ABB ACS880-1607LC Hardware Manual Download Page 31

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Mechanical installation

Contents of this chapter

This chapter describes the mechanical installation of the converter units.

DC/DC converter units

For checking the installation site, moving the unit and installing cabinets, see

ACS800

liquid-cooled multidrive mechanical installation

(3AFE68715466 [English]).

Energy storage

Obey the energy storage manufacturer's instructions.

Internal cooling system

See chapter

Internal cooling circuit

Mechanical installation 31

Summary of Contents for ACS880-1607LC

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 1607LC DC DC converter units Hardware manual ...

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Page 3: ...80 1607LC DC DC converter units Hardware manual Table of contents 3 Mechanical installation 5 Electrical installation 8 Start up 2019 ABB Oy All Rights Reserved 3AXD50000431342 Rev A EN EFFECTIVE 2019 06 28 ...

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Page 5: ...dule 21 Overheating protection of the filter 22 Overview of the control connections of the BCU control unit 22 Converter unit control devices 23 DC switch disconnector 23 Charging switch 23 Door lights 24 ACX AP x control panel 24 PC connection 24 Fieldbus control 25 Type designation labels 25 Type designation label of the DC DC converter unit 25 Type designation labels of the DC DC converter modu...

Page 6: ...n 39 Contents of this chapter 39 Safety 39 Electrical safety precautions 41 General notes 41 Printed circuit boards 41 Optical components 42 Checking the insulation of the energy storage cable 43 Connecting the control cables for the converter unit 43 Default I O connection diagram 43 Connecting the control cables 43 Control cable connection procedure 47 Connecting the energy storage cable and loa...

Page 7: ... converter module 74 Removing the module 76 Reinstalling the module 76 Capacitors 76 Reforming the capacitors 76 Control panel 76 Cleaning the control panel 76 Replacing the control panel battery 77 Control unit 77 BCU control unit types 77 Replacing the memory unit 77 Replacing the BCU control unit battery 78 LEDs and other status indicators 10 Internal cooling circuit 81 Contents of this chapter...

Page 8: ...ing torques 95 Electrical connections 95 Mechanical connections 95 Insulation supports 96 Cable lugs 96 Input power DC bus connection 96 Output power energy storage connection 96 Control accuracy Current and voltage control performance data 96 Coolant connections 97 Optical components 97 Protection classes 97 Ambient conditions 99 Materials 99 Applicable standards 99 Markings 100 Disclaimers 100 G...

Page 9: ...ead the software function specific warnings and notes before changing the default settings of a function For each function the warnings and notes are given in the section describing the related user adjustable parameters Read the task specific safety instructions before starting the task See the section describing the task Target audience This manual is intended for people who plan the installatio...

Page 10: ...ard built in a housing often rail mountable Control unit One section of a cabinet installed drive A cubicle is typically behind a door of its own Cubicle Charges or discharges an external energy storage such as a battery or capacitor bank from or into the DC bus DC DC converter Converter power electronics related components and DC capacitors enclosed in a metal frame or enclosure Intended for cabi...

Page 11: ...al 3AUA0000085967 ACS880 primary control program firmware manual 3AUA0000098062 ACS880 primary control program quick start up guide Manuals for application programs Crane Winder etc Brake unit and DC DC converter unit manuals 3AXD50000481491 ACS880 607LC 1 phase brake units hardware manual 3AXD50000020967 ACS880 3 phase brake control program firmware manual 3AXD50000431342 ACS880 1607LC DC DC conv...

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Page 13: ...les under the command of one control unit Parallel DC DC converter modules must have a common energy storage Each parallel module must have the output cabling of its own We also recommend that you use identical cablings cable type cross sectional area and length and have identical load for each module For other solutions contact ABB Typically the DC DC converter is used in marine applications for ...

Page 14: ...rging circuit _ U2 V2 W2 U2 V2 W2 ES 1 ES ES ES 2 ES 3 L L 1 2 3 4 Drive DC bus 1 DC DC converter module 2 Filter module 3 Energy storage 4 This figure shows a simplified main circuit diagram of a DC DC converter with the DC switch disconnector and charging circuit L L _ U2 V2 W2 U2 V2 W2 ES 1 ES ES ES 2 ES 3 1 2 3 4 5 6 Drive DC bus 1 DC switch disconnector 2 DC DC converter module 3 Filter modul...

