ABB ACS880-207LC Hardware Manual Download

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Overview of the control connections of the BCU control unit

The diagram shows the control connections and interfaces of the BCU control unit.

FXX

FXXX

Control panel.

Analog and digital I/O extension modules and
fieldbus communication modules can be inserted
into slots 1, 2 and 3.

1
2
3

Fiber optic links to power modules (inverter,
supply, brake or converter)

Memory unit

Ethernet port. Not in use.

Slot 4 for RDCO-0x

Safety option interface. Only in use for the invert-
er units.

Terminal blocks.

26 Operation principle and hardware description

Summary of Contents for ACS880-207LC

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 207LC IGBT supply units Hardware manual ...

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Page 3: ...ACS880 207LC IGBT supply units Hardware manual Table of contents 3 Electrical installation 6 Start up and operation 2019 ABB Oy All Rights Reserved 3AXD50000174782 Rev A EN EFFECTIVE 2019 06 30 ...

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Page 5: ...19 Incoming cubicle 19 Door closed 20 Door open 21 Supply module cubicle 21 Door open 22 Filter cubicle 22 Door open 23 Auxiliary control cubicle 23 Door closed 24 Door open 25 Overview of power and control connections 26 Overview of the control connections of the BCU control unit 27 Supply unit control devices 27 Main switch disconnector breaker 27 Auxiliary voltage switch 27 Grounding switch 28 ...

Page 6: ...the power supply cable for the charging circuit 46 Connecting the control cables for the supply unit 46 Connection diagram 46 Connection procedure 46 Grounding the outer shields of the control cables at the cabinet entry 48 Routing the control cables inside the cabinet 49 Connecting control cabling 50 Powering the heating and lighting equipment options G300 and G301 50 Connection diagram 51 Connec...

Page 7: ...n in the incoming cubicle 80 Replacing the fan in the auxiliary control cubicle 81 Supply modules 81 Replacing the supply module 81 Removing the module 83 Reinstalling the module 84 LCL filters 84 Replacing the capacitors of the LCL filter 85 Charging resistors 85 Replacing the charging resistors 86 Capacitors of the DC circuit 86 Reforming the capacitors 86 Replacing the capacitors 86 Control pan...

Page 8: ...a BCU 104 Efficiency 104 Protection classes 105 Ambient conditions 106 Materials 106 Standards 106 Markings 107 Compliance with the EN 61800 3 2004 107 Approvals 107 Disclaimers 107 Generic disclaimer 107 Cybersecurity disclaimer 9 Internal cooling circuit 109 Contents of this chapter 109 Applicability 109 Internal cooling system 111 Connection to a cooling unit 111 Connection to an ACS880 1007LC ...

Page 9: ...116 Coolant flow rate limits 116 Cooling circuit materials Further information Table of contents 9 ...

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Page 11: ...mission use or service the drive The complete safety instructions are given in ACS880 liquid cooled multidrive cabinets and modules safety instructions 3AXD50000048633 English Read 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 Re...

Page 12: ...s are marked with option codes such as E205 The options included in the drive can be identified from the option codes visible on the type designation label The option selections are listed in section Type designation key page 31 Use of component designations Some device names in the manual include the item designation in brackets for example Q20 to make it possible to identify the components in th...

Page 13: ...BT IGBT supply module s under control of one control board and related components IGBT supply unit DC circuit between rectifier and inverter Intermediate circuit Inverter module s under control of one control board and related components One inverter unit typically controls one motor Inverter unit IGBT supply unit ISU Inductor capacitor inductor filter LCL filter Drive for controlling several moto...

Page 14: ...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 converter units hardware manu...

Page 15: ...ors There can be one inverter unit only single drives or several inverter units multidrives connected to the intermediate circuit The LCL filter is an essential part of the IGBT supply unit The supply module does not work without the filter It suppresses the AC voltage distortion and current harmonics The high AC inductance smooths the line voltage waveform distorted by the high frequency switchin...

