ABB ACS880-204LC User manual

—

ABB INDUSTRIAL DRIVES

ACS880-204LC IGBT supply modules

Hardware manual

ACS880-204LC IGBT supply modules

Hardware manual

Table of contents

5. Electrical installation

7. Start-up

EN

EFFECTIVE: 2019-06-30

Table of contents

1 Introduction to the manual

13Contents of this chapter ..........................................................................

13Applicability ........................................................................................

13Safety instructions ................................................................................

13Target audience ...................................................................................

14Categorization by frame size and option code ...............................................

14Use of component designations ................................................................

14Terms and abbreviations .........................................................................

15Related documents ...............................................................................

2 Operation principle and hardware description

17Contents of this chapter ..........................................................................

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

18Simplified main circuit diagram ..............................................................

18Charging ........................................................................................

19Overview diagram of the drive system .........................................................

19Cooling system ....................................................................................

20Single-line circuit diagrams of the supply unit ................................................

20Frame 1×R8i ...................................................................................

21Frame R8i multiples ...........................................................................

22IGBT supply module hardware .................................................................

22Frame R8i hardware ..........................................................................

22Module layout ..............................................................................

23Coolant connectors ........................................................................

23Connectors X50…X59 ....................................................................

24Fiber optic connectors .....................................................................

25Control interfaces .................................................................................

25BCU control unit of frame R8i and multiples ..............................................

26Overview of the control connections of the BCU control unit ...........................

27Supply unit control devices ......................................................................

27Main disconnecting device ...................................................................

27Auxiliary voltage switch .......................................................................

27Operating switch ...............................................................................

27Emergency stop and emergency stop reset buttons .....................................

27ACX-AP-x control panel ......................................................................

28Line-up charging switch ......................................................................

28Local charging control switch ................................................................

28DC switch-disconnector ......................................................................

28Charging switch for unit charging ...........................................................

28DC switch-disconnector for line-up charging .............................................

29PC connection .................................................................................

29Fieldbus control ................................................................................

29Type designation labels ..........................................................................

30Type designation key .............................................................................

30IGBT supply module ..........................................................................

30LCL filter ........................................................................................

Table of contents 5

3 Moving and unpacking the module

31Contents of this chapter ..........................................................................

31Moving and unpacking the module .............................................................

4 Cabinet construction

33Contents of this chapter ..........................................................................

33Limitation of liability ...............................................................................

33Switching, disconnecting and protecting solution ............................................

33Frame R8i ......................................................................................

34Cabinet temperature supervision ...............................................................

35Installation examples .............................................................................

36BLCL-15LC-7 / BLCL-24LC-7 in a 600 mm wide Rittal VX25 enclosure ..............

36Layout drawing .............................................................................

37Pipe routing example (BLCL-15LC-7) ..................................................

37Pipe routing example (BLCL-24LC-7 and BLCL-25LC-7) ...........................

38Installation stages ..........................................................................

39Overview of kits ............................................................................

40Stage 1: Installation of common parts ..................................................

41Stage 2: Installation of LCL side plates and common AC bus ......................

42Stage 3: Installation of brackets for Flat-PLS holder .................................

43Stage 4A: BLCL-15LC-7: AC connection and fuse busbars installation ...........

44Stage 4B: BLCL-24LC-7: AC connection and fuse busbars installation ...........

45Stage 5: Installation of LCL choke mounting mechanics and LCL ISU connection .

46Stage 6: LCL choke and LCL choke busbar installation .............................

47

Stage 7: Heat exchanger, heat exchanger mechanics and cooling components

installation ...................................................................................

48

Stage 8A: BLCL-15LC-7: LCL capacitor support, fan support mechanics and fan

installation ...................................................................................

49

Stage 8B: BLCL-24LC-7: LCL capacitor support, fan support mechanics and fan

installation ...................................................................................

50Stage 9: Installation of LCL shroud kit ..................................................

51BLCL-25LC-7 in a 600 mm wide Rittal VX25 enclosure .................................

51Installation stages ..........................................................................

52Overview of kits ............................................................................

53Stage 1: Installation of common parts ..................................................

