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Maintenance

Contents of this chapter ...........................................................................

Maintenance intervals .............................................................................

Maintenance timers and counters ...............................................................

Internal liquid-cooling system ....................................................................

Power connections ................................................................................

Retightening the power connections ........................................................

Fans ..................................................................................................

Replacing the fan in the 600 mm wide incoming cubicle .................................

Replacing the cooling fan of a D8T supply module .......................................

Fuses ................................................................................................

Checking and replacing the AC fuses .......................................................

Checking and replacing the DC fuses .......................................................

Supply module .....................................................................................

Replacing the D8T supply module ...........................................................

Control panel .......................................................................................

Cleaning the control panel ....................................................................

Replacing the control panel battery ..........................................................

Control unit ..........................................................................................

Replacing the memory unit ...................................................................

Replacing the BCU control unit battery .....................................................

LEDs and other status indicators ................................................................

Control panel and panel platform/holder LEDs ............................................

Control unit LEDs ...............................................................................

Internal cooling circuit

Contents of this chapter ...........................................................................

Applicability .........................................................................................

Internal cooling system ............................................................................

Connection to a cooling unit ......................................................................

Connection to an ACS880-1007LC cooling unit ...........................................

Connection to a custom cooling unit .........................................................

General requirements ......................................................................

Coolant temperature control ...............................................................

Filling up and bleeding the internal cooling circuit ............................................

Drive line-ups with an ACS880-1007LC cooling unit ......................................

Drive line-ups with a custom cooling unit ...................................................

Draining the internal cooling circuit ..............................................................

Maintenance intervals .............................................................................

Technical data ......................................................................................

Coolant specification ...........................................................................

Coolant type .................................................................................

Temperature limits ..............................................................................

Pressure limits ..................................................................................

Coolant flow rate limits ........................................................................

Cooling circuit materials .......................................................................

Technical data

Contents of this chapter ...........................................................................

Ratings ..............................................................................................

Table of contents 7

Summary of Contents for ACS880-307LC

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 307LC diode supply units Hardware manual ...

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Page 3: ...ACS880 307LC diode supply units Hardware manual Table of contents 3 Electrical installation 6 Start up 3AXD50000579662 Rev A EN EFFECTIVE 2020 06 30 ...

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Page 5: ...me 1 D8T electrical components 20 Supply module cubicle layout frame 1 D8T cooling circuit 21 Supply module cubicle layout frame 2 D8T 21 Supply module cubicle layout frame 2 D8T electrical components 22 Supply module cubicle layout frame 2 D8T cooling circuit 23 Supply module layout frame D8T 24 Overview of the control connections of the BCU control unit 25 Supply unit control devices 25 Overview...

Page 6: ...uting the control cables inside the cabinet 44 Connecting control cabling 46 Connecting a PC 4 The control unit 47 Contents of this chapter 48 BCU x2 layout 50 Default I O diagram of the supply control unit 52 External power supply for the control unit XPOW 52 The X485 connector 53 Safe torque off XSTO XSTO OUT 53 FSO xx safety functions module connection X12 53 SDHC memory card slot 54 Connector ...

Page 7: ... LEDs and other status indicators 76 Control panel and panel platform holder LEDs 77 Control unit LEDs 8 Internal cooling circuit 79 Contents of this chapter 79 Applicability 79 Internal cooling system 81 Connection to a cooling unit 81 Connection to an ACS880 1007LC cooling unit 81 Connection to a custom cooling unit 81 General requirements 81 Coolant temperature control 82 Filling up and bleedin...

Page 8: ...7 600 mm wide incoming cubicle or input cubicle 98 Tightening torques 98 Electrical connections 98 Mechanical connections 98 Insulation supports 98 Cable lugs 99 Typical power cable sizes 101 Electrical power network specification 101 Control unit board connection data 101 Auxiliary circuit current consumption 101 Efficiency 101 Protection classes 102 Ambient conditions 103 Materials 103 Color 103...

Page 9: ...ish 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 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 instal...

Page 10: ...nverter DC link Digital input DI Diode rectifier and related components enclosed in a metal frame or enclosure Inten ded for cabinet installation Diode supply module Diode supply modules under control of one control board and related components Diode supply unit Frequency converter for controlling AC motors Drive Diode supply unit DSU Physical size of the drive or power module Frame frame size Inc...

Page 11: ...S880 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 manual 3AXD50000024671 ACS880 DC DC converter control program...

