shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg.

  • Page 64: Connecting A Pc

    64 Electrical installation Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. A PC (with eg, the Drive composer PC tool) can be connected as follows: 1.

  • Page 65: Installation Checklist

    Installation checklist 65 Installation checklist Installation checklist 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 66 66 Installation checklist Make sure that … The cooling air flows freely in and out of the drive. If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground- to-phase varistor).

  • Page 67: Start-Up

    Start-up Contents of this chapter This chapter describes the start-up procedure of the ACS880-207 IGBT supply units. The underlined tasks are needed for certain cases only. The option codes (if any) are given in brackets. The default device designations (if any) are given in square brackets. For example: Supply unit with the grounding switch ([Q9], option +F259).

  • Page 68: Start-Up Procedure

    68 Start-up Start-up procedure Tasks Safety WARNING! Follow the safety instructions during the start-up procedure. See Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). Only qualified electricians are allowed to start-up the drive. Checks/Settings with no voltage connected Make sure that the disconnector of the supply transformer is locked to the off (0) position, that means no voltage is, or cannot be connected to drive inadvertently.
  • Page 69 Start-up 69 Tasks Powering up the auxiliary circuit of the supply unit Make sure that it is safe to connect voltage. Make sure that: •nobody is working on the unit or circuits that are wired from outside into the cabinets •covers of the motor terminal boxes are on.

  • Page 70: Electromagnetic Interlocking

    70 Start-up Tasks Turn the operating switch [S21] to on (1) position to activate the Run enable signal of the supply unit. WARNING! Never use the green (I) push button of the main breaker ([Q1], option +F255) for closing. If the button is not disabled, it closes the main breaker immediately without the drive DC link charging sequence.

  • Page 71: Disconnecting And Temporary Grounding The Drive (Including The Input Power Terminals)

    Start-up 71 4. Supply unit with the grounding switch ([Q9], option +F259): Switch the grounding switch WARNING! Do not use excessive force. There is electromagnetic interlocking in use. See section Electromagnetic interlocking (page 70). 5. Switch off the auxiliary voltage by turning the auxiliary voltage switch [Q21] to the off position.

  • Page 72: Powering-Up The Supply Unit / Drive

    72 Start-up 1. Close the cabinet doors, if not yet closed. 2. Make sure that it is safe to connect voltage. Ensure that: • nobody is working on the unit or circuits that are wired from outside into the cabinets, •...

  • Page 73: Maintenance

    Contents of this chapter This chapter instructs how to maintain the IGBT supply unit and how to interpret its fault indications. The information is valid for cabinet-installed ACS880-207 IGBT supply units. WARNING! Only qualified electricians are allowed to do the work described in this chapter.
  • Page 74 Cleaning IP22 and IP42 air inlet and outlet meshes Checking tightness of cable and busbar terminals. Tightening if needed. Checking ambient conditions (dustiness, corrosion, temperat- ure) Cleaning the heatsink of the sup- ply module Other ABB-SACE main circuit breaker maintenance...

  • Page 75: Maintenance Timers And Counters

    Replacement Note: • 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. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 76: Cleaning The Door Air Inlets (Ip22 And Ip42)

    76 Maintenance 1. Stop the drive and do the steps in section Electrical safety precautions (page 46) before you start the work. 2. Open the cabinet door. 3. Clean the interior of the cabinet. Use a vacuum cleaner and a soft brush. 4.

  • Page 77: Replacing The Inlet Door Filters (Ip54)

    Maintenance 77 Replacing the inlet door filters (IP54) ￭ 1. Stop the drive and do the steps in section Electrical safety precautions (page 46) before you start the work. 2. Remove the fasteners at the top of the grating. 3. Lift the grating and pull it away from the door. 4.

  • Page 78: Power Connections And Quick Connectors

    See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

  • Page 79: Replacing R8I Module Cooling Fan (Speed-Controlled Version)

    Maintenance 79 Replacing R8i module cooling fan (speed-controlled version) ￭ The module is equipped with a fan unit that contains two cooling fans. WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 80: Replacing R8I Module Cooling Fan (Direct-On-Line Version)

    80 Maintenance Replacing R8i module cooling fan (direct-on-line version) ￭ WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
  • Page 81 Maintenance 81...