Page 16: ...ectly connected to the full supply voltage The charging current must be limited until the capacitors are charged and ready for normal use In cabinet installed units a resistive charging circuit consisting of fuses a contactor and charging resistors is used The resistive charging circuit is in use after power up as long as DC voltage has risen to a predefined level The control program has a functio...

Page 17: ...dard always with F253 6 Charging circuit 7 LCL filter R03 8 IGBT supply module T01 9 Common mode filter R1 10 DC fuses F2 11 Inverter modules T11 12 Motor s M 3 M 3 3 M 3 3 4 5 7 11 8 2 1 11 11 10 10 9 10 10 12 6 9 9 9 Auxiliary voltage transformer T21 option G344 1 Auxiliary voltage switch Q21 2 Main switch disconnector Q1 option F253 standard always with F250 3 AC fuses F1 4 Main contactor Q2 op...

Page 18: ...drawing shows an example of an IGBT supply unit Cables enter the cabinet through the bottom 1 2 3 4 Incoming cubicle ICU Contains the power input cable terminals and switchgear 1 LCL filter cubicle Contains LCL filter s 2 Supply module cubicle Contains IGBT supply module s of frame size R8i 3 Auxiliary control cubicle Contains control electronics and customer I O connections 4 18 Operation princip...

Page 19: ...contain main disconnecting device main switch disconnector or main circuit breaker but is otherwise similar Supply units with high power can contain two incoming cubicles Then only one of them contains charging components otherwise the cubicles are similar Door closed 2 1 3 4 5 6 7 Auxiliary voltage disconnector 1 Meters 2 Charging circuit disconnector AC side 3 Option F259 Grounding switch 4 Char...

Page 20: ...or AC side 2 DC fuses 3 Option F259 Grounding switch 4 Charging circuit disconnector DC side 5 BAMU measurement unit 6 Option F255 Main circuit breaker 7 Cooling fan and heat exchanger 8 Charging resistors 9 Input power cable terminals L1 L2 L3 10 20 Operation principle and hardware description ...

Page 21: ...Door open 2 1 3 3 4 5 6 7 4 DC fuses 1 Common mode filters 2 IGBT supply module of frame size R8i 3 Coolant connections 4 Air to liquid heat exchanger installed below each module 5 Behind the mounting plate Fan Forces air inside the cubicle through the heat exchanger 6 Mounting plate with terminal blocks for customer connections 7 Operation principle and hardware description 21 ...

Page 22: ...t The cubicle contains LCL filter s There are no switches or devices on the cabinet door Door open 2 1 4 3 AC fuses 1 Capacitors Inductors are located behind the capacitors 2 CIO 01 I O module 3 Cooling fan and heat exchanger 4 22 Operation principle and hardware description ...

Page 23: ...tion shows an example of auxiliary control cubicle layout The composition and size of the cubicle vary depending on the selected options Door closed 2 1 Control panel 1 Operating switches 2 Operation principle and hardware description 23 ...

Page 24: ...r open 2 1 3 4 CIO 01 I O module 1 BCU control unit 2 Cooling fan and heat exchanger 3 Transformer Two transformers can also be behind the assembly plates 4 24 Operation principle and hardware description ...

Page 25: ...rolled using the local control devices installed on the cabinet door No additional control connections are needed However it is possible to control the unit through the control panel and the fieldbus read the status information through the control panel fieldbus and relay output halt the unit with an externally wired emergency stop button if the unit is equipped with an emergency stop option The s...

Page 26: ... panel 7 Analog and digital I O extension modules and fieldbus communication modules can be inserted 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 26 Operation principle and hardware description ...

Page 27: ...age meters open the main breaker of the supply transformer Especially in case of a circuit breaker the main circuit breaker does not isolate the charging circuit To isolate the charging circuit use the charging switch Q3 Note The earthing grounding switch Q9 option F259 and the main switch disconnector are electrically interlocked only one of the switches can be closed at a time To close the switc...

