ABB ACS880-207 User manual

ABB industrial drives

Hardware manual

ACS880-207 IGBT supply 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 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

Cabinet design and construction instructions for ACS880 air-

cooled and liquid-cooled multidrive modules

3AUA0000107668

BCU-02/12/22 control units hardware manual 3AUA0000113605

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

System description

Parallel connected ACS880-207 IGBT supply units system

description

3AXD50000032517

Parallel connected ACS880-307 +A018 diode supply units

system description

3AXD50000032421

Parallel connected ACS880-907 regenerative rectifier units

system description

3AXD50000036609

Option manuals and guides

ACS-AP-x assistant control panels user’s manual 3AUA0000085685

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

manual

3AUA0000094606

Manuals and quick guides for I/O extension modules,

fieldbus adapters, safety options etc.

Hardware manual

ACS880-207 IGBT supply units

3AUA0000130644 Rev C

EN

EFFECTIVE: 2017-11-29

3. Electrical installation

5. Start-up

Table of contents

5

Table of contents

1. Introduction to the manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Categorization by frame size, option code and item designation . . . . . . . . . . . . . . . . . . 10

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Operation principle and hardware description

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Main circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Overview diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Layout drawing of an IGBT supply unit 1×R8i (limited scope version) . . . . . . . . . . . . . . 16

Overview drawing of a drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Layout drawings of the cubicles in the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Layout drawing of an auxiliary control cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Layout drawings of incoming cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Layout drawing of a 400 mm incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Layout drawing of a 600 mm incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Layout drawing of a 1000 mm incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Layout drawing of a supply module cubicle 2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Layout drawings of supply and LCL filter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

IGBT supply module (frame R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

LCL filter module (BLCL-1x-x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

LCL filter module (BLCL-2x-x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Overview of the control connections on the BCU control unit . . . . . . . . . . . . . . . . . . 28

Supply unit control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Door switches and devices for frame R8i cabinet (limited scope version) . . . . . . . 29

Door switches and devices for frame R8i cabinet . . . . . . . . . . . . . . . . . . . . . . . . . 30

Main switch-disconnector / breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Auxiliary voltage switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Grounding switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Charging switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operating switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Emergency stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

E-stop reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Other door controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

The ACS-AP-W control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6

Type designation label of the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Type designation label of the supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Type designation label of the LCL filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Type designation keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Type designation key of the cabinet-installed IGBT supply unit . . . . . . . . . . . . . . . . 35

Type designation key of the IGBT supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Type designation key of the filter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3. Electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . 43

Connecting the input power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Connection diagram (frame 1×R8i, limited scope version) . . . . . . . . . . . . . . . . . . . . 44

Connection diagram (frame R8i and multiples) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Connection procedure (frame R8i, limited scope version) . . . . . . . . . . . . . . . . . . . . 46

Connection procedure (frame R8i and multiples) . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Setting the voltage range of the auxiliary voltage transformers (option +G344) . . . . . . 52

[T21/T101] connections (400...500 V units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

[T21/T101] connections (690 V units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

[T111] connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Checking the settings of the cooling fan transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Connecting the control cables for the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Connection procedure (frame R8i, limited scope version) . . . . . . . . . . . . . . . . . . . . 55

Connection procedure (frame R8i and multiples) . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Grounding the outer shields of the control cables at the cabinet lead-through . . 57

Wiring the functional safety options +Q951, +Q952, +Q963, +Q964 or +Q979 . . . . . . 60

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4. Installation checklist

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5. Start-up

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

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Checks/Settings with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Powering up the auxiliary circuit of the supply unit . . . . . . . . . . . . . . . . . . . . . . . . 64

Setting up the supply unit parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Powering up the main circuit of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Switching off the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Disconnecting and temporary grounding the drive

(excluding the input power terminals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Disconnecting and temporary grounding the drive

7

(including the input power terminals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

6. Maintenance

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Maintenance timers and counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Cleaning the door air inlets (IP22 and IP42, option +B054) . . . . . . . . . . . . . . . . . . . . 72

Cleaning the door air inlets (IP54, option +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Replacing the outlet (roof) filters (IP54, option +B055) . . . . . . . . . . . . . . . . . . . . . . . . 74

