ABB ACS880-107 User manual

Brand: ABB

Model: ACS880-107

Type: User manual

ABB industrial drives

Hardware manual

ACS880-107 inverter units

List of related manuals

You can find manuals and other product documents in PDF format on the Internet. See section

Document library on the Internet on the inside of the back cover. For manuals not available in the

Document library, contact your local ABB representative.

General drive manuals Code (English)

Safety instructions for ACS880 multidrive cabinets and

modules

3AUA0000102301

Electrical planning instructions for ACS880 multidrive

cabinets and modules

3AUA0000102324

Mechanical installation instructions for ACS880 multidrive

cabinets

3AUA0000101764

Supply unit manuals

ACS880-207 IGBT supply units hardware manual 3AUA0000130644

ACS880 IGBT supply control program firmware manual 3AUA0000131562

ACS880-307 +A003 diode supply units hardware manual 3AUA0000102453

ACS880-307 +A018 diode supply units hardware manual 3AXD50000011408

ACS880 diode supply control program firmware manual 3AUA0000103295

ACS880-907 regenerative rectifier units hardware manual 3AXD50000020546

ACS880 regenerative rectifier control program firmware

manual

3AXD50000020827

Inverter unit manuals and guides

ACS880-107 inverter units hardware manual 3AUA0000102519

ACS880 primary control program firmware manual 3AUA0000085967

ACS880 primary control program quick start-up guide 3AUA0000098062

Brake unit and DC/DC converter unit manuals

ACS880-607 1-phase brake units hardware manual 3AUA0000102559

ACS880-607 3-phase brake units hardware manual 3AXD50000022034

ACS880 brake control program firmware manual 3AXD50000020967

ACS880-1607 DC/DC converter units hardware manual 3AXD50000023644

ACS880 DC/DC converter control program firmware

manual

3AXD50000024671

Option manuals and guides

ACX-AP-x Assistant control panels user’s manual 3AUA0000085685

Drive composer start-up and maintenance PC tool user’s

manual

3AUA0000094606

ACS880 +C132 marine type-approved cabinet-built drives

supplement

3AXD50000039629

Manuals and quick guides for I/O extension modules,

fieldbus adapters, safety options etc.

Hardware manual

ACS880-107 inverter units

3AUA0000102519 Rev D

EFFECTIVE: 2017-07-14

4. Electrical installation

6. Start-up

Table of contents

1. Introduction to the manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Categorization by frame size, option code and item designation . . . . . . . . . . . . . . . . . . 12

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety data (SIL, PL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2. Hardware description

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Inverter unit hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cabinet system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Inverter module frame sizes R1i to R4i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Module layout examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Standard cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Layout of cubicle with frame R1i…R4i modules in their own compartments (option

+C204) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Inverter module frame size R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Standard cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Layout of cubicle with frame R5i modules in their own compartments (option +C204)

Inverter module frame sizes R6i and R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Motor cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Inverter module frame size R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Control electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Motor cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

The drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Overview of control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Frames R1i…R7i (with ZCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Frame R8i and multiples (with BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

The ACS-AP-W control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Control by PC tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Other control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

DC switch/disconnector (option +F286) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Charging switch (frame R8i and multiples only) . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Inverter unit type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Inverter module type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Inverter unit type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3. The inverter control unit

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

ZCU control unit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

BCU control unit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

ZCU-12 layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

ZCU-14 layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

BCU layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Default I/O connection diagram (ZCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Default I/O connection diagram (BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . . 55

ZCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

BCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

DI6 as PTC sensor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input . . . . . . . . . . . . . . . . . . . 56

DIIL input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Safe torque off (XSTO, XSTO OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

FSO-xx safety functions module connection (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SDHC memory card slot (BCU-x2 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Control unit connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4. Electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Static electricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Optical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Connecting the motor cable – Frame sizes R1i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . 67

Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Motor cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Connecting the motor cable – Frame sizes R6i and R7i . . . . . . . . . . . . . . . . . . . . . . . . 69

Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Motor cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Connecting the motor cables – Frame size R8i and multiples without common motor termi-

nal cubicle or sine output filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Connection diagram (without option +H366) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Connection diagram (with option +H366) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Motor cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Removing the fan carriage of an inverter module . . . . . . . . . . . . . . . . . . . . . . . . . 74

Removing the inverter module(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Connecting the motor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Re-inserting the inverter modules into the cubicle . . . . . . . . . . . . . . . . . . . . . . . . . 82

Connecting the motor cables – Frame size R8i and multiples with common motor terminal

cubicle (+H359) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Output busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Installing optional modules on the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Installing an FSO-xx safety functions module (frame sizes R1i…R7i) . . . . . . . . . . . . 85

Installing an FSO-xx safety functions module (frame sizes R8i and multiples) . . . . . 86

Installation of I/O extension, fieldbus adapter and pulse encoder interface modules . 88

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Connecting a PC to the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Panel bus (Control of several inverter units from one control panel) . . . . . . . . . . . . . . . 92

5. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

6. Start-up

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Connecting voltage to auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Checks with auxiliary voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Connecting voltage to inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Checks with voltage connected to inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Control from an overriding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

7. Maintenance

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Cleaning the door air inlets (IP22 and IP42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Cleaning the door air inlets (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Replacing the outlet (roof) filters (IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Module heatsinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Module cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Replacement of module fan (frames R1i and R2i) . . . . . . . . . . . . . . . . . . . . . . . . 110

Replacement of module fan (frames R3i and R4i) . . . . . . . . . . . . . . . . . . . . . . . . 111

Replacement of main cooling fan (frame R5i without option +C204) . . . . . . . . . . 112

Replacement of main cooling fan (frame R5i with option +C204) . . . . . . . . . . . . 113

Replacement of auxiliary cooling fan (frame R5i) . . . . . . . . . . . . . . . . . . . . . . . . 114

Replacement of module fan(s) (frames R6i and R7i) . . . . . . . . . . . . . . . . . . . . . . 115

Replacement of module fans (frame R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Replacement of circuit board compartment fan (frame R8i) . . . . . . . . . . . . . . . . 118

Cabinet cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Replacing the cabinet fan(s) (Frames R1i…R5i) . . . . . . . . . . . . . . . . . . . . . . . . . 120

Replacing the control cubicle fan (Frame R8i and multiples) . . . . . . . . . . . . . . . . 121

Inverter module replacement (frames R1i…R4i in their own compartments, option +C204)

122

Inverter module replacement (frame R5i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Frame R5i (without option +C204) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Frame R5i with option +C204 (modules in their own compartments) . . . . . . . . . . . 124

Inverter module replacement (frames R6i and R7i) . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Inverter module replacement (frame R8i and multiples) . . . . . . . . . . . . . . . . . . . . . . . 127

DC fuse replacement (frame R8i and multiples) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

FSO-xx safety functions module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

8. Technical data

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Inverter modules used, DC fuses, DC capacitances . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Noise and cooling characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Sine output filter data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Input power (DC) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Motor (AC) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Mechanical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Insulation supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

9. Circuit diagrams

10. Dimensions and weights

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Frames R1i…R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Frames R1i…R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Frames R6i and R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Dimension drawing, 400 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Dimension drawing, cubicle with 2×R8i modules (without +C128 or +H353) . . . . . . 155

Dimension drawing, drive control unit (DCU) (300 mm) . . . . . . . . . . . . . . . . . . . . . . 156

11. The Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 158

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Single inverter unit (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Dual-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Single-channel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Frame n×R8i inverter unit (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Multiple inverter units (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Multiple inverter units (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Introduction to the manual 11

Introduction to the manual

What this chapter contains

This chapter gives basic information on the manual.

Applicability

The manual is applicable to ACS880 multidrive inverter units that form a part of an

ACS880 multidrive system. ACS880 multidrive inverter units have the basic type

designation of ACS880-107.

Safety instructions

Follow all safety instructions delivered with the drive.