54Stage 2: Installation of LCL side plates and common AC bus ......................

55Stage 3: Installation of brackets for Flat-PLS holder .................................

56Stage 4: AC connection and fuse busbars installation ...............................

57Stage 5: Installation of LCL choke mounting mechanics and LCL ISU connection .

58Stage 6: LCL choke and LCL choke busbar installation .............................

59

Stage 7: Heat exchanger, heat exchanger mechanics and cooling components

installation ...................................................................................

60Stage 8: LCL capacitor support, fan support mechanics and fan installation .....

61Stage 9: Installation of LCL shroud kit ..................................................

62One R8i module in a 400 mm wide Rittal VX25 enclosure ..............................

62Layout drawing .............................................................................

63Pipe routing example ......................................................................

64Installation stages ..........................................................................

65Overview of kits ............................................................................

66Stage 1: Installation of common parts ..................................................

67Stage 2: Side plate, module mounting mechanics and quick connectors .........

6 Table of contents

68Stage 3: Flat-PLS support kit for AC and common AC connection busbars ......

69Stage 4: Fan, heat exchanger and cooling components .............................

70Stage 5A: Installation of DC busbars ...................................................

71

Stage 5B: Installation of DC switch, DC connection and common mode filter

busbar kits ..................................................................................

72Stage 6: Module installation ..............................................................

73Stage 7: Installation of shrouding ........................................................

74Two R8i modules in a 600 mm wide Rittal VX25 enclosure .............................

74Layout drawing .............................................................................

75Pipe routing example ......................................................................

76Installation stages ..........................................................................

77Overview of kits ............................................................................

78Stage 1: Installation of common parts ..................................................

79Stage 2: Side plate, module mounting mechanics and quick connectors .........

80Stage 3: Flat-PLS support kit for AC and common AC connection busbars ......

81Stage 4: Fan, heat exchanger and cooling components .............................

82Stage 5A: Installation of DC busbars ...................................................

83

Stage 5B: Installation of DC switch, DC connection and common mode filter

busbar kits ..................................................................................

84Stage 6: Module installation ..............................................................

85Stage 7: Installation of shrouding ........................................................

86Three R8i modules in a 800 mm wide Rittal VX25 enclosure ..........................

86Layout drawing .............................................................................

87Pipe routing example ......................................................................

88Installation stages ..........................................................................

89Overview of kits ............................................................................

90Stage 1: Installation of common parts ..................................................

91Stage 2: Side plate, module mounting mechanics and quick connectors .........

92Stage 3: Flat-PLS support kit for AC and common AC connection busbars ......

93Stage 4: Fan, heat exchanger and cooling components .............................

94Stage 5A: Installation of DC busbars ...................................................

95

Stage 5B: Installation of DC switch, DC connection and common mode filter

busbar kits ..................................................................................

96Stage 6: Module installation ..............................................................

97Stage 7: Installation of shrouding ........................................................

5 Electrical installation

99Contents of this chapter ..........................................................................

99Safety and liability ................................................................................

100Electrical safety precautions ....................................................................

101Isolation from AC supply networks .............................................................

102Isolation from common DC bus .................................................................

102General notes .....................................................................................

102Printed circuit boards .........................................................................

102Optical components ...........................................................................

103Checking the insulation of the assembly ......................................................

103Checking the insulation of the input cable .................................................

103Checking the compatibility with IT (ungrounded) systems ..................................

104Connecting the input power cables/busbars ..................................................

104Connection diagram ..........................................................................

105

Connection procedure for power connections inside the IGBT supply module cu-

bicle .............................................................................................

Table of contents 7

106Connection procedure ........................................................................

108Connecting the LCL filter ........................................................................

109Main breaker / contactor .........................................................................

109Installing the charging circuit ....................................................................

109Connecting the external power supply cable for the auxiliary circuit ......................

110Connecting the control cables ..................................................................

110Connection diagram ..........................................................................

110Connection procedure ........................................................................

111Connectors X50…X59 and fiber optic connectors (frame R8i) .........................

112Connecting a PC ..................................................................................

113Installing optional modules ......................................................................