Page 15: ...ipment are visible 1 2 3 4 5 6 7 8 8 9 10 11 7 6 4 3 5 DC DC converter cubicles 1 Energy storage cabinet 2 Drive DC bus 3 DC switch disconnector 4 Charging components 5 DC DC converter module 6 Filter module 7 Cabling between DC DC converter unit and energy storage 8 Energy storage disconnecting device 9 Energy storage protective circuit breaker 10 Energy storage 11 Operation principle and hardwar...

Page 16: ... 3 6 6 4 5 8 9 10 11 7 AC supply 1 Input AC fuses 2 Supply module 3 DC bus 4 Inverter DC fuses with or without a DC switch disconnector 5 Inverter modules 6 Motors 7 DC fuses DC bus side with or without a DC switch disconnector 8 DC DC converter unit converter and filter module 9 Output DC fuses 10 Customer defined energy storage with disconnecting and protection devices 11 16 Operation principle ...

Page 17: ...how the components of the converter unit cubicle with door closed and with door open and shrouds removed In this figure the DC DC converter unit cubicle has the DC switch disconnector and charging circuit 1 2 19 20 18 21 8 7 6 4 5 13 12 14 11 9 10 15 3 3 17 17 16 With DC switch disconnector and charging Door closed Door open R8i DC DC converter module T11 1 1 BDCL filter module R13 1 2 Module cool...

Page 18: ...P13 x X33 1 11 Coolant IN 12 Coolant OUT back Auxiliary measurement unit 13 Auxiliary measurement unit fuses 14 Inlet manifold with stop and drain valves 15 Outlet manifold with stop and drain valves 16 Heat exchanger 17 Door lights Charging OK P11 x green DC DC converter disconnected P12 x white Load disconnected P13 x white P11 1 P13 1 18 DC switch disconnector handle Q11 1 19 Charging switch ha...

Page 19: ... filter module R13 1 2 Module cooling fans 3 Cable entries for energy storage cables 4 Energy storage connection ES ES 5 Control unit A41 6 Output DC fuses F13 xx 7 DC fuses DC bus side F11 xx 8 Auxiliary measurement unit 9 Auxiliary measurement unit fuses 10 Connection from the energy storage disconnecting device to the load disconnected indic ator P13 x X33 1 11 Coolant IN 12 Coolant OUT back Op...

Page 20: ... 3 Handle 4 Fiber optic connectors 5 Quick connector AC connection the counterpart fastened to the cabinet behind the module 6 Terminal block X50 auxiliary power input for internal boards 7 Terminal block X51 and X52 Safe torque off in inverter modules only 8 Terminal block X53 24 V DC power output 9 Auxiliary voltage selector 115 or 230 V 10 Unpainted fastening hole The grounding point PE between...

Page 21: ... Quick connector 6 Converter module connection 7 Overheating protection of the filter By default the BDCL filter is protected against overheating caused by a faulty fan for example with a thermistor and the temperature monitoring function of the control program If the filter temperature becomes too high the temperature monitoring function stops the DC DC converter module automatically Operation pr...

Page 22: ...ted into slots 1 2 and 3 1 2 3 Fiber optic links to power modules inverter supply brake or converter 8 Memory unit 4 Ethernet port Not in use 9 Slot 4 for RDCO 0x 5 Safety option interface Only in use for the invert er units 10 Terminal blocks 6 Converter unit control devices The figure shows an example of the door control devices of the DC DC converter The selection and exact location of control ...

Page 23: ...e converter modules must be charged through a charging circuit Charging switch A converter unit with a DC switch disconnector Q11 option F286 also has a charging circuit and a charging switch Q10 on the cubicle door Before closing the DC switch disconnector close the charging switch After the precharging is finished the Charging OK indicator P11 green on the cabinet door illuminates and you can cl...

Page 24: ...ontrol panel For the instructions on the use of the panel see ACX AP x Assistant control panels user s manual 3AUA0000085685 English For the parameter settings see the firmware manual PC connection There is an USB connector on the front of the panel that can be used to connect a PC to the converter When a PC is connected to the control panel the control panel keypad is disabled Fieldbus control Yo...