Page 28: ...tory view actual signals change parameter settings change between local and external control The Run enable command at digital input DI2 must be on 1 so that the supply unit can be started and stopped with the control panel in the local mode That is the case when the operating switch S21 is switched to the on 1 position To change between local and remote control mode press the Loc Rem key of the c...

Page 29: ...r Q40 is needed for isolating the line up charging circuit from the DC link when the supply unit has the DC switch disconnector Q11 and AC DC line up charging circuit PC connection There is a USB connector on the front of the control panel that can be used to connect a PC to the drive When a PC is connected to the control panel the control panel keypad is disabled See also section Connecting a PC ...

Page 30: ...cludes the ratings appropriate markings a type designation and a serial number of the unit Example label is shown below Quote the complete type designation and serial number when contacting technical support 1 2 3 4 5 6 Type designation see section Type designation key page 31 1 Frame size 2 Short time withstand current rating see chapter Technical data degree of protection UL CSA specific ations ...

Page 31: ...o the rating table xxxxx Voltage range 380 415 V AC This is indicated in the type designation label as typical input voltage level 3 400 V AC 3 380 500 V AC This is indicated in the type designation label as typical input voltage levels 3 400 480 500 V AC 5 525 690 V AC This is indicated in the type designation label as typical input voltage levels 3 525 600 690 V AC 7 Option codes plus codes Supp...

Page 32: ...material aluminum G314 DC bus material tin plated copper G315 Supply connection by cables G316 Supply connection by busbars G317 230 V AC control voltage G320 Halogen free wiring and materials G330 Emergency stop push button on the door red G331 Electrical disconnect push button on the door black opens main contactor main circuit breaker G332 Meters for A V kW and kWh G333 V meter with selector sw...

Page 33: ...twork K483 Ethernet switch for PROFINET K493 Ethernet switch with optical link for PROFINET K494 I O extensions FIO 11 analog I O extension module L500 FIO 01 digital I O extension module L501 FDCO 01 optical DDCS communication adapter module L503 FDCO 02 optical DDCS communication adapter module L508 RDCO 04 DDCS communication adapter module L509 FAIO 01 analog I O extension module L525 FDIO 01 d...

Page 34: ... R704 Swedish R705 Finnish R706 French R707 Spanish R708 Portuguese R709 Russian R711 Weak supply networks In weaker supply networks with a short circuit ratio less than 8 it is highly recommended to add an additional BAMU auxiliary measurement unit to the drive In such kind of networks there is risk of unnecessary DC overvoltage tripping due to disturbances caused by probable high voltage THD in ...

Page 35: ...recautions These electrical safety precautions are for all personnel who do work on the drive motor cable or motor WARNING Obey these instructions If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrician do not do installation or maintenance work Go through these steps before you begin any installation or maintenance work 1 Keep the cabinet doo...

Page 36: ...ive 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 de energized If the measurement requires removal or disassembly of shrouding or other cabinet structures obey the local laws and regulat...

Page 37: ...ning notice to them Disconnect any external power sources from the control circuits before you do work on the control cables After you disconnect the drive always wait for 5 minutes to let the intermediate circuit capacitors discharge before you continue 3 Protect any other energized parts in the work location against contact 4 Take special precautions when close to bare conductors 5 Measure that ...

Page 38: ...continue 3 Protect any other energized parts in the work location against contact 4 Take special precautions when close to bare conductors 5 Measure that the installation is de energized Use a multimeter with an impedance of at least 1 Mohm Make sure that the voltage between the drive input power terminals and the grounding PE busbar is close to 0 V 6 Install temporary grounding as required by the...

Page 39: ... the cable selection instructions see Electrical planning instructions for ACS880 liquid cooled multidrive cabinets and modules 3AXD50000048634 English Connection procedure WARNING Obey the instructions in Safety instructions for ACS880 liquid cooled multidrive cabinets and modules 3AXD50000048633 English If you ignore them injury or death or damage to the equipment can occur 1 Do the steps in sec...