Page 12: ...12 ...

Page 13: ...age in the DC link of the drive The main difference between the ordinary diode diode bridge and the controlled diode thyristor bridge is the controllability You cannot control the operation of the diodes but you can control the thyristors By controlling the thyristors you can limit the AC current of the drive at the power up without additional charging circuit in the supply unit or in inverter uni...

Page 14: ...on is standard If the drive has an even number of supply modules you can order it as a 12 pulse version option A004 The 12 pulse supply connection eliminates the fifth and seventh harmonics which substantially reduces the harmonic distortion of the line current and the conducted emissions The 12 pulse connection requires a three winding transformer or two separate transformers There must be phase ...

Page 15: ... A B 6 pulse connection A 12 pulse connection B Supply transformer 1 Switching equipment 2 Diode supply modules 3 Operation principle and hardware description 15 ...

Page 16: ...3 5 6 6 5 5 6 Main circuit breaker Q1 1 AC fuses 2 Supply module T01 including choke and rectifier 3 Supply module DC fuses 4 Inverter module DC fuses with or without DC switches 5 Inverter module T11 6 Motor 7 Auxiliary voltage switch Q21 option G344 or G451 8 Auxiliary voltage transformer T21 option G344 9 16 Operation principle and hardware description ...

Page 17: ...t This drawing shows an example of a diode supply unit 1 2 3 6 10 8 11 5 4 7 9 Auxiliary control cubicle 1 Incoming cubicle 2 Supply module cubicle 3 Control devices See section Supply unit control devices 4 11 Operation principle and hardware description 17 ...

Page 18: ...e for cooling fan monitoring A115 99 3 BCU control unit A51 4 Auxiliary voltage transformers behind the assembly plates T21 option G344 T115 option G451 in some deliveries also T125 5 Cooling fan and heat exchanger G115 99 6 Inlet manifold with stop and drain valves 7 Outlet manifold with stop and drain valves 8 18 Operation principle and hardware description ...

Page 19: ...ary voltage supply breaker switch fuse Q21 1 6 Grounding switch Q9 x option F259 4 7 Not in use 8 CIO 01 I O module for cooling fan control A115 x 10 Cooling fan and heat exchanger G115 x 11 Input power cable terminals L1 L2 L3 12 Inlet manifold with stop and drain valves 13 Outlet manifold with stop and drain valves 14 Operation principle and hardware description 19 ...

Page 20: ... CIO 01 I O module for distributed I O bus control A115 101 3 Cabinet light switch S130 101 option G301 4 Module 1 AC fuses F3 11 1 5 Module 1 DC fuses F2 11 1 6 Supply module T01 1 7 Cabinet heater E95 101 option G300 8 Cabinet fan G115 101 9 1 Latter number is for the first supply module cubicle The number increases in other cubicles if any Supply module cubicle layout frame 1 D8T cooling circui...

Page 21: ... Cabinet light H310 101 option G301 1 Cabinet fan miniature circuit breaker F115 101 2 CIO 01 I O module for distributed I O bus control A115 101 3 Cabinet light switch S130 101 option G301 4 Module 1 AC fuses F3 1 1 5 Module 1 DC fuses F2 11 1 6 Supply module 1 T01 1 7 Module 2 AC fuses F3 4 or F3 7 1 8 Module 2 DC fuses F2 21 1 9 Supply module T01 2 10 Cabinet heater E95 101 option G300 11 Opera...

Page 22: ... 6 7 4 2 4 4 5 3 Heat exchanger 1 Inlet manifold with stop and drain valves 2 Outlet manifold with stop and drain valves 3 Inlet pipes cold coolant from main pipe to modules and heat exchanger 4 Output pipes warm coolant to main pipe from modules and heat exchanger 5 Supply modules T01 x 6 Draining pipes inlet draining pipe and outlet draining pipe 7 22 Operation principle and hardware description...

Page 23: ...out frame D8T 4 4 6 1 3 1 2 5 3 AC input busbars 1 DC output busbars 2 Lifting eyes 3 Coolant in and out connectors 4 Fiber optic connectors 5 230 115 V supply connection 6 Operation principle and hardware description 23 ...

Page 24: ... 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 24 Operation principle and hardware description ...