Cleaning the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Power connections and quick connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Tightening the power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Replacing the cooling fan of the IGBT supply module (frame R8i) . . . . . . . . . . . . . . . 75

Replacing the direct-on-line (option +C188) module fan (frame R8i) . . . . . . . . . . . . . 77

Replacing the circuit board compartment fan (frame R8i) . . . . . . . . . . . . . . . . . . . . . 78

Replacing the fan of the LCL filter (BLCL-1x-x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Replacing the fan of the LCL filter (BLCL-2x-x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Replacing the fan in the incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Replacing the fan in the auxiliary control cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Replacing the roof fan for IP54 cabinet (option +B055) . . . . . . . . . . . . . . . . . . . . . . . 84

IGBT supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Cleaning the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Reduced run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Starting reduced run operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Resuming normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Replacing the IGBT supply module (limited scope version) . . . . . . . . . . . . . . . . . . . . 87

Replacing the IGBT supply module (frame R8i and multiples) . . . . . . . . . . . . . . . . . . 90

LCL filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Replacing the LCL filter (limited scope version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Replacing the LCL filter (frame R8i and multiples) . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Checking and replacing the DC fuses (limited scope version) . . . . . . . . . . . . . . . . . 101

Checking and replacing the AC fuses (limited scope version) . . . . . . . . . . . . . . . . . 103

Checking and replacing the DC fuses (frame R8i and multiples) . . . . . . . . . . . . . . . 104

Checking and replacing the AC fuses (frame R8i and multiples) . . . . . . . . . . . . . . . 104

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Transferring the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

LEDs and other status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

7. Technical data

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

8

Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Main circuit AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Main circuit DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Fuses on CVAR board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

LCL filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Terminal and lead-through data for the input power cable . . . . . . . . . . . . . . . . . . . . . 118

Frame R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

400 mm incoming cubicle with main switch, bottom cable entry . . . . . . . . . . . . . . . 118

600 mm incoming cubicle – main switch (+F253) . . . . . . . . . . . . . . . . . . . . . . . . . . 119

600 mm incoming cubicle with main switch, bottom cable entry . . . . . . . . . . . . . . . 120

600 mm incoming cubicle with main breaker, bottom cable entry . . . . . . . . . . . . . . 121

600 mm incoming cubicle with main breaker, top cable entry . . . . . . . . . . . . . . . . . 122

1000 mm incoming cubicle with main breaker, bottom cable entry . . . . . . . . . . . . . 123

1000 mm incoming cubicle with main breaker, top cable entry . . . . . . . . . . . . . . . . 124

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Mechanical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Insulation supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Control unit connection data (BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

8. The control unit

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Default I/O connection diagram (BCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

External power supply for the control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . . . . 136

Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

SDHC memory card slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Introduction to the manual 9

1

Introduction to the manual

What this chapter contains

This chapter gives basic information on the manual.

Applicability

The manual is applicable to the cabinet-installed ACS880-207 IGBT supply units that form

a part of an ACS880 multidrive system.

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 and

multidrive 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 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.

10 Introduction to the manual

Purpose of the manual

This manual helps in installing, commissioning, using and maintaining a multidrive with

and IGBT supply unit.

Contents of the manual

• Introduction to the manual

• Operation principle and hardware description

• Electrical installation

• Installation checklist

• Start-up

• Maintenance

• Technical data

• The control unit.

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 main manuals have been listed

on the back of the front cover.

Categorization by frame size, option code and item

designation

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

marked with the size identifier.

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

example, ACS880-207-0420A-3 where 0420A is the unit size. The option codes of the unit

are listed after the plus sign. Section Type designation keys on page 35 explains the type

designation code in detail.

The frame size of the IGBT supply module is, for example, R8i. The Ratings table on

page 109 lists the frame sizes.

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

[Q2] to make it possible to identify the components in the circuit diagrams of the drive.

Introduction to the manual 11

Terms and abbreviations

Term/Abbreviation Description

Auxiliary control cubicle

(ACU)

The cubicle with auxiliary devices such as auxiliary voltage circuit breakers,

control electronics, measurement boards, etc.

BCON Type of a control board

BCU Type of a control unit (contains BCON)

Control board Circuit board in which the control program runs.

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 (for UL/CSA installations)

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

DI Digital input

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

unit and one or multiple inverter units connected by the DC link. The drive may

also contain other units such as the brake unit.