Page 25: ...al planning instructions for ACS880 multidrives cabinets and modules 3AUA0000102324 English 6 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 7 Type designation labels of the DC DC ...

Page 26: ...0 multidrives cabinets and modules 3AUA0000102324 English 6 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 7 26 Operation principle and hardware description ...

Page 27: ...he fields in the basic code are separated by hyphens The plus codes follow the basic code Each plus code starts with an identifying letter common for the whole product series followed by descriptive digits The plus codes are separated by plus signs DESCRIPTION CODE Basic codes Product series ACS880 Construction cabinet installed liquid cooled DC DC converter unit When no options are se lected Supp...

Page 28: ...ded TN and ungrounded IT networks E210 DC switch F286 Cabinet heater G300 Cabinet lighting G301 115 V AC control voltage G304 DC busbar material tin plated copper G315 230 V AC control voltage G320 Halogen free wiring G330 Wire marking class A1 G338 Wire marking class A2 G339 Wire marking class A3 G340 Wire marking class B1 G341 Wire marking class C1 G342 Voltage measurement with BAMU G442 Bottom ...

Page 29: ...an RAL colors P966 Emergency Stop category 0 with opening main contactor breaker Q951 Emergency Stop category 1 with opening main contactor breaker Q952 Emergency Stop category 0 without opening main contactor breaker Q963 Emergency Stop category 1 without opening main contactor breaker Q964 Emergency Stop category configurable 0 or 1 with STO Q979 English manuals R700 German manuals1 R701 Italian...

Page 30: ...ltage range DC voltage corresponding AC input voltages 3 525 690 V This is indicated in the type designation label as typical input voltage level 742 849 976 V DC 7 Option codes plus codes Internal du dt filtering Standard with 690 V modules E205 Type designation key of the filter module The designation code of the BDCL filter is divided in subcodes The first 4 letters and two numbers give the typ...

Page 31: ...converter units For checking the installation site moving the unit and installing cabinets see ACS800 liquid cooled multidrive mechanical installation 3AFE68715466 English Energy storage Obey the energy storage manufacturer s instructions Internal cooling system See chapter Internal cooling circuit 3 Mechanical installation 31 10 ...

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Page 33: ...ity whatsoever 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 Generic guidelines See Electrical planning instructions for ACS880 liquid cooled multidrive cabinets and modules 3AXD50000048634 English for the generic guidelines for planning ...

Page 34: ...UDC 1 35 UAC with IGBT supply units with modules ACS880 204 UDC 1 41 UAC can be changed with supply unit parameter group 123 DC volt ref where UDC Drive DC voltage in the DC bus UAC Drive input voltage AC We recommend to measure the energy storage voltage If the energy storage is a super capacitor voltage measurement is obligatory unless the capacitor withstands the maximum DC voltage of the drive...

Page 35: ...ng to the converter unit delivery The customer or the system integrator must verify the operation of the circuit breaker by short circuit calculations taking into account impedances of the converter filter cabling and energy storage and minimum and maximum state of charge of the energy storage The customer or the system integrator must take into account the impact of ageing to storage impedances E...

Page 36: ...al cable sizes See the technical data Minimizing electromagnetic interference The customer or the system integrator must obey these rules in order to minimize the electromagnetic interference caused by rapid current changes in the energy storage cables Shield the energy storage cabling completely either by using shielded cable or a metallic enclosure Unshielded single core cable can only be used i...

Page 37: ...d between the units is inherently shared according to the power or current references No additional settings are required If the operating mode selection 197 13 is DC voltage Tune the load sharing using the droop control function Master follower operation of the parallel units The control program does not support the master follower link between several units However it is possible to implement th...

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Page 39: ...50000048633 English If you ignore the safety instructions injury or death or damage to the equipment can occur If you are not a qualified electrician do not do installation or maintenance work 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 dam...

Page 40: ...ossible Lock out and tag out Disconnect any dangerous external voltages from the control circuits After you disconnect power from the drive always wait 5 minutes to let the intermediate circuit capacitors discharge before you continue 4 Protect any other energized parts in the work location against contact 5 Take special precautions when close to bare conductors 6 Measure that the installation is ...

