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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
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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.
5
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)
27
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
6
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
7
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
8
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
9
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
10
Introduction to the manual 11
1
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
D
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
2
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.
M
3~
M
3~
~3
M
3~
1
2
3
4
5
6
7
8
9
66
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
8
3
4
1
2
7
7
7
5
6
9
/