113Installing and using CIO-01 I/O module .......................................................

6 Installation checklist of the drive

115Contents of this chapter ..........................................................................

115Checklist ...........................................................................................

7 Start-up

117Contents of this chapter ..........................................................................

118Start-up procedure ................................................................................

120Switching the supply unit off .....................................................................

120Additional instructions for closing the DC switch-disconnector ............................

8 Maintenance

121Contents of this chapter ..........................................................................

121Maintenance intervals ............................................................................

123Maintenance timers and counters ..............................................................

123Cooling system ....................................................................................

123Cabinet .............................................................................................

123Cleaning the interior of the cabinet .........................................................

124Power connections ...............................................................................

124Retightening the power connections .......................................................

124Cooling fans .......................................................................................

124Replacing the cooling fan of the IGBT supply module (frame R8i) ....................

126Replacing the cooling fan of the LCL filter .................................................

127IGBT supply module ..............................................................................

127Replacing the IGBT supply module (frame R8i) ..........................................

127Removing the module .....................................................................

129Reinstalling the module ...................................................................

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

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

130Control panel ......................................................................................

130Cleaning the control panel ...................................................................

130Replacing the control panel battery .........................................................

130Control unit .........................................................................................

130Replacing the memory unit ..................................................................

131Replacing the BCU control unit battery ....................................................

131LEDs and other status indicators ...............................................................

131Control panel and panel platform/holder LEDs ...........................................

132R8i module LEDs ..............................................................................

8 Table of contents

9 Ordering information

133Contents of this chapter ..........................................................................

134Kit code key ........................................................................................

135Frame R8i and multiples .........................................................................

135IGBT supply modules .........................................................................

136LCL filters .......................................................................................

137Control panel ...................................................................................

138Control electronics ............................................................................

138Control unit ..................................................................................

138Fiber optic cables ..........................................................................

138Auxiliary measurement unit (BAMU) ....................................................

139CIO-01 I/O module .........................................................................

139Mechanical installation accessories ........................................................

139Adapter kit (for Rittal VX25 enclosures) ................................................

140Module top/bottom guides ................................................................

141Shrouding ...................................................................................

142Marine support kit for LCL filters .........................................................

142AC-side components ..........................................................................

142Main circuit breakers and wagons .......................................................

150IEC busbar shim kits ......................................................................

150Main circuit breaker and wagon cover ..................................................

151AC fuses ....................................................................................

152AC-DC charging kits for line-up charging ..............................................

153AC busbars for LCL filters ................................................................

153LCL fuse busbars ..........................................................................

154LCL choke installation kits ................................................................

156LCL capacitor installation kits ............................................................

157LCL ISU connection kits ..................................................................

157AC busbars .................................................................................

158Quick connector ............................................................................

158DC-side components .........................................................................

158DC bus installation parts (for Rittal VX25 enclosures) ...............................

159DC connection parts 1 of 2 (for Rittal VX25 enclosures) .............................

160DC fuses ....................................................................................

161DC switch-disconnector kits for unit charging .........................................

162DC charging kits for unit charging (for units with DC switch-disconnector) .......

162Charging resistors or unit charging (for units with DC switch-disconnector) ......

162DC switch-disconnector for line-up charging ..........................................

163DC connection parts 2 of 2 (for Rittal VX25 enclosures) .............................

163Flat-PLS busbars (common DC) for LCL filters .......................................

164Charging mechanics .......................................................................

164DC connection charging mechanics ....................................................

165Common mode filter busbars ............................................................

165Common mode filters .....................................................................

165Cooling system parts .........................................................................

165Coolant distribution manifold kits ........................................................

167Piping ........................................................................................

168Heat exchanger ............................................................................

168Cooling system parts for LCL filters .....................................................

169Cooling fans for LCL filters ...............................................................

170Cooling fans for IGBT supply modules .................................................

Table of contents 9

10 Internal cooling circuit

171Contents of this chapter ..........................................................................

171Applicability ........................................................................................

171Internal cooling system ..........................................................................

173Connection to a cooling unit .....................................................................

173Connection to an ACS880-1007LC cooling unit ..........................................