Page 40: ...ion in the contact surfaces PE PE 6 If fire insulation is used make an opening in the mineral wool sheet according to the diameter of the cable 7 Remove rubber grommets from the cable entries for the cables to be connected Cut adequate holes into the rubber grommets Slide the grommets onto the cables Slide the cables into the cubicle through the conductive sleeves and attach the grommets to the ho...

Page 41: ...name DXXT 11 code 35080082 10 Connect the twisted shields of the cables to the PE busbar of the cabinet Tighten the screws to the torque given under Tightening torques page 101 11 Connect the phase conductors of the input cable to the L1 L2 and L3 terminals Tighten the screws to the torque given under Tightening torques page 101 12 Reinstall the shrouding removed earlier 13 Close the cubicle door ...

Page 42: ...er must provide the auxiliary voltage from an external supply to the drive For details see the delivery specific circuit diagrams Connection diagram External fan voltage supply External control voltage supply Q115 PE 1 3 5 2 4 6 PE L1 N Q20 PE 1 3 5 2 4 6 PE L1 N 42 Electrical installation ...

Page 43: ...re present depending on drive configuration The voltage settings of transformer T21 are made at terminal blocks T21_X1 X2 and T115_X1 X2 respectively For cabinet layout see chapter Operation principle and hardware description T21 tap settings 690 V units 690 V 1 660 V 2 600 V 3 575 V 4 540 V 5 525 V 6 7 U1 8 TP1 9 TP2 10 T21_X1 T21_X2 1 230 V 2 3 4 N 5 Ĭ Electrical installation 43 11 ...

Page 44: ...former connections are made at the factory The connection of the primary winding of the fan transformer depends on the actual system voltage The voltage settings of cooling fan transformers T115 and T125 are made at terminal blocks T115_X1 X2 and T125_X1 X2 respectively T115 and T125 tap settings 690 V units 690 V 1 660 V 2 600 V 3 575 V 4 540 V 5 525 V 6 7 U1 8 TP1 9 TP2 10 T115_X1 T125_X1 T115_X...

Page 45: ...harging circuit components are located in the incoming cubicle If the delivery contains an IPU unit see the delivery specific circuit diagrams for wiring Activate and tune the charging function in the control program For information on tuning the parameters see ACS880 IGBT supply control program firmware manual 3AUA0000131562 English Electrical installation 45 11 ...

Page 46: ...s at the cabinet entry Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions as follows example constructions are shown below the actual hardware may vary 1 Loosen the tightening screws of the EMI conductive cushions and pull the cushions apart 2 Cut adequate holes to the rubber grommets in the entry plate and put the cables through the grommets and the cushions...

Page 47: ...roup the cables for each grommet as follows ensuring that each cable has a proper contact to the cushions on both sides Max number of cables per grommet Cable diameter in mm 4 13 3 17 2 25 1 25 5 Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions Electrical installatio 5 Arrange the bunches according to size from thickest to the thinnest between...

Page 48: ...e the existing trunking in the cabinet wherever possible Use sleeving if cables are laid against sharp edges When running cables to or from a swing out frame leave enough slack at the hinge to allow the frame to open fully 48 Electrical installation ...

Page 49: ...irs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by inductive coupling 100 Electrical installation 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 ...

Page 50: ...res for the cabinet heater and lighting to terminal block X22 at the mounting plate Connection diagram External lighting voltage supply External heating voltage supply Q130 PE 1 3 5 2 4 6 PE L1 N X22 49 50 Q130 F130 Q95 PE 1 3 5 2 4 6 PE L1 N X22 47 48 Q95 F95 Internal wiring of the cabinet lighting light ing supply off fault contact open X22 49 X22 50 Internal wiring of the cabinet heating heat i...

Page 51: ...e safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Note Pay attention to the free space required by the cabling or terminals coming to the optional modules 1 Repeat the steps described in section Electrical safety precautions page 35 2 Ensure by measuring that the I O terminals of the control unit especially the relay output terminals are saf...

Page 52: ...52 ...