  • Page 82: Replacing The Circuit Board Compartment Fan

    82 Maintenance Replacing the circuit board compartment fan ￭ Frame R8i modules are equipped with a fan blowing air through the circuit board compartment. The fan is accessible from the front of the module. WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]).
  • Page 83 Maintenance 83 7. Remove the fan from the fan holder. 8. Put the fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder. 9. Install and tighten the four nuts removed earlier. 10.

  • Page 84: Replacing The Fan Of The Lcl Filter (Blcl-1X-X)

    84 Maintenance Replacing the fan of the LCL filter (BLCL-1x-x) ￭ WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 85: Replacing The Fan Of The Lcl Filter (Blcl-2X-X)

    Maintenance 85 Replacing the fan of the LCL filter (BLCL-2x-x) ￭ WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 86: Replacing The Cooling Fan In The Incoming Cubicle

    86 Maintenance Replacing the cooling fan in the incoming cubicle ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 46) before you start the work.

  • Page 87: Replacing The Roof Fan For Ip54 Cabinet (Option +B055)

    Maintenance 87 Replacing the roof fan for IP54 cabinet (option +B055) ￭ WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 88: Igbt Supply Module

    88 Maintenance Different fan models IGBT supply module Reduced run ￭ A “reduced run” function is available for supply/rectifier units consisting of parallel-connected modules. The function makes it possible to continue operation with limited current even if one (or more) module is out of service, for example, because of maintenance work. In principle, reduced run is possible with only one module, but the physical requirements of operating the motor still apply;...

  • Page 89: Starting Reduced Run Operation

    2. If the control unit is powered from the faulty module, connect the control unit to another 24 V DC power supply. ABB strongly recommends using an external power supply with supply/rectifier units consisting of parallel-connected modules.

  • Page 90: Replacing The Igbt Supply Module (Limited Scope Version)

    90 Maintenance Replacing the IGBT supply module (limited scope version) ￭ WARNING! Only qualified electricians are allowed to this work. Read the complete safety instructions of the drive. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
  • Page 91 • Do not use the module pull-out ramp with plinth heights of over 50 mm.The ramp supplied with the drive system is designed for a plinth height of 50 mm (the standard plinth height of ABB cabinets). Do not leave the module Do not tilt! max.
  • Page 92 Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). 1. Disconnect the drive from the AC power line and make sure it is safe to start the work.
  • Page 93 Maintenance 93 11. Replace the module: install the module in reverse order. Mind you fingers. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. Note: Be careful not to break the fastening screws: tighten the fastening screws of the module to 22 N·m (16.2 lbf·ft) and fastening bolts of the DC output busbars to 70 N·m (51.6 lbf·ft) •...
  • Page 94 94 Maintenance...

  • Page 95: Replacing The Igbt Supply Module (Frame R8I And Multiples)

    Maintenance 95 Replacing the IGBT supply module (frame R8i and multiples) ￭ WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
  • Page 96 96 Maintenance WARNING! If you ignore the following instructions, injury or death, or damage to the equipment can occur. • Do not use the module extraction/installation ramp with plinth heights which exceeds the maximum allowed height. • Secure the module extraction/installation ramp carefully. •...
  • Page 97 • Wear protective gloves and long sleeves! Some parts have sharp edges. Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]).
  • Page 98 98 Maintenance 11. Replace the module: install the module in reverse order. Mind you fingers. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. Note: Be careful not to break the fastening screws: tighten the fastening screws of the module to 22 N·m (16.2 lbf·ft) and fastening bolts of the DC output busbars to 70 N·m (51.6 lbf·ft).
  • Page 99 Maintenance 99...
  • Page 100 100 Maintenance...

  • Page 101: Lcl Filter

    ABB cabinets). Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). 1. Disconnect the drive from the AC power line and make sure it is safe to start the work.
  • Page 102 102 Maintenance 10. Replace the module: install the module in reverse order. Mind you fingers. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. Note: Be careful not to break the fastening screws: tighten the fastening screws of the module to 22 N·m (16.2 lbf·ft) and fastening bolts of the DC output busbars to 70 N·m (51.6 lbf·ft).
  • Page 103 Maintenance 103...