Page 41: ...nts WARNING Obey these instructions If you ignore them damage to the equipment can occur Handle the fiber optic cables with care When you unplug the fiber optic cables always hold the connector not the cable itself Do not touch the ends of the fibers with bare hands as the ends are extremely sensitive to dirt Do not bend the fiber optic cables too tightly The minimum allowed bend radius is 35 mm 1...

Page 42: ...actory Also there are voltage limiting circuits inside the drive which cut down the testing voltage automatically Check the insulation resistance of the energy storage as instructed by its manufacturer Check the energy storage cable as follows 1 Make sure that the cable is disconnected from the DC DC converter and energy storage all conductors and the shield 2 At the converter unit end connect all...

Page 43: ...ns page 39 before you start the work 2 Run the control cables into the cabinet as described in section Grounding the outer shields of the control cables at the cabinet entry below 3 Route the control cables as described in section Routing the control cables inside the cabinet 4 Connect the control cables as described in section Connecting control cabling Grounding the outer shields of the control ...

Page 44: ...exposed B Stripped part covered with copper foil C Cable shield 1 Copper foil 2 Shielded twisted pair 3 Grounding wire 4 Note for top entry of cables When each cable has its own rubber grommet sufficient IP and EMC protection can be achieved However if very many control cables come to one cabinet plan the installation beforehand as follows 1 Make a list of the cables coming to the cabinet 2 Sort t...

Page 45: ...since it is grounded at the lead through Keep any signal wire pairs twisted as close to the terminals as possible Twisting wire with its return wire reduces disturbances caused by inductive coupling 6 If more than one cable go through a grommet seal the grommet by applying Loctite 5221 catalogue number 25551 inside the grommet Routing the control cables inside the cabinet Use the existing trunking...

Page 46: ...both ends if they are in the same ground line with no significant voltage drop between the end points 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 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end poin...

Page 47: ...arallel modules each module must have the output cabling of its own The cablings must also be identical cable type cross sectional area and length 1 Shielded 3 conductor cable and 360 degree grounding of the cable shield at the cable entry When you use parallel cables make sure they are identical type cross sectional area length etc 2 Disconnecting device for service purposes 3 Connection to the l...

Page 48: ...the contact surfaces 1 Stop the drive and do the steps in section Electrical safety precautions page 39 before you start the work 2 Open the door of the DC DC converter cubicle and remove the shrouding if any 3 Lead the cables into the cubicle 4 Ground the cable shield 360 degrees at the cable entry An example grounding arrangement is shown below 5 Cut the cables to suitable length Strip the cable...

Page 49: ...damage to the equipment can occur If you are not a qualified electrician do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 39 before you start the work 2 Open the door of the DC DC converter cubicle and remove the shrouding 3 Run the load disconnected indicator cable inside the cubicle and connect to the appropriate terminal ...

Page 50: ...he module 6 Tighten the grounding screw to a torque of 0 8 N m Note The screw tightens the connections and grounds the module It is essential for fulfilling the EMC requirements and for proper operation of the module Connecting a PC A PC with eg the Drive composer PC tool can be connected as follows 1 Connect an ACx AP x control panel to the unit either by inserting the control panel into the pane...

Page 51: ... units of the drive 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 6 Control units of the drive 51 ...

Page 52: ... for analog input AI2 I current U voltage AI2 Termination switch for drive to drive link D2D D2D TERM Ground selection Determines whether DICOM is separated from DIOGND ie the common reference for the digital inputs floats See the ground isolation diagram DICOM DIOGND 7 segment display Multicharacter indications are displayed as repeated se quences of characters U is indicated briefly before o Con...

Page 53: ...85 Fiber optic connection to modules 1 and 2 VxT transmitter VxR receiver V1T V1R V2T V2R Fiber optic connection to modules 3 7 BCU 12 22 only VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to modules 8 12 BCU 22 only VxT transmitter VxR receiver V8T V8R V12T V12R Data logger memory card for inverter module communication SD CARD Real time clock battery voltage is higher than 2...