• Read the complete safety instructions before you install, commission, use or

service the drive. The complete safety instructions are given in ACS880 multidrive

cabinets and modules safety instructions (3AUA0000102301 [English]).

• Read the software function specific warnings and notes before changing the

default settings of the 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 install, start up, and service ACS880 multidrives.

Read the manual before working on the drive. You are expected to know the fundamentals

of electricity, wiring, electrical components and electrical schematic symbols.

12 Introduction to the manual

Contents of the manual

• Hardware description describes the inverter unit and its role in the drive system.

• The inverter control unit describes the connections of the drive control unit, the main

interface for the control connections of the inverter unit.

• Electrical installation contains the cabling and wiring instructions.

• Installation checklist contains a list of items to check before start-up.

• Start-up describes the start-up sequence of the inverter unit.

• Maintenance provides maintenance instructions.

• Technical data contains the technical specifications of the inverter unit, for example

ratings, sizes and technical requirements, and provisions for fulfilling the requirements

for CE and other markings.

• Circuit diagrams.

• Dimensions and weights contains dimension data and drawings.

• The Safe torque off function describes the implementation of a safe torque off circuit.

Related documents

The multidrive user documentation consists of technical drawings and a set of manuals.

The technical drawings are tailor-made for each drive. The composition of the manual set

depends on the composition of the drive, eg. which supply unit type, options and inverter

control program has been ordered by the customer. The manuals are listed on the inside

of the front cover.

Categorization by frame size, option code and item designation

Some descriptions, instructions, technical data and dimensional drawings which concern

only a certain group of units may be marked with the symbol of the frame size (such as

“R2i”, “4×R8i”, etc.). The marking derives from the quantity and basic construction of the

inverter modules that form the inverter unit. For example, the frame size “2×R8i” indicates

that the inverter unit consists of two frame size R8i inverter modules connected in parallel.

The frame size is marked on the type designation labels. The frame size of each inverter

module is also shown in the rating tables (Ratings, page 133).

The instructions and technical data which concern only certain optional selections 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 labels (page 41).

Some device names in the manual include the item designation in brackets, for example

[Q21] to make it possible to identify the components in the circuit diagrams of the drive.

Terms and abbreviations

Term/Abbreviation Description

BCU-02/12/22 Type of a control unit used with frame R8i (and multiples) inverter units.

Consists of a BCON board and other components built in a sheet metal

housing. The numeral in the type designation varies according to the number of

inverter modules that can be connected to the control unit.

Control board Circuit board in which the control program runs.

Introduction to the manual 13

Control unit Control board built in a rail-mountable housing

Cubicle One section of a cabinet-installed drive. A cubicle is typically behind a door of

its own.

CVAR Varistor board

DC link DC circuit between supply unit and inverter unit(s)

DCU Drive control unit; the cubicle that contains the control electronics of, and

optional equipment related to, a frame R8i (or multiples) inverter unit.

DI Digital input

Drive Frequency converter for controlling AC motors. The drive consists of the supply

unit (aka line-side converter) and one or multiple inverter units (aka motor-side

converters) connected by the DC link. The drive may also contain other units

such as the brake unit.

FAIO-01 Optional analog I/O extension module

FCAN-01 Optional CANopen adapter module

FCNA-01 Optional ControlNet™ adapter module

FDIO-01 Optional digital I/O extension module

FDNA-01 Optional DeviceNet™ adapter module

FDPI Optional diagnostics and panel interface

FEA-03 Optional I/O extension adapter

FECA-01 Optional EtherCAT adapter module

FEN-01 Optional TTL incremental encoder interface module

FEN-11 Optional TTL absolute encoder interface module

FEN-21 Optional resolver interface module

FEN-31 Optional HTL incremental encoder interface module

FENA-11 Optional Ethernet adapter module for Ethernet/IP™, Modbus TCP and

PROFINET-IO protocols

FENA-21 Optional Ethernet adapter module for Ethernet/IP™, Modbus TCP and

PROFINET-IO protocols, 2-port

FEPL-02 Optional Ethernet POWERLINK adapter module

FIO-01 Optional digital I/O extension module

FIO-11 Optional analog I/O extension module

FLON-01 Optional LonWorks® adapter module

FPBA-01 Optional PROFIBUS DP adapter module

FPTC-01 Optional thermistor protection module

FPTC-02 Optional ATEX-certified thermistor protection module for potentially explosive

atmospheres

Term/Abbreviation Description

14 Introduction to the manual

Frame (size) Relates to the construction of power modules (such as an inverter module). For

example, several inverter module types with different power ratings may have

the same basic construction, and the frame size is used in reference to all those

modules.