Page 53: ... 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 The control unit is connected to the IGBT supply module s by fiber optic cables In this manual the name BCU x2 represents the control unit types BCU 02 BCU 12 and BCU 22 These have a different number of power module connections 2 7 and 12 respectively but are ...

Page 54: ... 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 55: ...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 8 V If the LED is off whe...

Page 56: ...vertemperature 2 DI2 Run enable 3 1 run enable 3 DI3 MCB fb 2 0 main contactor breaker open 4 DI4 Not in use by default Can be used for eg auxiliary circuit breaker fault 5 DI5 Not in use by default Can be used for eg earth fault monitoring 6 DI6 Reset 3 0 1 fault reset 7 DIIL Not in use by default Can be used for eg emergency stop XDIO Digital input outputs 1 DIO1 Not in use by default 2 DIO2 Not...

Page 57: ...urrent 0 4 20 mA Rin 100 ohm or voltage 0 2 10 V Rin 200 kohm input selected by switch AI2 Change of setting requires reboot of control unit External power supply for the control unit 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 XD...

Page 58: ...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 59: ... 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 60: ... 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 61: ...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...

Page 62: ...62 ...

Page 63: ...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 64: ...connected to the appropriate terminals and the terminals have been tightened to the proper torque The voltage setting of the auxiliary voltage transformers if any is correct See the electrical installation instructions If a drive bypass connection will be used The direct on line contactor of the motor and the drive output contactor are either mechanically and or electrically interlocked ie cannot ...

Page 65: ...es 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 The same device designations are also used in the circuit diagrams typically Safety WARNING Only qualified electricians are allowed to do the work described in this chapter Obey all safety instructions in Safety instructions for ACS880...

Page 66: ... and IRDH275B Ground Fault Monitor Operating Manual by Bender code TGH1386en Powering up the auxiliary circuit Make sure that it is safe to connect voltage Ensure that nobody is working on the unit or circuits that have been wired from outside into the cabinet the cover of the motor terminal box is in place Drives with a voltmeter P5 option G334 Make sure that the circuit breaker of the measuring ...

Page 67: ...ion F259 Open the grounding switch Drives with a DC switch disconnector Q11 option F286 Make sure that all DC switch disconnectors Q11 are closed and charging switches Q10 are open in all IGBT supply module cubicles See also Additional instructions for closing the DC switch disconnector page 68 Drives with a main switch disconnector Q1 option F253 Close the main switch disconnector Drives with a m...

Page 68: ...line up charging Q40 is closed Force the charging circuit of the unit on via setting the local charging control switch S4 to position 1 Wait for a few seconds for the DC bus charging up to nominal voltage level Charge the IGBT supply modules close the charging switch Q10 of the units that are to be powered up After the IGBT supply modules are charged and the charging light P11 on the cabinet door ...

Page 69: ...ents 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 207LC IGBT supply units 7 Maintenance 69 ...

Page 70: ...ns R Supply module fan 230 V R R Supply module fan 115 V Batteries R Control panel battery R R Control unit battery Connections and environment P P P P P P P P P P P P P Quality of supply voltage Spare parts I I I I I I I I I I I I I Spare parts P P P P P P P P P P P P P DC circuit capacitor reforming spare mod ules and spare capacitors Inspections I I I I I I I I I I I I I Checking tightness of c...

Page 71: ... parameter This feature is especially useful as a service reminder For more information see the firmware manual Cabinet Cleaning the interior of the cabinet WARNING Read the safety instructions given in Safety instructions for ACS880 liquid cooled multidrive cabinets and modules 3AXD50000048633 English If you ignore them injury or death or damage to the equipment can occur WARNING Use a vacuum cle...

Page 72: ...quid cooled multidrive cabinets and modules 3AXD50000048633 English If you ignore them injury or death or damage to the equipment can occur 1 Repeat the steps described in section Electrical safety precautions page 35 2 Check the tightness of the cable connections Use the tightening torques given in the technical data 72 Maintenance ...