Page 54: ...ust be connected to OUT 6 2 SGND 3 IN1 4 IN2 5 IN1 Not in use 6 SGND 7 IN2 8 SGND XDI Digital inputs 1 DI1 Temp fault 1 0 overtemperature 2 DI2 Not in use by default 3 DI3 4 DI4 5 DI5 6 DI6 7 DIIL XDIO Digital input outputs 1 DIO1 Not in use by default 2 DIO2 Not in use by default 3 DIOGND Digital input output ground 4 DIOGND Digital input output ground XD24 Auxiliary voltage output 5 24VD 24 V DC...

Page 55: ...XPOW The control unit is powered from a 24 V DC 2 A supply through terminal block XPOW With a type BCU control unit a second supply can be connected to the same terminal block for redundancy The XD2D connector The XD2D connector provides an RS 485 connection that can be used for basic master follower communication with one master drive and multiple followers fieldbus control through the embedded f...

Page 56: ...r control unit De energizing the IN1 and or IN2 terminals of other units supply DC DC converter or brake unit will stop the unit but not constitute a true safety function FSO xx safety functions module connection X12 See the user manual of the FSO xx module Note that the FSO xx safety functions module is not in use in supply or DC DC converter or brake units SDHC memory card slot The BCU x2 has an...

Page 57: ... 4 Connector pitch 5 mm wire size 2 5 mm2 Total load capacity of these outputs is 4 8 W 200 mA 24 V m the power taken by DIO1 and DIO2 Digital inputs DI1 DI6 XDI 1 XDI 6 Connector pitch 5 mm wire size 2 5 mm2 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Input type NPN PNP DI1 DI5 NPN DI6 Hardware filtering 0 04 ms digital filtering up to 8 ms DI6 XDI 6 can alternatively be used as an input for a PT...

Page 58: ... 2 5 mm2 Safe torque off connection XSTO Input voltage range 3 30 V DC Logic levels 0 5 V 1 17 V Note For the unit to start both connections must be 1 This applies to all control units including drive inverter supply brake DC DC converter etc control units but true Safe torque off functionality is only achieved through the XSTO connector of the drive inverter control unit EMC immunity according to...

Page 59: ...OGND 8 XDIO DIO1 1 DIO2 2 DIOGND 3 DIOGND 4 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 DIIL 7 XSTO OUT 1 SGND 2 IN1 3 IN2 4 XSTO OUT IN1 5 SGND 6 IN2 7 SGND 8 Common mode voltage between each AI input and AGND is 30 V Ground Ground selector DICOM DIOGND settings DICOM DIOGND ON All digital inputs share a common ground DICOM connected to DIOGND This is the default setting DICOM DIOGND OFF Ground of di...

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Page 61: ...nt operating conditions meet the drive ambient conditions specification and enclosure rating IP code or UL enclosure type The supply voltage matches the nominal input voltage of the drive See the type designation label The drive cabinet has been attached to floor and if necessary due to vibration etc also by its top to the wall or roof If the drive is connected to a network other than a symetrical...

Page 62: ...he regulations The motor cable has been connected to the appropriate terminals the phase order is right and the terminals have been tightened to the proper torque The motor cable has been routed away from other cables No power factor compensation capacitors have been connected to the motor cable The control cables have been connected to the appropriate terminals and the terminals have been tighten...

Page 63: ...to do the work described in this chapter In addition the electrician engineer must know the energy storage system he is about to take into use and the DC DC converter control program and operation principle Obey all the safety instructions in Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English and Electrical safety precautions page 39 If you ignore the safety inst...

Page 64: ...unit has been inspected and is OK See the installation checklist Make sure that the drive is ready for the converter unit power up The supply and inverter units have been installed according to the instructions given in their hardware manuals The supply unit has been started up according to the instructions given in the appropriate supply unit manual The inverter units have been started up accordi...

Page 65: ...F255 or the main contactor Q2 option F250 of the drive supply unit yet You must not power up the drive DC bus yet Setting the parameters Set the DC DC converter parameters See chapter Start up in the DC DC converter control program firmware manual 3AXD50000024671 English If you need information on the use of the control panel see ACX AP x assistant control panels user s manual 3AUA0000085685 Engli...