The frame size marking indicates the quantity and frame size of the inverter

modules, eg. “3×R8i”.

To determine the frame size of an inverter unit, see the rating tables in chapter

Technical data.

FSCA-01 Optional Modbus/RTU adapter module

FSO-xx Optional safety function modules

IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type

widely used in drives due to their easy controllability and high switching

frequency

Intermediate circuit DC link

INU Inverter unit

Inverter Converts direct current and voltage to alternating current and voltage.

Inverter module Inverter bridge, related components and drive DC link capacitors enclosed

inside a metal frame or enclosure. Intended for cabinet installation.

Inverter unit The part of the drive that converts DC to AC for the motor. Consists of one or

more inverter modules and their auxiliary components.

The inverter unit is also capable of feeding energy from a decelerating motor

into the DC link.

I/O Input/Output

Multidrive Drive for controlling several motors which are typically coupled to the same

machinery. Includes one supply unit, and one or several inverter units.

Panel bus A method of connecting the inverter units so that one control panel (or PC) can

be used to control them all. See page 92.

Parameter In the control program, user-adjustable operation instruction to the drive, or

signal measured or calculated by the drive

PLC Programmable logic controller

RDCO-0x DDCS communication module

RFI Radio-frequency interference

SAR Safe acceleration range

SBC Safe brake control

SIL Safety integrity level

SLS Safely-limited speed without encoder

SS1 Safe stop 1

SSE Safe stop emergency

SSM Safe speed monitor without encoder

STO Safe torque off. See chapter The Safe torque off function.

Term/Abbreviation Description

Introduction to the manual 15

 Safety data (SIL, PL)

Supply unit The part of the drive that converts AC to DC. Consists of one or more supply

modules and their auxiliary components such as the LCL filter.

Some supply units are also capable of feeding regenerative energy back into

the supply network.

UPS Uninterruptible power supply

ZCU-12 Type of a control unit used in frame R5i inverter units.

ZCU-14 Type of a control unit used in frame R1i…R4i, R6i and R7i inverter units.

Abbr. Reference Description

Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in respect

of their resistance to faults and their subsequent behavior in the fault

condition, and which is achieved by the structural arrangement of the

parts, fault detection and/or by their reliability. The categories are: B, 1,

2, 3 and 4.

CCF EN ISO 13849-1 Common cause failure (%)

DC EN ISO 13849-1 Diagnostic coverage

FIT IEC 61508 Failure in time: 1E-9 hours

HFT IEC 61508 Hardware fault tolerance

MTTF

EN ISO 13849-1 Mean time to dangerous failure: (The total number of life units) / (the

number of dangerous, undetected failures) during a particular

measurement interval under stated conditions

PFD

avg

IEC 61508 Probability of failure on demand

PFH IEC 61508 Probability of dangerous failures per hour

PL EN ISO 13849-1 Performance level. Levels a…e correspond to SIL

SC IEC 61508 Systematic capability

SFF IEC 61508 Safe failure fraction (%)

SIL IEC 61508 Safety integrity level (1…3)

SILCL IEC/EN 62061 Maximum SIL (level 1…3) that can be claimed for a safety function or

subsystem

SS1 IEC/EN 61800-5-2 Safe stop 1

STO IEC/EN 61800-5-2 Safe torque off

T1 IEC 61508-6 Proof test interval. T1 is a parameter used to define the probabilistic

failure rate (PFH or PFD) for the safety function or subsystem.