  • Page 104: Replacing The Lcl Filter (Frame R8I And Multiples)

    104 Maintenance Replacing the LCL filter (frame R8i and multiples) ￭ Refer to the drawings below. WARNING! Obey the safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 105 Maintenance 105 WARNING! • Do not use the module extraction/installation ramp with plinth heights which exceeds the maximum allowed height. • Secure the module extraction/installation ramp carefully. • Push the module into the cabinet and pull it from the cabinet carefully preferably with help from another person.
  • Page 106 106 Maintenance Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). 1. Stop the drive (if running) and do the steps in section...
  • Page 107 Maintenance 107...

  • Page 108: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. Reforming the capacitors ￭...

  • Page 109: Fuses

    Maintenance 109 Fuses Checking and replacing the DC fuses (limited scope version) ￭ WARNING! Only qualified electricians are allowed to this work. Read the complete safety instructions of the drive. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1.

  • Page 110: Checking And Replacing The Ac Fuses (Limited Scope Version)

    110 Maintenance Checking and replacing the AC fuses (limited scope version) ￭ WARNING! Only qualified electricians are allowed to this work. Read the complete safety instructions of the drive. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1.

  • Page 111: Checking And Replacing The Dc Fuses (Frame R8I And Multiples)

    Maintenance 111 Checking and replacing the DC fuses (frame R8i and multiples) ￭ WARNING! Only qualified electricians are allowed to this work. Read the complete safety instructions of the drive. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1.

  • Page 112: Checking And Replacing The Ac Fuses (Frame R8I And Multiples)

    112 Maintenance 4. DC fuses (a) are located on top of the IGBT supply module. Check the condition of the fuses. In case of a blown fuse, replace all fuses with similar fuses: slacken the nuts of the fuses and pull the fuses out. Do not unscrew the nuts completely, not to drop them inside the module below.

  • Page 113: Control Panel

    Maintenance 113 Control panel For detailed information on the control panel, see ACx-AP-x assistant control panels user’s manual (3AUA0000085685 [English]). Cleaning the control panel ￭ Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could scratch the display window.

  • Page 114: Memory Unit

    114 Maintenance 1. Turn the lid on the back of the control panel counter-clockwise until the lid opens. 2. Remove the battery gently. 3. Replace the battery with a new CR2032 battery. The battery holder has grip nails. First slide the battery and then press on the other side. The battery will snap in. 4.

  • Page 115: Leds And Other Status Indicators

    Maintenance 115 LEDs and other status indicators Warnings and faults reported by the control program are displayed on the control panel on the cabinet door. For further information, see the firmware manual. Control panel and panel platform/holder LEDs ￭ The ACS-AP-… control panel has a status LED. The control panel mounting platform or holder has two status LEDs.
  • Page 116 Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information.

  • Page 117: Technical Data

    Technical data 117 Technical data Contents of this chapter This chapter contains the technical data valid for the cabinet-installed ACS880-207 IGBT supply units.

  • Page 118: Ratings

    118 Technical data Ratings Light-overload Consists No-overload use Heavy-duty use of module ACS880- type Frame 207-… ACS880- 104-… A (DC) A (AC) A (DC) A (DC) A (DC) (DC) (DC) = 400 V (with U1 = 3~400 V AC and U2 = 566 V DC) 0420A-3 0470A-3 0580A-3...
  • Page 119 Technical data 119 Nominal output power Nominal apparent power Light-overload use (10% overload capability) ratings Continuous rms current. 10% overload is allowed for one minute every 5 minutes. Output power in light-overload use Heavy-duty use (50% overload capability) ratings Continuous rms current. 50% overload is allowed for one minute every 5 minutes. Output power in heavy-duty use Note: The ratings apply at an ambient temperature of 40 °C (104 °F).

  • Page 120: Derating

    1 percentage point for every added 100 m (328 ft). For example, the derating factor for 1500 m (4921 ft) is 0.95. For altitudes above 2000 m (6562 ft), contact ABB. If surrounding air temperature is below +40 °C, the derating can be reduced by 1.5 percentage points for every 1 °C reduction in temperature.