173Connection to a custom cooling unit ........................................................

173General requirements .....................................................................

173Coolant temperature control .............................................................

174Filling up and bleeding the internal cooling circuit ...........................................

174Drive line-ups with an ACS880-1007LC cooling unit .....................................

174Drive line-ups with a custom cooling unit ..................................................

176Draining the internal cooling circuit .............................................................

176Maintenance intervals ............................................................................

176Technical data .....................................................................................

176Coolant specification ..........................................................................

176Coolant type ................................................................................

176Temperature limits .............................................................................

178Pressure limits .................................................................................

178Coolant flow rate limits .......................................................................

178Cooling circuit materials ......................................................................

11 Technical data

181Contents of this chapter ..........................................................................

182Ratings .............................................................................................

182Definitions ......................................................................................

183Derating .........................................................................................

183Ambient temperature derating ...........................................................

183Altitude derating ............................................................................

183Type equivalence table ..........................................................................

184Fuses ...............................................................................................

184LCL filters ..........................................................................................

184Kit contents .....................................................................................

185Technical data ..................................................................................

185Charging kit contents .............................................................................

185Dimensions and weights .........................................................................

185Free space requirements ........................................................................

185Allowable mounting orientations ................................................................

186Losses, cooling data and noise .................................................................

188Tightening torques ................................................................................

188Electrical connections ........................................................................

188Mechanical connections ......................................................................

188Insulation supports ............................................................................

188Cable lugs ......................................................................................

189Typical power cable sizes .......................................................................

191Electrical power network specification .........................................................

191Control unit connection data ....................................................................

191Coolant connections ..............................................................................

191Efficiency ...........................................................................................

191Protection classes ................................................................................

192Optical components ..............................................................................

10 Table of contents

193Ambient conditions ...............................................................................

194Cooling .............................................................................................

194Materials ...........................................................................................

194Internal cooling circuit ........................................................................

195Auxiliary circuit current consumption ...........................................................

195Control equipment .............................................................................

195Cooling fans ....................................................................................

195Definitions ......................................................................................

195Standards and markings .........................................................................

196Disclaimers ........................................................................................

196Generic disclaimer ............................................................................

196Cybersecurity disclaimer .....................................................................

12 Control units of the drive

197Contents of this chapter ..........................................................................

197General .............................................................................................

198BCU-x2 control unit layout and connections ..................................................

200Default I/O diagram of the supply control unit ................................................

201External power supply for the control unit (XPOW) ..........................................

201The XD2D connector .............................................................................

202The X485 connector ..............................................................................

202Safe torque off (XSTO, XSTO OUT) ...........................................................

202FSO-xx safety functions module connection (X12) ..........................................

202SDHC memory card slot .........................................................................

203Connector data ....................................................................................

205BCU-x2 ground isolation diagram ...........................................................

13 Dimension drawings

207Contents of this chapter ..........................................................................

208Frame R8i module ................................................................................

209Quick connector ...............................................................................

210LCL filter components ............................................................................

210Grid-side choke (BLCL-15LC-7 and BLCL-24LC-7) ......................................

211Grid-side choke (BLCL-25LC-7) ............................................................

212Converter-side choke (BLCL-15LC-7 and BLCL-24LC-7) ...............................

213Converter-side choke (BLCL-25LC-7) ......................................................

214Capacitor .......................................................................................

215Control electronics ................................................................................

215BCU control unit ...............................................................................

216DPMP-01 door mounting kit .................................................................

217Main circuit breaker ...............................................................................

217E2.2S-A (IEC/UL/CSA) .......................................................................

218E4.2S-A (IEC/UL/CSA) .......................................................................

219AC fuses ...........................................................................................

219Fuses of type 170M64xx .....................................................................

219Fuses of type 170M70xx .....................................................................

220DC fuses ...........................................................................................

14 Example circuit diagrams

221Contents of this chapter ..........................................................................

Table of contents 11

221Contents of example circuit diagrams .........................................................

221ACS880-204LC IGBT supply unit 2×R8i (3AXD10000695767) ........................