Page 25: ...pment 7 Emergency stop button S61 option G331 8 Control panel A59 option J400 or J412 9 Auxiliary voltage supply breaker switch fuse Q21 10 Voltage meter P5 x option G334 11 Selector switch for phase voltage meter S5 x option G334 12 Phase current meter s P2 x option G335 13 Grounding switch Q9 x option F259 14 Main supply breaker Q1 x option F255 15 Main disconnecting device Q1 x The supply unit ...

Page 26: ...nding switch Q9 x option F259 Using the switch you can temporarily ground the main AC busbars of the supply unit during the maintenance work The switch has an operating handle on the cabinet door WARNING The grounding switch does not ground the input power terminals of the drive or the auxiliary control voltage circuits Operating switch S21 The operating switch S21 is a standard device By default ...

Page 27: ... the breaker of the supply transformer of the drive The button is wired to a terminal block at the factory The user connects the external circuit to be controlled on site An electrical on off push button S23 option G332 on the cabinet door for tripping the supply unit The button is connected in series with the operating switch The button trips the Run enable signal and further the main contactor b...

Page 28: ...ing switch S21 is switched to the ENABLE RUN position Type designation labels Each diode supply module and unit has a type designation label The type designation stated on the label contains information on the specifications and configuration of the unit Supply unit 1 2 3 4 5 6 7 8 Type designation 1 Frame size 2 Cooling method 3 Degree of protection 4 UL CSA data 5 Ratings 6 Valid markings 7 Seri...

Page 29: ...id markings 7 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 8 Operation principle and hardware description 29 ...

Page 30: ...aterial copper cable supply conductors standard wiring material power and control cabling through the bottom of the cabinet ACS AP W assistant control panel ACS880 diode supply control program coated circuit boards lead through type cable entries multilingual door device label sticker complete documentation in English in a USB memory stick 307LC Size Refer to the rating table in the technical data...

Page 31: ... wiring and materials G330 Emergency stop push button on the door red G331 Electrical disconnect push button on the door black opens main contactor ACB G332 kW meter on door G333 V meter with selector switch G334 A meter in one phase G335 Arc monitoring G336 Arc monitoring with current monitoring unit G337 Additional wire markings G338 G339 G340 G341 G342 Corrosion indicator G343 Auxiliary voltage...

Page 32: ...66 Emergency stop category 0 with safety relays by opening the main breaker contactor Q951 Emergency stop category 1 with safety relays by opening the main breaker contactor Q952 Earth fault monitoring for IT ungrounded systems Q954 Supply transformer breaker disconnect push button red wired to terminals on the door Q959 Emergency stop category 0 with safety relays by activating the Safe torque of...

Page 33: ...oltage range 525 690 V This is indicated in the type designation label as typical input voltage levels 3 525 600 690 V AC 7 Plus codes Half controlled diode thyristor bridge as standard A018 Marine type approval C132 Marine product certification only with C132 C209 Extended warranty 24 30 P904 Extended warranty 36 42 P909 Extended warranty 60 66 P911 Operation principle and hardware description 33...

Page 34: ...34 ...

Page 35: ...tion protections etc see ACS880 multidrive cabinets and modules electrical planning instructions 3AUA0000102324 English WARNING Obey the safety instructions given in ACS880 liquid cooled multidrive cabinets and modules safety instructions 3AXD50000048633 English If you ignore the safety instructions injury or death or damage to the equipment can occur If you are not a qualified electrical professi...

Page 36: ...on F259 if present Do not use excessive force as the switch has electromagnetic interlocking If the drive is equipped with a DC DC converter unit optional Open the DC switch disconnector Q11 option F286 of the DC DC converter Open the disconnecting device of the energy storage connected to the DC DC converter unit outside the drive cabinet Open the auxiliary voltage switch disconnector if present ...

Page 37: ... coating are potentially unreliable so only measure at uncoated portions Note that the coating does not constitute a safe or touch proof insulation 6 If the drive is not equipped with a grounding switch install temporary grounding as required by the local regulations 7 Ask the person in control of the electrical installation work for a permit to work General notes Static electricity WARNING Use a ...

Page 38: ...gram for the 6 pulse supply unit See also the delivery specific circuit diagrams 1 2 L2 L3 PE L1 Fuses or other protection means for the short circuit protection of the cable 1 Grounding of the cable shield at the cable entry 360 degrees grounding 2 Additional information See the technical data for the dimensions of the cable entries and the dimensions and tightening torques of the terminals Use a...