Performing a proof test at a maximum interval of T1 is required to keep

the SIL capability valid. The same interval must be followed to keep the

PL capability (EN ISO 13849) valid. Note that any T1 values given

cannot be regarded as a guarantee or warranty.

See also section Maintenance (page 167).

Term/Abbreviation Description

16 Introduction to the manual

Hardware description 17

Hardware description

What this chapter contains

This chapter describes a typical drive system and the hardware of the inverter unit. The

information is valid for all ACS880-107 inverter units. The ACS880-107 is an inverter unit

for controlling asynchronous AC induction motors, permanent magnet synchronous

motors, ABB synchronous reluctance (SynRM) motors, and AC induction servomotors.

Operation principle

The supply unit connects to the AC supply network and converts the AC voltage into DC.

The DC voltage is distributed through the DC bus to all inverter units. The inverter unit

converts the DC back to AC that rotates the motor. The inverter units of ACS880

multidrives are of the type ACS880-107.

18 Hardware description

The following diagram depicts a typical drive system.

5 5

Item Explanation

1 Main switch-disconnector [Q1]

2AC fuses

3 Main contactor [Q2]

4 Supply module [T01] (including choke, rectifier and DC fuses)

5 Inverter DC fuses (or DC switch/disconnector and charging circuit)

6 Inverter modules [T11…]

7Motor

8 Auxiliary voltage switch [Q21]

9 Auxiliary voltage transformer [T21]

Hardware description 19

Inverter unit hardware

 General

An inverter unit contains the components required to control one motor, for example the

inverter module(s) with the necessary equipment such as control electronics, fusing,

cabling and switchgear.

ACS880-107 inverter units range from 1.5 to 5600 kW in power. ACS880-107 inverter

units employ inverter modules from frame size R1i to R8i. Up to approximately 500 kW,

inverter units consist of one module only; higher powers are achieved by connecting

multiple R8i modules in parallel.

All inverter modules used in the ACS880-107 inverter units have coated circuit boards as

standard.

 Cabinet system

An inverter unit is built into one or more adjoining cubicles and contains the components

that are required to control one motor. At smaller inverter sizes, a single cubicle may

contain several inverter units, each controlling a different motor. On the other hand, large

inverter units consist of parallel-connected modules and may occupy several cubicles.

Examples of the cabinet configurations are included below as well as in the chapter

Dimensions and weights. The motor cabling direction is optionally up or down – see below

under each module frame size for specific information.

The section Control interfaces (page 36) below shows the available control and I/O options

of the inverter unit.

 Cooling

Each inverter module has its own cooling fan(s). Control cubicles may have additional

cooling fans.

The inverter cubicles have the air intake at the lower part of the door. The intake can

optionally be through the floor, adding 130 mm (5.12”) to the standard depth of 600 mm

(23.62”) of the cabinet.

The cooling air outlets are on the roof of each cubicle. Some configurations have

exhauster fans fitted inside the top compartment of the cubicle. A channeled air outlet is

optional.

20 Hardware description

 Inverter module frame sizes R1i to R4i

The motor (output) cables are connected to either detachable or non-detachable screw

terminal blocks at the bottom of the cubicle. The modules have a built-in ZCU-14 drive

control unit, which contains the basic I/Os and slots for optional I/O modules; for

descriptions of the I/O terminals, see chapter The inverter control unit (page 47).

The modules have an internal capacitor pre-charge circuit.

External optional equipment is primarily installed on mounting plates in the same cubicle.

Module layout examples

Frame R1i (Frame R2i has a similar layout)

Item Explanation

1 Power unit

2 DC (input) connections

3 Motor (output) connection (obscured). This has been

wired to a separate terminal block in the lower part of the

cubicle.

4 ZCU-14 control unit mounted on top of the power unit

5 Grounding/strain relief rail for control cables.

6 I/O terminal blocks

7 3 slots for optional modules

8 Memory unit

9 Connection for FSO-xx safety functions module

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ABB ACS880-107 User manual

ABB ACS880-107 User manual

ABB ACS880-107 User manual

Related papers

Other documents