222ACS880-204LC IGBT supply unit 4×R8i (3AXD10000695768) ........................

223Frame 2×R8i .......................................................................................

247Frame 4×R8i .......................................................................................

Further information

12 Table of contents

Introduction to the manual

Contents of this chapter

This chapter gives basic information on the manual.

Applicability

The manual is applicable to the ACS880-204LC liquid-cooled IGBT supply modules for

user-defined cabinet installations.

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 liquid-cooled multidrive

cabinets and modules safety instructions (3AXD50000048633 [English]).

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

settings of a function. For each function, the warnings and notes are given in the section

describing the related user-adjustable parameters.

• 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 installation, install, start up and service the

drive, or create instructions for the end user of the drive concerning the installation and

maintenance of the drive.

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

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

1

Introduction to the manual 13

The manual is written for readers worldwide. Both SI and imperial units are shown.

Categorization by frame size and option code

The instructions and technical data which concern only certain module or frame sizes are

marked with a size identifier.

The module size can be identified from the basic code visible on the type designation label,

for example, “ACS880-204LC-0400A-7”, where 0400A is the module size. The option codes

of the module are listed after a plus sign. Chapter Ordering information, section Frame R8i

and multiples explains the type designation code in detail.

The frame size of the module can be, for example, R8i or 2×R8i, the latter representing a

supply unit consisting of two parallel-connected R8i supply modules. The table under section

Ratings lists the units and frame sizes.

Use of component designations

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

[Q20], to make it possible to identify the components in the circuit diagrams of the drive.

Terms and abbreviations

DescriptionTerm

Assistant control panelACS-AP-x

Auxiliary measurement unitBAMU

Type of control boardBCON

Type of control unitBCU

Internal power supply board in frame R8i modulesBDPS

I/O module for controlling cabinet fansCIO

Circuit board in which the control program runsControl board

Control board built in a housing (often rail-mountable)Control unit

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

DC circuit between rectifier and inverterDC link

Distributed drives communication system protocolDDCS

Digital inputDI

Frequency converter for controlling AC motorsDrive

Electromagnetic compatibilityEMC

Electromagnetic interferenceEMI

Physical size of the drive or power moduleFrame, frame size

Incoming unitICU

Insulated gate bipolar transistorIGBT

IGBT bridge and related components enclosed inside a metal frame or enclosure.

Intended for cabinet installation.

IGBT supply module

IGBT supply module(s) under control of one control board, and related components.IGBT supply unit

Part of the cabinet line-up that contains the input power cable terminals. Can also

contain switching equipment etc.

Incoming unit

DC circuit between rectifier and inverterIntermediate circuit

Inverter unitINU

Inverter bridge, related components and drive DC link capacitors enclosed in a metal

frame or enclosure. Intended for cabinet installation.

Inverter module

IGBT supply unitISU

Inductor-capacitor-inductor filterLCL filter

14 Introduction to the manual

DescriptionTerm

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

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

Multidrive

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

measured or calculated by the drive.

In some (for example fieldbus) contexts, a value that can be accessed as an object,

eg, variable, constant, or signal.

Parameter

DDCS communication moduleRDCO-0x

Radio-frequency interferenceRFI

Supply module(s) under control of one control board, and related components.Supply unit