  • Page 121: Derating For Output Voltage Boosting

    Note: The drive voltage rating must always be selected according to the boosted voltage value. Note: Auxiliary voltage transformer must be set according to supply voltage levels. If drive selection based on boosted voltage level causes unsuitable tap setting to auxiliary voltage transformer, consult your local ABB representative.

  • Page 122: Fuses

    122 Technical data Fuses Main circuit AC fuses ￭ Unit type Rating Type Example ACS880-207-… = 400 V (Range 380 … 415 V) 0420A-3 630 A, 690 V, size 3 Flush end type 170M6410 0580A-3 1000 A, 690 V, size 3...

  • Page 123: Main Circuit Dc Fuses

    Technical data 123 Main circuit DC fuses ￭ Unit type Rating Type Example ACS880-207-… = 400 V (Range 380 … 415 V) 0420A-3 900 A, 690 V, size 3 Flush end contact 170M6413 0580A-3 1100 A, 690 V, size 3...

  • Page 124: Lcl Filters

    124 Technical data LCL filters Unit type Frame LCL filter type ACS880-207-… = 400 V (Range 380 … 415 V) 0420A-3 ACS880-BLCL-13-5+C183+C188+P922+V991 0580A-3 ACS880-BLCL-13-5+C183+C188+P922+V991 0810A-3 ACS880-BLCL-15-5+C183+C188+P922+V991 1130A-3 2×R8i ACS880-BLCL-24-5+C183+C188+P922+V991 1330A-3 2×R8i ACS880-BLCL-24-5+C183+C188+P922+V991 1580A-3 2×R8i ACS880-BLCL-25-5+C183+C188+P922+V991 2350A-3 3×R8i 2×ACS880-BLCL-24-5+C183+C188+P922+V991 3110A-3 4×R8i 2×ACS880-BLCL-25-5+C183+C188+P922+V991...

  • Page 125: Dimensions

    Technical data 125 Dimensions Unit type Height 1 Height 2 Width 1 Width 2 Depth 1 Depth 2 ACS880- 207-… = 400 V (Range 380 … 415 V) 0420A-3 2145 84.5 2315 91.1 1000 39.4 1600 63.0 29.8 0580A-3 2145 84.5 2315 91.1...

  • Page 126: Free Space Requirements

    126 Technical data Free space requirements Unit type Above Front Left Right ACS880- 207-… = 400 V (Range 380 … 415 V) 0420A-3 15.7 27.6 0580A-3 15.7 27.6 0810A-3 15.7 27.6 1130A-3 15.7 27.6 1330A-3 15.7 27.6 1580A-3 15.7 27.6 2350A-3 15.7 27.6...
  • Page 127 Technical data 127 Unit type Above Front Left Right ACS880- 207-… Includes the door switches. Does not include the space needed for the door opening. Measured from the base plate of the cabinet top. Note: 320 mm (12.28 in) is required for fan replacement of IP54 cabinets.

  • Page 128: Losses, Cooling Data And Noise

    128 Technical data Losses, cooling data and noise Unit type Air flow Noise Efficiency lossISU lossLCL lossTOTAL ACS880- /min 207-… = 400 V (Range 380 … 415 V) 0420A-3 2200 1295 97.8 0580A-3 2200 1295 97.7 0810A-3 13.3 2200 1295 97.7 1130A-3 12.2...

  • Page 129: Terminal And Cable Entry Data For The Input Power Cable

    Technical data 129 Terminal and cable entry data for the input power cable 600 mm incoming cubicle – main circuit breaker (+F255), top cable ￭ entry The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type. See the technical data. Front Side...

  • Page 130: 1000 Mm Incoming Cubicle - Main Circuit Breaker (+F255), Top Cable Entry

    130 Technical data 1000 mm incoming cubicle – main circuit breaker (+F255), top cable ￭ entry The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type. See the technical data. Side Front...