Page 39: ...num contact can cause oxidation in 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 36 2 Open the door of the incoming cubicle 3 Remove the shrouding covering the input terminals 4 Peel off 3 to 5 cm of the outer insulation of the cables above the lead through plate for 360 high frequency gr...

Page 40: ...11 Reinstall the shrouding removed earlier 12 Close the door 3 PE PE 40 Electrical installation ...

Page 41: ...10 9 7 6 8 Electrical installation 41 11 ...

Page 42: ...abinets and modules safety instructions 3AXD50000048633 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 1 Stop the drive if running and do the steps in section Electrical safety precautions page 36 before you start the work 2 Run the control cables into t...

Page 43: ...se its conductive surface Cover the turned shield and the stripped cable with copper foil to keep the shielding continuous 1 A B C 2 2 3 4 5 Stripped cable A Conductive surface of the shield 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 an...

Page 44: ...ow the control unit The drawing below represents a drive with additional I O terminal block option L504 Without the block the grounding is made the same way Notes Do not ground the outer shield of the cable here since it is grounded at the lead through Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by indu...

Page 45: ...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 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 points Electrical installation 45 11 ...

Page 46: ...panel holder or platform or by using an Ethernet eg Cat 5e networking cable 2 Remove the USB connector cover on the front of the control panel 3 Connect an USB cable Type A to Type Mini B between the USB connector on the control panel 3a and a free USB port on the PC 3b 4 The panel will display an indication whenever the connection is active 5 See the documentation of the PC tool for setup instruc...

Page 47: ...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 4 The control unit 47 ...

Page 48: ...g 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 Control progr...

Page 49: ...tion 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 of...

Page 50: ...Energized running 250 V AC 30 V DC 2 A Norm closed NC 11 22 23 31 32 11 12 13 21 33 Common COM 12 Norm open NO 13 XRO2 Fault 1 2 Energized no fault 250 V AC 30 V DC 2 A Note If drive is equipped with a liquid cool ing unit the relay output controls the cooling unit start signal Then the selection Fault 1 may also be changed to Started by bit 12 of parameter 195 12 See ACS880 diode supply control p...

Page 51: ... 5 6 7 8 Digital input ground DICOM 2 24 V DC 200 mA5 24VD 3 Digital input output ground DIOGND 4 Ground selection switch6 DICOM DIOGND ON OFF Analog inputs reference voltage output XAI 10 V DC RL 1 10 kohm VREF 1 5 6 7 1 2 3 4 10 V DC RL 1 10 kohm VREF 2 Ground AGND 3 Not in use by default 0 2 10 V Rin 200 kohm7 AI1 4 AI1 5 Not in use by default 0 4 20 mA Rin 100 ohm8 AI2 6 AI2 7 AI1 current volt...

Page 52: ...ected to DIOGND OFF DICOM and DIOGND separate 7 Current 0 4 20 mA Rin 100 ohm or voltage 0 2 10 V Rin 200 kohm input selected by switch AI1 Change of setting requires reboot of control unit 8 Current 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 i...

Page 53: ...n 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 DC DC converter or brake units SDHC memory card slot 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 ...

Page 54: ...tch 5 mm wire size 2 5 mm2 Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 As inputs 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Fil tering 1 ms Input output mode selection by paramet ers As outputs Total output current from 24VD is limited to 200 mA DIO1 can be configured as a frequency input 0 16 kHz with hardware filtering of 4 microseconds for 24 V level square wave signal sinusoidal or...

Page 55: ... 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 IEC 61326 3 1 Connector pitch 5 mm wire size 2 5 mm2 Safe torque off output XSTO O...

Page 56: ...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 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 digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO signal ground DIOGND Isolati...

Page 57: ... WARNING Stop the drive and do the steps in section Electrical safety precautions page 36 before you start the work Make sure that The ambient 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 insulation resistance of the input po...

Page 58: ...tened to the correct torque Proper grounding has also been measured according to the regulations The motor cable is connected to the correct terminals the phase order is correct and the terminals are tightened to the correct torque The motor cable is routed away from other cables No power factor compensation capacitors are connected to the motor cable If an external brake resistor is connected to ...

Page 59: ...rt up This default start up procedure is valid for a supply unit equipped with a main breaker Q1 option F255 and an external auxiliary voltage supply option G307 Note For the functional safety options the start up instructions are given in separate option manuals Reserve the necessary option manuals at hand before the supply unit start up Obey their start up instructions WARNING Obey the safety in...