Page 66: ... system integrator installed device The load disconnected indicator P13 x goes out Close the energy storage protective circuit breaker customer or system integrator installed device Testing the DC DC converter operation Set parameter 120 12 Run enable 1 to On Set parameter 122 01 User Power ref to 0 A Set current limits to low values for example 130 119 Minimum current to 50 A 130 120 Maximum curr...

Page 67: ...cidental restart set parameter 120 19 Enable start signal to value Off Disconnecting the energy storage Open the energy storage protective circuit breaker Open the energy storage disconnecting device Lock out and tag out The load disconnected indicator P13 x is lit Disconnecting the DC DC converter Open the DC switch disconnector Q11 option F286 Lock out and tag out The DC DC converter disconnecte...

Page 68: ...icle reinstall any shrouds and close the door Reconnect the DC DC converter and energy storage See Connecting voltage to the drive and converter control unit page 65 Charging the DC DC converter and connecting voltage to the converter page 65 and Connecting the energy storage to the DC DC converter page 66 Starting the DC DC converter Change the control panel to local mode loc rem key Set paramete...

Page 69: ...dules 3AXD50000048633 English If you ignore the safety instructions injury or death or damage to the equipment can occur If you are not a qualified electrician do not do installation or maintenance work Maintenance intervals The table below shows the maintenance tasks which can be done by the end user The complete maintenance schedule is available on the Internet www abb com drivesservices For mor...

Page 70: ...d maintenance action if needed I Performance of on off site work commissioning tests measurements or other work P Replacement R Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions ABB recommends annual drive inspections to ensure the highest reliability and optimum performance Note Long term ...

Page 71: ...uses on the DC bus side For the location of the fuses see the figures The converter fuses F11 x on the drive DC bus side marked with a in the figure The output fuses F13 x on the energy storage side are marked with b in the figure a a b b Converter unit with a DC switch disconnector Converter unit without a DC switch disconnector WARNING Obey the safety instructions given in Safety instructions fo...

Page 72: ...e the shrouds 4 Slacken the nuts of the headless screws of the fuses so that you can slide out the fuse blocks Make note of the order of the washers on the screws 5 Remove the screws nuts and washers from the old fuses and attach them to the new fuses Make sure to keep the washers in the original order 6 Insert the new fuses into their slots in the cubicle 7 Tighten the nuts to torque as follows B...

Page 73: ...ntenance work WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges 1 Stop the drive and do the steps in section Electrical safety precautions page 39 before you start the work 2 Remove the shrouding in front of the fan if any 3 Disconnect the fan wiring 4 Remove the two retaining screws a 5 Pull the fan outwards to separate it f...

Page 74: ...essure is lowered down by stopping the pumps and draining the coolant High pressure warm coolant 6 bar max 50 C is present in the internal cooling circuit when it is in operation WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges Removing the module 1 Repeat the steps described in section Electrical safety precautions 2 Remove...

Page 75: ...b on both sides of the cubicle into a suitable container Open the drain valves c on both sides of the cubicle This will drain all modules in the cubicle a b c 7 After the module has drained disconnect the piping from the module 8 Remove the module retaining screws at the top and the bottom of the module Maintenance 75 ...

Page 76: ...able fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements are available from ABB Do not use other than ABB specified spare parts Contact an ABB service representative for spare parts and repair services Reforming the capacitors The capacitors must be reformed if the drive has not been powered either in storage or unused for a year or more The manufacturing date i...

Page 77: ...ontrol unit WARNING Do not remove or insert the memory unit when the control unit is powered 1 Stop the drive and do the steps in section Electrical safety precautions page 39 before you start the work 2 Make sure that the control unit is not powered 3 Undo the fastening screw and pull the memory unit out 4 Install a memory unit in reverse order Replacing the BCU control unit battery Replace the r...

Page 78: ...us green Control panel Data is transferred between the PC and the unit through the USB connection of the control panel Flickering green There is an active warning in the unit Blinking green There is an active fault in the unit Continuous red There is a fault that requires the stopping and restarting of the drive converter inverter Blinking red The Bluetooth interface is enabled in discoverable mod...