Related documents

CodeManual

General manuals

3AXD50000048633

ACS880 liquid-cooled multidrive cabinets and modules safety instructions

3AXD50000048634

ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions

3AUA0000107668

Drive modules cabinet design and construction instructions

3AUA0000113605

BCU-02/12/22 control units hardware manual

3AXD50000126880

CIO-01 I/O module for distributed I/O bus control user's manual

Supply module manuals

3AXD50000284436

ACS880-204LC IGBT supply modules hardware manual

3AUA0000131562

ACS880 IGBT supply control program firmware manual

3AXD50000220717

ACS880 multidrives, Optimal grid control (option +N8053) supplement

3AXD50000164745

Optimal grid control of ACS880 IGBT supply control program supplement

3AXD50000045157

ACS880-304LC+A019 diode supply modules hardware manual

3AUA0000103295

ACS880 diode supply control program firmware manual

Inverter module manuals and guides

3AXD50000045610

ACS880-104LC inverter modules hardware manual

3AUA0000085967

ACS880 primary control program firmware manual

3AUA0000098062

ACS880 primary control program quick start-up guide

Brake module and DC/DC converter module manuals

3AXD50000184378

ACS880-604LC 1-phase brake chopper modules hardware manual

3AXD50000371631

ACS880-1604LC DC/DC converter modules hardware manual

3AXD50000024671

ACS880 DC/DC converter control program firmware manual

Option manuals

3AXD50000129607

ACS880-1007LC liquid cooling unit user's manual

3AUA0000085685

ACX-AP-x assistant control panels user’s manual

3AXD50000117840

BAMU-12C auxiliary measurement unit hardware manual

3AUA0000094606

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

3AUA0000127808

Drive application programming (IEC 61131-3) manual

Manuals and quick guides for I/O extension modules, fieldbus adapters, safety functions modules, etc.

See www.abb.com/drives/documents for all manuals on the Internet.

You can find all documentation related to the multidrive modules on the Internet at

https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content.

Introduction to the manual 15

16

Operation principle and hardware

description

Contents of this chapter

This chapter describes how the IGBT supply unit works and the hardware of the

ACS880-204LC IGBT supply module.

Operation principle

IGBT supply unit rectifies three-phase AC current to direct current for the intermediate DC

link of the drive. The intermediate DC link supplies the inverters that run the motors. There

can be one inverter unit only (single drives) or several inverter units (multidrives) connected

to the intermediate circuit.

The LCL filter is an essential part of the IGBT supply unit. The supply module does not work

without the filter. It suppresses the AC voltage distortion and current harmonics. The high

AC inductance smooths the line voltage waveform distorted by the high-frequency switching

of the converter. Capacitive component of the filter effectively filters the high-frequency (over

1 kHz) harmonics.

2

Operation principle and hardware description 17

￭ Simplified main circuit diagram

The following figure shows the simplified main circuit diagram of the rectifier.



1

2

3 4

5

6

AC voltage1.

AC fuses2.

LCL filter3.

IGBT supply module4.

DC fuses5.

DC voltage6.

￭ Charging

A charging circuit powers up the DC link capacitors of the drive system smoothly. Discharged

capacitors cannot be directly connected to the full supply voltage. The charging current

must be limited until the capacitors are charged and ready for normal use.

The control program has a function for controlling the charging circuit. For further information,

see the firmware manual.

ACS880-204LC contains two charging circuits: AC-DC charging circuit charges the cabinet

line-up, and DC-DC charging circuit charges the DC capacitors of one cubicle.

18 Operation principle and hardware description

Overview diagram of the drive system

The following figure shows a simplified diagram of a common DC bus drive system.

AC supply1

Input AC fuses2

LCL filter3

IGBT supply unit4

Supply unit DC fuses5

DC bus6

Inverter DC fuses (with or without DC switch-disconnector)7

Inverter units (in the example, one of the two units consists of two inverter modules connected in parallel)8

DC fuses for optional brake chopper9

Optional brake chopper10

Motor(s)11

Cooling system

See chapter Internal cooling circuit (page 171).

Operation principle and hardware description 19

Single-line circuit diagrams of the supply unit

The following figures are examples of possible IGBT supply unit configurations. The tables

give explanations for the numbers and letters of the diagrams. They also indicate if the

customer can order the components from ABB or if the customer needs to acquire them

separately. For components, see the chapter Ordering information.

￭ Frame 1×R8i

The following figure shows a connection example of a supply unit with one frame R8i module.

AC supply1

Incoming cubicleA

Main circuit breaker2

AC-DC charging kit (line-up charging)3

DC switch-disconnector for line-up charging4

LCL filter cubicleB

AC fuses5

LCL filter kit6

IGBT supply module cubicleC

DC-DC charging kit7

DC link8

DC switch-disconnector9

DC fuse10

Common mode filter11

IGBT supply module (frame R8i)12

20 Operation principle and hardware description

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ABB ACS880-204LC User manual

ABB ACS880-204LC User manual

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