Page 60: ...ttings of breakers switches in the auxiliary circuits Make sure that the voltage settings of the auxiliary voltage transformers option G344 are according to the actual power line voltage See the delivery specific circuit diagrams Transformer T21 is selected by option G344 T101 and T111 are present if required by the options specified by the customer Starting and checking the cooling system Action ...

Page 61: ...d boot Check the correct voltage range parameter 195 01 Supply voltage Reboot the control unit by parameter 196 08 Control board boot If you need more information on the use of the control panel see ACX AP x assistant control panels user s manual 3AUA0000085685 English Powering up the drive Action Close the disconnecting device of the supply unit Drive with main breaker Q1 option F255 Unlock the w...

Page 62: ...he validation tasks On load checks Action Make sure that the cooling operates properly no overtemperature related warnings or faults Switching the supply unit off 1 Stop the motors connected to inverter units See the inverter unit hardware and firmware manuals 2 Turn the operating switch S21 to the OFF 0 position to deactivate the Run enable signal and to switch off the main disconnecting device m...

Page 63: ...ructions 3AXD50000048633 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 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 drivess...

Page 64: ...ls I I I I I I I I I I I I I Ambient conditions dustiness moisture corrosion temperature I I I I I I I I I I I I I Cooling liquid pipe connections Spare parts I I I I I I I I I I I I I Spare part stock Other I I I I I I I I I I I I I ABB SACE Air circuit breaker maintenance I I I I I I I I I I I I I ABB Contactors maintenance 1 Replace CIO module or reset fan counters see CIO 01 I O module for dis...

Page 65: ...tions 3AXD50000048633 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 1 Stop the drive and do the steps in section Electrical safety precautions page 36 before you start the work 2 Examine the tightness of the cable connections Use the tightening torques ...

Page 66: ...e 36 before you start the work 2 Remove the shrouding in front of the fan if any 3 Disconnect the fan wiring Remove the CIO module 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 surrounding the fan unit 7 Install a new fan in reverse order 4 5 6 66 Maintenance ...

Page 67: ...fety precautions page 36 2 Remove any shrouding in front of the cooling fan 3 Remove the support bracket of the fan 4 Disconnect the fan wiring 5 Undo the two retaining screws 6 Pull the fan outwards to separate it from the heat exchanger housing 7 Install new fan in reverse order Align the guide pins at the rear of the fan cowling with the slots in the bottom guide then reinstall the retaining sc...

Page 68: ...se assemblies Remove the screws nuts and washers 8 pcs from the top and bottom of the DC fuses Write down the correct order of the washers Remove the screws and nuts from the L shaped busbars Remove the DC fuses and the L shaped busbars 6 Remove the screw nut and washer in the middle 7 Remove the screws 3 pcs 1 per each phase from the L shaped busbars above the fuses 8 Remove the screws that attac...

Page 69: ...ent Wear protective gloves and long sleeves Some parts have sharp edges 1 Stop the motors connected to the drive 2 Repeat the steps described in section Electrical safety precautions page 36 3 Open the cubicle door 4 Remove any shrouding in front of the DC fuses 5 Remove the screws nuts and washers from the old fuses Write down the correct order of the washers Pull the fuses out 6 Install the new ...

Page 70: ...ply module WARNING Obey the safety instructions of the drive 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 70 Maintenance ...

Page 71: ... If necessary extend the hoses Open the inlet and outlet drain valves This will drain all modules in the cubicle 6 After the cubicle has drained disconnect the piping from the module 7 2 D8T module If lower module needs to be replaced remove the cooling fan see the fan replacement instructions 8 Remove any shrouding above the module 9 Remove the DC fuses above the module See section Checking and r...

Page 72: ... module lift the module and place it on the module guide plate Keep the weight on the lifting device b Push the module into cabinet c Fasten the module fastening screws d Remove the lifting chains e Reinstall the DC busbars and fuses above the module f Connect the plug connector and fiber optic connectors g Reconnect the coolant pipes to the module h Fill up the cooling system i Reinstall all shro...

Page 73: ...11 12 12 6 10 Maintenance 73 ...

Page 74: ...5 English Cleaning the control panel Use a soft damp cloth to clean the control panel Avoid harsh cleaners which could scratch the display window Replacing the control panel battery For instructions on how to replace the control panel battery see ACx AP x assistant control panels user s manual 3AUA0000085685 English 74 Maintenance ...