  • Page 131: Tightening Torques

    Technical data 131 Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Electrical connections ￭ Size Torque Strength class 0.5 N·m (4.4 lbf·in) 4.6...8.8 1 N·m (9 lbf·in) 4.6...8.8 4 N·m (35 lbf·in) 9 N·m (6.6 lbf·ft) 22 N·m (16 lbf·ft) 42 N·m (31 lbf·ft)

  • Page 132: Electrical Power Network Specification

    50/60 Hz, variation ± 5% of nominal frequency Imbalance Max. ± 3% of nominal phase-to-phase input voltage Short-circuit withstand Supply units with the ABB-defined main switch-disconnector and fuses: strength (IEC/EN 61439-1) •Rated peak withstand current I = 105 kA •Rated short-time withstand current I...

  • Page 133: Typical Power Cable Sizes

    Technical data 133 Typical power cable sizes The tables below give current carrying capacity (I ) for aluminum and copper PVC/XLPE Lmax insulated cables. A correction factor K = 0.70 is used. Time const is the temperature time constant of the cable. The cable sizing is based on max.
  • Page 134 134 Technical data Copper cable PVC insulation XLPE insulation Conductor temperature 70 °C Conductor temperature 90 °C Size ⌀ [mm] Time const. [s] Time const. [s] Lmax Lmax 3 × 1.5 + 1.5 3 × 2.5 + 2.5 (3 × 4 + 4) 3 ×...

  • Page 135: Protection Classes

    • Maximum long-term tensile load: 1 N (3.6 ozf) • Flexing: Max. 1000 cycles ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components from Avago Technologies’ Versatile Link range. Note that the optical component type is not directly related to the actual communication speed.
  • Page 136 136 Technical data Operation Storage Transportation installed for stationary in the protective package in the protective package Installation site altitude 0…4000 m (0…13123 ft)* Output derated above 1000 m (3281 ft). *Neutral-grounded TN and TT network systems, non- corner-grounded IT net- work systems.

  • Page 137: 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 138: Disclaimers

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized...

  • Page 139: The Control Unit

    The control unit 139 The control unit Contents of this chapter This chapter • describes the connections of the control unit • contains the specifications of the inputs and outputs of the control unit. General The BCU-x2 control unit is used with frame size R8i and multiples. The BCU-x2 consists of a BCON-12 control board (and a BIOC-01 I/O connector board and power supply board) built in a metal housing.

  • Page 140: Bcu-X2 Layout

    140 The control unit BCU-x2 layout Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface, fieldbus...
  • Page 141 The control unit 141 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XD24 +24 V output (for digital inputs) XDIO XETH Ethernet port – Not in use XPOW External power input XRO1...

  • Page 142: Default I/O Diagram Of The Supply Control Unit

    142 The control unit Default I/O diagram of the supply control unit The diagram below shows the default I/O connections on the supply control unit (A51), and describes the use of the connections in the supply unit. Under normal circumstances, the factory-made wiring should not be changed.

  • Page 143: External Power Supply For The Control Unit (Xpow)

    The BCU-x2 has an on-board data logger that collects real-time data from the power modules to help fault tracing and analysis. The data is stored onto the SDHC memory card inserted into the SD CARD slot and can be analyzed by ABB service personnel.

  • Page 144: Connector Data

    144 The control unit Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 2.5 mm 24 V (±10%) DC, 2 A External power input. Two supplies can be connected for redundancy. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3) 250 V AC / 30 V DC, 2 A Protected by varistors...
  • Page 145 The control unit 145 Analog outputs AO1 and AO2 (XAO) Connector pitch 5 mm, wire size 2.5 mm 0…20 mA, R < 500 ohm load Frequency range: 0…500 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range XD2D connector Connector pitch 5 mm, wire size 2.5 mm Physical layer: RS-485...

  • Page 146: Bcu-X2 Ground Isolation Diagram

    146 The control unit BCU-x2 ground isolation diagram ￭ XPOW +24VI +24VI +VREF -VREF AGND AI1+ AI1- AI2+ AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO SGND XSTO OUT SGND SGND...

  • Page 147: 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 148 3AUA0000130644D © Copyright 2020 ABB. All rights reserved. Specifications subject to change without notice.

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