Page 79: ... Charging OK indicat or green Cabinet door lamps Note When the white lamps are on DC DC converter is disconnected from both the DC bus and the energy storage The DC DC converter unit is disconnected from the main DC bus Note Auxiliary voltages are to be disconnected separately DC DC converter disconnected white The disconnector of the energy storage is switched off Load disconnected indicator whit...

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Page 81: ...is applicable to cabinet built ACS880 liquid cooled drives Except where otherwise indicated the information is also applicable to drives built out of ACS880 liquid cooled multidrive modules Internal cooling system Note This section describes cabinet built liquid cooled ACS880 drives The information in this section can be used as guidelines for building a drive system out of ACS880 liquid cooled mo...

Page 82: ...m cooling unit 3 Air to liquid heat exchanger A L Heat sink HS Inlet valve a Inlet side drain valve b Outlet valve c Outlet side drain valve d The coolant used with ACS880 liquid cooled drive systems is Antifrogen L 25 or 50 water mixture See Coolant specification page 86 82 Internal cooling circuit ...

Page 83: ...the limits specified in Technical data page 86 Install a pressure regulator to make sure that the maximum permissible operating pressure is not exceeded Install a bleed valve at the highest point of the cooling circuit and a drain valve at the lowest point The materials that can be used are listed in Cooling circuit materials page 88 Coolant temperature control The temperature of the coolant in th...

Page 84: ...ion for the valve is usually near or at the cooling unit Observe the instructions given by the manufacturer of the cooling unit Pay special attention to filling up and bleeding the pumps properly as they may be damaged if operated when dry Draining coolant into the sewer system is not allowed 1 Open the bleed valve at the cooling unit 2 Open the inlet valve and the outlet side drain valve of one c...

Page 85: ... stop the pump or block the coolant flow with a valve 15 Re check the pressure and add coolant if necessary 16 Repeat steps 13 to 15 a few times until all air is let out of the cooling circuit Listen for a humming sound and or feel the piping for vibration to find out if there is still air left in the circuit Internal cooling circuit 85 ...

Page 86: ...it with coolant specified under Coolant specification page 86 drain the cooling circuit again Maintenance intervals As a general rule the quality of the coolant should be checked at intervals of two years This can be done by distributors of Antifrogen L see www clariant com if a 250 milliliter sample is provided Technical data Coolant specification Coolant type Antifrogen L by Clariant Internation...

Page 87: ... If there are no components with a maximum operating temperature of 55 C 131 F installed in the same space as the drive modules drive output current must be derated by 2 percentage points per 1 C 1 8 F temperature increase as shown by curve b The drawing below shows the derating factor k in relation to coolant temperature Internal cooling circuit 131 The drawing below shows the derating factor k i...

Page 88: ... compared with the atmospheric pressure when the cooling circuit is filled with coolant Air counterpressure in the expansion tank 40 kPa Design pressure PS 600 kPa Nominal pressure difference between main in out lines 120 kPa with 25 75 volume coolant solution 150 kPa with 50 50 volume coolant solution This has to be taken into account when dimensioning the liquid cooling circuit Maximum pressure ...

Page 89: ...umstances Even minor dissolution of copper can cause copper precipitation on aluminum and subsequent galvanic corrosion The liquid cooling system must not contain any zinc eg galvanized pipes If the plant incorporates normal iron pipes or cast iron accessories eg motor housings a cooling unit with a heat exchanger such as the ACS880 1007LC must be used to separate the systems Internal cooling circ...

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Page 91: ...351 400 391 R8i 0480A 7 0400A 7 12000 38 625 589 439 500 490 R8i 0530A 7 0500A 7 12000 56 750 707 527 600 590 R8i 0600A 7 0600A 7 12000 56 875 824 615 700 690 R8i 0670A 7 0700A 7 12000 56 1000 942 703 800 790 R8i 0750A 7 0800A 7 12000 56 1125 1060 790 900 880 R8i 0850A 7 0900A 7 24000 19 1250 1178 878 1000 980 2 R8i 0530A 7 1000A 7 24000 28 1500 1413 1054 1200 1180 2 R8i 0600A 7 1200A 7 24000 28 1...