Page 75: ...tions page 36 before you start the work 2 Make sure that the control unit is not powered 3 Remove 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 real time clock battery if the BATT OK LED is not illuminated when the control unit is powered 1 Stop the drive and do the steps in section Electrical safety pre...

Page 76: ...on LED Location The unit is functioning normally Continuous 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 r...

Page 77: ...LED is not lit Green BATT OK battery voltage is below 2 8 V the battery is missing or the control unit is not powered Internal voltage OK Green PWR OK The control program indicates that the equipment is faulty See the appropriate firmware manual Red FAULT Writing to SD card in progress Yellow WRITE Maintenance 77 ...

Page 78: ...78 ...

Page 79: ...cability The information in this chapter 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 Each cubicle has an inlet and an outlet manifold fitted with a stop valve and a drain valve The stop valves can be closed to isolate all modules ...

Page 80: ...supply unit each module has a dedicated air to liquid exchanger as shown for item 2 1 Inverter modules 2 To From 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 mixture See Coolant specification page 84 80 Internal cooling ci...

Page 81: ... the limits specified in Technical data page 84 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 86 Coolant temperature control The temperature of the coolant in t...

Page 82: ...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 83: ... 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 83 ...

Page 84: ...ied under Coolant specification page 84 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 International Ltd www clariant co...

Page 85: ...mperature increase as shown by curve a 45 50 C 113 122 F If components with a maximum operating temperature of 55 C 131 F are installed in the same space as the drive modules drive output current must be derated by 6 percentage points per 1 C 1 8 F temperature increase as shown by curve c If there are no components with a maximum operating temperature of 55 C 131 F installed in the same space as t...

Page 86: ...system compared with the atmospheric pressure when the cooling circuit is filled with coolant Air counterpressure in expansion vessel with ACS880 1007LC cooling unit 80 kPa Design pressure PS 600 kPa Nominal pressure difference 120 kPa with Antifrogen L 25 coolant solution 140 kPa with Antifrogen L 50 coolant solution This has to be taken into account when dimensioning the liquid cooling circuit M...

Page 87: ...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 88: ...88 ...

Page 89: ... A018 666 714 854 917 890 1170 932 1430 955 780 0780A 7 A018 906 972 1163 1248 1211 1590 1267 1950 1300 1060 1060A 7 A018 1255 1346 1610 1728 1677 2205 1757 2700 1800 1470 1470A 7 A018 1708 1833 2192 2352 2283 3000 2390 3675 2450 2000 2000A 7 A018 2558 2745 3283 3523 3420 4500 3585 5505 3670 3000 3000A 7 A018 3415 3665 4383 4704 4566 6000 4780 7350 4900 4000 4000A 7 A018 4266 4578 5475 5875 5703 7...

Page 90: ...f 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_1 Maximum output DC current Available for 10 s at start otherwise as long as allowed by module temperature SN Nominal apparent AC power Imax_2 Maximum input AC current PN Nominal output DC power Light overload use 50 overload capability ratings ILd...

Page 91: ...PC tool Type equivalence table Frame Basic module type Supply unit type UN 690 V 6 pulse D8T ACS880 304LC 0490A 7 A018 ACS880 307LC 0490A 7 A018 D8T ACS880 304LC 0780A 7 A018 ACS880 307LC 0780A 7 A018 D8T ACS880 304LC 1060A 7 A018 ACS880 307LC 1060A 7 A018 2 D8T ACS880 304LC 0780A 7 A018 ACS880 307LC 1470A 7 A018 2 D8T ACS880 304LC 1060A 7 A018 ACS880 307LC 2000A 7 A018 3 D8T ACS880 304LC 1060A 7 ...

Page 92: ...6416 1470A 7 A004 A018 2 size 3 2 900 12 170M6413 2000A 7 A004 A018 size 3 1250 12 170M6416 2940A 7 A004 A018 2 size 3 2 900 24 170M6413 4000A 7 A004 A018 2 size 3 2 900 36 170M6413 6000A 7 A004 A018 UL CSA Size IN Pcs Type Supply unit type ACS880 307LC A UN 690 V 6 pulse size 3 900 3 170M6413 0490A 7 A018 size 3 1250 3 170M6416 0780A 7 A018 size 23 1800 3 170M6904 1060A 7 A018 size 3 1250 6 170M6...