Page 73: ... page 35 before you start the work 2 Open the door of the LCL filter cubicle 3 Remove the shrouding in front of the fuses if any 4 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 cubicle Tighten the nuts first by hand or applying maximum ...

Page 74: ...4 74 Maintenance ...

Page 75: ...n 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 s below Tighten the nuts first by hand or applying maximum 5 N m force Tightening torques for M12 nuts are 50 N m 37 lbf ft for Bussmann fuses and 46 N m 34 lbf ft for Ferraz Shawmut fuses 5 Attach the shrouding if any and close the ...

Page 76: ...y precautions page 35 2 Remove any shrouding in front of the cooling fan 3 Disconnect the fan wiring 4 Undo the two retaining screws a 5 Pull the fan outwards to separate it from the heat exchanger housing 6 Install new fan in reverse order Align the guide pins b at the rear of the fan cowling with the slots c in the module bottom guide then reinstall the retaining screws a a b c 76 Maintenance ...

Page 77: ...e to the equipment can occur WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Repeat the steps described in section Electrical safety precautions page 35 before you start the work 2 Remove the shrouding in front of the fan if any 3 Disconnect the fan wiring 4 Remove the four screws and pull the fan unit out 5 Remove the two screws in front of the heat exchanger 6 Insta...

Page 78: ...ING Wear protective gloves and long sleeves Some parts have sharp edges 1 Repeat the steps described in section Electrical safety precautions page 35 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 screws and slide the fan unit out 5 Remove the four screws to detach the fan from the fan unit 6 Remove the eight screws surround...

Page 79: ...4 5 6 Maintenance 79 ...

Page 80: ...r death or damage to the equipment can occur WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Repeat the steps described in section Electrical safety precautions page 35 before you start the work 2 Open the door of the auxiliary control cubicle 3 Disconnect the fan wiring 4 Remove the fastening screws of the fan collar and slide the fan with the collar out 5 Detach the...

Page 81: ...owered 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 the shroud...

Page 82: ...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 82 Maintenance ...

Page 83: ...lish Reinstalling the module 1 Push the module carefully into its bay 2 Fasten the retaining screws at the top and the bottom of the module 3 Reinstall the DC busbars at the top of the module 4 Reconnect the coolant pipes to the module 5 Reconnect the control wiring to the module 6 Fill up the cooling system For instructions see section Filling up and bleeding the internal cooling circuit 7 Close ...

Page 84: ...epeat the steps described in section Electrical safety precautions page 35 before you start the work 2 Open the door of the LCL filter cubicle 3 Remove the shrouding in front of the capacitors if any 4 Disconnect the wiring of the capacitors 5 Remove the six fastening screws in front of the capacitor unit 6 Remove the three bolts below each capacitor 7 Remove the four screws of the capacitor unit ...

Page 85: ...cur WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Repeat the steps described in section Electrical safety precautions page 35 before you start the work 2 Open the door of the incoming cubicle 3 Remove the fastening screws of the charging resistor unit two screws on the back and one screw on the front part of the charging resistor unit Slide the resistor unit out 4 D...

Page 86: ...s on the type designation label For information on reforming the capacitors see Converter module capacitor reforming instructions 3BFE64059629 English in the ABB Library https library abb com en If the drive module has been stored for one to three years turn on the mains power for 30 minutes without load then continue as usual If the drive module has been stored for less than a year continue as us...

Page 87: ...nit to the new control 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 35 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 Maintenance 87 ...

Page 88: ...nel 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 mode and ready for pairing Blinking blue ACS AP W only Data is being transferred through the Bluetooth interface of th...

Page 89: ...Technical data Contents of this chapter This chapter contains the technical data valid for the cabinet installed ACS880 207LC IGBT supply units 8 Technical data 89 ...