Page 92: ...on page 139 I1 Continuous rms input AC current No overload capability at the coolant temperature of 40 C 104 F and air temperature of 45 C 113 F I2 Continuous rms output DC current No overload capability at the coolant temperature of 40 C 104 F and air temperature of 45 C 113 F Imax Maximum output DC current Available for 10 s at start otherwise as long as allowed by module temperature Sn Nominal ...

Page 93: ...73 170M6501 1400 A 1800A 7 BDCL filters Each DC DC converter module has its own BDCL filter module Ordering code BDCL filter type Frame ACS880 1607LC 3AXD50000332687 BDCL 14LC 7 R8i 0400A 7 3AXD50000332687 BDCL 14LC 7 R8i 0500A 7 3AUA0000190873 BDCL 15LC 7 R8i 0600A 7 3AUA0000190873 BDCL 15LC 7 R8i 0700A 7 3AUA0000190873 BDCL 15LC 7 R8i 0800A 7 3AUA0000190873 BDCL 15LC 7 R8i 0900A 7 3AXD5000033268...

Page 94: ...10 0600A 7 710 644 800 2010 0700A 7 710 644 800 2010 0800A 7 710 644 800 2010 0900A 7 1425 644 1600 2010 1000A 7 1425 644 1600 2010 1200A 7 1425 644 1600 2010 1400A 7 1425 644 1600 2010 1600A 7 1425 644 1600 2010 1800A 7 Free space requirements Leave 400 0 mm 15 75 in free space above the basic roof level 400 mm 15 75 in 94 Technical data ...

Page 95: ...8 6 120 14 2 5 2 5 2 3 8 4 2 14 8 2 R8i 1600A 7 98 6 120 14 2 5 2 5 2 3 8 4 9 17 1 2 R8i 1800A 7 Tightening torques Unless a tightening torque is specified in the text the following torques can be used Electrical connections Note Torque Size Strength class 4 6 8 8 0 5 N m 4 4 lbf in M3 Strength class 4 6 8 8 1 N m 9 lbf in M4 Strength class 8 8 4 N m 35 lbf in M5 Strength class 8 8 9 N m 6 6 lbf f...

Page 96: ... V 95 of UDC Drive DC voltage in the DC bus This is indicated in the type designation label as typical output voltage range 50 688 764 878 V DC Recommended output voltage 150 V 80 of UDC Voltage U2 See section Ratings Current Control accuracy Current and voltage control performance data Step response time 10 ms for a reference step 0 to 50 of the drive nominal current Current control dynamic re sp...

Page 97: ...d components also enable the use of Hard Clad Silica HCS cables which allow longer connection distances thanks to their lower attenuation HCS cables cannot be used with 5 MBd optical components The maximum lengths of fiber optic links for POF and HCS cables are 20 and 200 meters respectively Protection classes IP22 Degrees of protection IEC EN 60529 IP42 option B054 IP54 option B055 III Overvoltag...

Page 98: ...weather protected locations Contamination Class 2C2 Class 1C2 Class 3C2 Chemical gases Class 2S2 Class 1S3 packing must support this otherwise 1S2 Class 3S1 Solid particles No conductive dust al lowed IEC EN 60721 3 1 1997 IEC EN 60721 3 1 1997 IEC 61800 5 1 Vibration IEC 60068 2 6 2007 EN 60068 2 6 2008 Envir onmental testing Part 2 Tests Test Fc Vibration sinusoidal 10 57 Hz max 0 075 mm amplitu...

Page 99: ...VCI emitter bags PP tape PET strap sheet metal steel for sea transport with or without containerization for long storage periods in environments where roofed and humidity controlled storage cannot be arranged Cabinets are fastened to the pallet with screws and braced from the top end to the package walls to prevent swaying inside the package Package elements are at tached to each other with screws...

Page 100: ...usly ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface again...

Page 101: ...wings Contents of this chapter This chapter contains the following dimension data Dimension drawings of DC DC converter unit Location and size of output terminals for energy storage cables 12 Dimension drawings 101 ...

Page 102: ...Unit with 1 R8i converter module 102 Dimension drawings ...

Page 103: ...Dimension drawings 103 ...

Page 104: ...Location and size of energy storage connection terminals 104 Dimension drawings ...

Page 105: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

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