Page 93: ...170M6549 3000A 7 A018 2 size 3 2 1100 16 170M6549 4000A 7 A018 2 size 3 2 1100 20 170M6549 5000A 7 A018 2 size 3 2 1100 24 170M6549 6000A 7 A018 12 pulse size 3 1100 4 170M6549 0920A 7 A004 A018 2 size 3 2 800 8 170M6546 1470A 7 A004 A018 2 size 3 2 1100 8 170M6549 2000A 7 A004 A018 2 size 3 2 800 16 170M6546 2940A 7 A004 A018 2 size 3 2 1100 16 170M6549 4000A 7 A004 A018 2 size 3 2 1100 24 170M65...

Page 94: ...e ACS880 304LC Supply unit type ACS880 307LC kg mm mm mm 6 pulse 300 644 400 2002 D8T 0490A 7 A018 0490A 7 A018 300 644 400 2002 D8T 0780A 7 A018 0780A 7 A018 300 644 400 2002 D8T 1060A 7 A018 1060A 7 A018 450 644 400 2002 2xD8T 0780A 7 A018 1470A 7 A018 450 644 400 2002 2xD8T 1060A 7 A018 2000A 7 A018 750 644 800 2002 3xD8T 1060A 7 A018 3000A 7 A018 900 644 800 2002 4xD8T 1060A 7 A018 4000A 7 A01...

Page 95: ...20 88 70 11 9 3 0 5000A 7 A018 68 120 102 84 12 6 3 6 6000A 7 A018 12 pulse 67 120 34 28 4 2 1 2 0920A 7 A004 A018 67 120 34 28 4 2 1 2 1470A 7 A004 A018 67 120 34 28 4 2 1 2 2000A 7 A004 A018 68 120 68 56 8 4 2 4 2940A 7 A004 A018 68 120 68 56 8 4 2 4 4000A 7 A004 A018 68 120 102 84 12 6 3 6 6000A 7 A004 A018 Terminal and cable entry data for the input power cable These drawings from front side a...

Page 96: ... 400 mm wide input cubicle 96 Technical data ...

Page 97: ... 600 mm wide incoming cubicle or input cubicle Technical data 97 ...

Page 98: ...s 8 8 70 N m 52 lbf ft M12 Strength class 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 ...

Page 99: ...79 1376 1637 1881 2237 2740 3229 262 318 368 425 486 572 659 1182 1492 1776 2042 2422 2967 3478 210 256 297 343 392 462 533 2 32 2 38 2 41 2 44 2 49 2 54 2 58 2 3 70 21 Cu 2 3 95 29 Cu 2 3 120 41 Cu 2 3 150 41 Cu 2 3 185 57 Cu 2 3 240 72 Cu 2 3 300 88 Cu 1881 2237 2740 3229 638 728 859 989 2042 2422 2967 3478 514 588 693 800 3 44 3 49 3 54 3 58 3 3 150 41 Cu 3 3 185 57 Cu 3 3 240 72 Cu 3 3 300 88 ...

Page 100: ...820 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 10...

Page 101: ...L 508A CSA C22 2 No 14 13 Connection Dy 11 d0 or Dyn 11 d0 Transformer specification for 12 pulse supply IEC 60076 1 2011 Phase shift between secondaries 30 electrical Voltage difference between secondaries 0 5 Short circuit impedance of secondaries 5 Short circuit impedance difference between secondaries 10 of the percentage impedance To avoid a potentially destructive DC voltage level in an eart...

Page 102: ...nvironmental paramet ers and their severities Stationary use of weather protected locations Contamination Chemical gases Class 2C2 Solid particles Class 2S2 Chemical gases Class 1C2 Solid particles Class 1S3 packing must support this otherwise 1S2 Chemical gases Class 3C2 Solid particles Class 3S2 No conductive dust al lowed 2 Pollution degree IEC EN 60721 3 2 1997 IEC EN 60721 3 1 1997 IEC EN 607...

Page 103: ...h film PE thickness 0 04 mm VCI emitter bags PP tape PET strap sheet metal steel Container package option P929 For sea transport in containers Recommended for land and air transport when storage time prior to installation exceeds 6 months or storage is arranged in partially weather protected conditions Disposal The main parts of the drive can be recycled to preserve natural resources and energy Pr...

Page 104: ... 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 authentication measures encryption of data installation of anti virus programs etc to protect the...

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