Page 90: ...328 1360 1704 1746 1793 1775 2728 2250 1819 1500 2 R8i 0850A 7 1500A 7 1593 1633 2045 2095 2151 2130 3274 2700 2182 1800 3 R8i 0670A 7 1800A 7 1788 1832 2294 2351 2414 2390 3674 3030 2449 2020 3 R8i 0750A 7 2020A 7 1965 2013 2522 2584 2653 2627 4038 3330 2692 2220 3 R8i 0850A 7 2220A 7 2363 2422 3033 3108 3191 3159 4856 4010 3237 2670 4 R8i 0750A 7 2670A 7 2593 2657 3328 3411 3502 3467 5329 4400 3...

Page 91: ...ut DC current Available for 10 s at start otherwise as long as allowed by module temperature Sn Nominal apparent AC power Imax Maximum input AC current Pn Nominal output DC power Light overload use 50 overload capability ratings ILd Continuous current 50 overload is allowed for one minute every 5 minutes PLd Output power in light overload use Heavy duty use 50 overload capability ratings IHd Conti...

Page 92: ... 9 0 0850A 7 0770A 7 1 BLCL 24LC 7 2 12 0 0530A 7 0930A 7 1 BLCL 24LC 7 2 18 0 0600A 7 1090A 7 1 BLCL 24LC 7 2 18 0 0670A 7 1180A 7 1 BLCL 25LC 7 2 18 0 0750A 7 1360A 7 1 BLCL 25LC 7 2 18 0 0850A 7 1500A 7 2 BLCL 24LC 7 3 27 0 0670A 7 1800A 7 2 BLCL 24LC 7 3 27 0 0750A 7 2020A 7 2 BLCL 24LC 7 3 27 0 0850A 7 2220A 7 2 BLCL 25LC 7 4 36 0 0750A 7 2670A 7 2 BLCL 25LC 7 4 36 0 0850A 7 2930A 7 3 BLCL 24...

Page 93: ... 170M7061 Bussmann 690 1600 3 0930A 7 170M7062 Bussmann 690 2000 3 1090A 7 170M7062 Bussmann 690 2000 3 1180A 7 170M7063 Bussmann 690 2500 3 1360A 7 170M7063 Bussmann 690 2500 3 1500A 7 170M7061 Bussmann 690 1600 6 1800A 7 170M7062 Bussmann 690 2000 6 2020A 7 170M7062 Bussmann 690 2000 6 2220A 7 170M7063 Bussmann 690 2500 6 2670A 7 170M7063 Bussmann 690 2500 6 2930A 7 170M7062 Bussmann 690 2000 9 ...

Page 94: ...480A 7 170M6549 Bussmann 1000 1100 2 0560A 7 170M6500 Bussmann 1100 1250 2 0620A 7 170M6501 Bussmann 1100 1400 2 0700A 7 170M6501 Bussmann 1100 1400 2 0770A 7 170M6548 Bussmann 1100 1000 4 0930A 7 170M6549 Bussmann 1000 1100 4 1090A 7 170M6500 Bussmann 1100 1250 4 1180A 7 170M6501 Bussmann 1100 1400 4 1360A 7 170M6501 Bussmann 1100 1400 4 1500A 7 170M6500 Bussmann 1100 1250 6 1800A 7 170M6501 Buss...

Page 95: ... 12 0 13 7 52 0480A 7 58 8 1 0 4 14 1 13 7 52 0560A 7 58 8 1 0 4 15 7 13 7 52 0620A 7 58 8 1 0 5 18 4 13 7 52 0700A 7 58 8 1 0 5 20 9 13 7 52 0770A 7 59 11 3 0 5 21 3 23 2 88 0930A 7 59 11 3 0 6 25 3 23 2 88 1090A 7 59 11 8 0 7 28 6 23 2 88 1180A 7 59 11 8 0 8 31 0 23 2 88 1360A 7 59 11 8 0 9 35 1 23 2 88 1500A 7 61 18 7 1 0 39 3 38 0 144 1800A 7 61 18 7 1 2 45 6 38 0 144 2020A 7 61 18 7 1 3 51 7 ...

Page 96: ...Internal cooling circuit data See chapter Internal cooling circuit 96 Technical data ...

Page 97: ...nd above show the terminal and lead through dimensions for incoming and input cubicles The dimensions are given in millimeters Tightening torque for the cable lug connection depends on the bolt size and type See section Tightening torques page 101 400 mm wide input cubicle Technical data 97 ...

Page 98: ...98 Technical data ...

Page 99: ... 600 mm wide incoming cubicle or input cubicle Technical data 99 ...

Page 100: ... 1000 mm wide input cubicle 100 Technical data ...

Page 101: ...ass 8 8 120 N m 90 lbf ft M16 Mechanical connections Note Max torque Size Strength class 8 8 6 N m 53 lbf in M5 Strength class 8 8 10 N m 7 4 lbf ft M6 Strength class 8 8 24 N m 17 7 lbf ft M8 Insulation supports Note Max torque Size Strength class 8 8 5 N m 44 lbf in M6 Strength class 8 8 9 N m 6 6 lbf ft M8 Strength class 8 8 18 N m 13 3 lbf ft M10 Strength class 8 8 31 N m 23 lbf ft M12 Cable l...

Page 102: ...262 1182 210 2 32 2 3 70 21 Cu 1376 318 1492 256 2 38 2 3 95 29 Cu 1637 368 1776 297 2 41 2 3 120 41 Cu 1881 425 2042 343 2 44 2 3 150 41 Cu 2237 486 2422 392 2 49 2 3 185 57 Cu 2740 572 2967 462 2 54 2 3 240 72 Cu 3229 659 3478 533 2 58 2 3 300 88 Cu 1881 638 2042 514 3 44 3 3 150 41 Cu 2237 728 2422 588 3 49 3 3 185 57 Cu 2740 859 2967 693 3 54 3 3 240 72 Cu 3229 989 3478 800 3 58 3 3 300 88 Cu ...

Page 103: ...0 3329 4073 4779 274 334 386 446 510 602 696 2 32 2 38 2 41 2 44 2 50 2 55 2 58 2 3 70 35 2 3 95 50 2 3 120 70 2 3 150 70 2 3 185 95 2 3 240 120 2 3 300 150 1859 2139 2525 3099 3636 723 837 957 1128 1304 2441 2820 3329 4073 4779 579 669 765 903 1044 3 41 3 44 3 50 3 55 3 58 3 3 120 70 3 3 150 70 3 3 185 95 3 3 240 120 3 3 300 150 2139 2525 3099 3636 1116 1276 1504 1304 2820 3329 4073 4779 892 1020...

Page 104: ...otec tion UL 508A CSA C22 2 No 14 13 0 99 Fundamental power factor cos phi1 Harmonics are below the limits defined in IEEE519 Harmonic distortion THD Current THD Voltage Rsc 2 51 3 20 2 5 0 8 100 In nth harmonic component IN nominal current 1 Other loads may influence the THD value THD Total Harmonic Distortion THD The voltage THD depends on the short circuit ratio Rsc The spectrum of the distorti...

Page 105: ...ass 1S3 packing must support this otherwise 1S2 IEC EN 60721 3 3 2002 Classification of environ mental conditions Part 3 3 Classification of groups of environmental paramet ers and their severities Stationary use of weather protected locations Chemical gases Class 3C2 Solid particles Class 3S2 No conductive dust al lowed Contamination IEC EN 60721 3 2 1997 2 9 Hz max 3 5 mm amplitude 9 200 Hz 10 m...

Page 106: ... 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 The main parts of the drive...

Page 107: ... to be connected to and to communicate information and data via a network interface It is Customer s sole responsibility to provide and continuously 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 authenti...

Page 108: ...108 ...

Page 109: ...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 110: ... 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 114 110 Internal cooling circuit ...

Page 111: ...e limits specified in Technical data page 114 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 116 Coolant temperature control The temperature of the coolant in th...

Page 112: ...on 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 cu...

Page 113: ... 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 113 ...

Page 114: ...t with coolant specified under Coolant specification page 114 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 115: ... 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 116: ... 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 117: ...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...

Page 118: ...118 ...

Page 119: ... 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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