FCAN-01 Optional CANopen® adapter module

FCNA-01 Optional ControlNet™ adapter module

FDCO-01 Optional DDCS communication module

FDNA-01 Optional DeviceNet™ adapter module

FDPI-02 Diagnostics and panel interface

FEA-03 Optional option module extension adapter

FECA-01 Optional EtherCAT® adapter module

FENA-11 Optional high-performance Ethernet/IP™, Modbus/TCP and PROFINET

adapter module

FENA-21 Optional high-performance Ethernet/IP™, Modbus/TCP and PROFINET

adapter module

FEPL-01 FEPL-01 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

Frame (size) Relates to the construction of power modules (such as Inverter). 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 module (not used in supply units)

12 Introduction to the manual

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

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

frequency

IGBT supply module IGBT type rectifier and related components enclosed inside a metal frame or

enclosure. Intended for cabinet installation.

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

components such as LCL filters, main contactor, fuses etc. See IGBT supply

module.

Incoming cubicle (ICU) In cabinet-installed drives, ICU is the incoming unit (cubicle) which contains

main circuit breaker and the busbars for the input power cable.

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.

ISU IGBT supply unit

I/O Input/Output

LCL filter Inductor-capacitor-inductor filter for attenuating harmonics

Limited scope Simplified version of a low power multidrive (400V and 500V) with less options

and configurations. Includes only max 980A DSU, max 810A IGBT supply units

and R1i-R7i inverter units.

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

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

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

signal measured or calculated by the drive

RDCO-0x Optional DDCS communication module

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

Single drive Drive for controlling one motor

Term/Abbreviation Description

Operation principle and hardware description 13

2

Operation principle and

hardware description

What this chapter contains

This chapter describes the operation basics and the hardware of the IGBT supply unit

(ACS880-207).

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 motor. 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. 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.

14 Operation principle and hardware description

 Main circuit diagram

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

 Charging

Charging is always needed to power up the DC link capacitors smoothly. Discharged

capacitors cannot be connected to the full supply voltage. The voltage must be increased

gradually until the capacitors are charged and ready for normal use. In ACS880-207 IGBT

supply units, a resistive charging circuit consisting of fuses, a contactor and charging

resistors, is used. The resistive charging circuit is in use after power-up as long as DC

voltage has risen to a predefined level.

The IGBT supply control program has a function for controlling the charging circuit in the

IGBT supply unit. For further information, see the firmware manual.

LCL filter

DC fuses

IGBT supply module

AC fuses

DC output

AC input

Operation principle and hardware description 15

Overview diagram of the drive

The following figure shows a single-line diagram of a drive with an IGBT supply unit.

The figure includes:

Description

1. Auxiliary voltage transformer ([T21], option +G344)

2. Auxiliary voltage switch [Q21]

3. Main switch-disconnector ([Q1], option +F253) (standard, always with +F250)

4. AC fuses [F1]

5. Main contactor ([Q2], option +F250) (standard, always with +F253)

6. Charging switch fuse [Q3]

7. Charging contactor [Q4]

8. Charging resistors [R1]

9. LCL filter [R03]

10. IGBT supply module [T01]

11. Common mode filter [R1]

12. DC fuses [F2]

13. Inverter modules [T11]

14. Motor(s)

M

3~

M

3~

~ 3

M

3~

3

4

5

9

1310

2

1

1313

12 12

11

1212

14

6

7

8

11 11 11

16 Operation principle and hardware description

Layout drawing of an IGBT supply unit 1×R8i (limited

scope version)

Note that there is also another version of 1×R8i supply unit available, see the drawings

below. The multidrive version contains separate auxiliary control and incoming cubicles.

No. Description

1. Incoming cubicle

2. IGBT supply module cubicle

3. BCU control unit [A51] with optional modules

4. AC fuses [F1]

5. Main switch-disconnector ([Q1], option +F253)

6. Input power cable connections [L1, L2, L3]

7. Location of PE busbar and input power cable lead-throughs

8. LCL filter module [R03]

9. DC fuses [F2]

10. IGBT supply module [T01]

11. Module cooling fan

12. Cabinet cooling fan

13. Auxiliary voltage switch [Q21]

14. Charging assembly plate containing charging contactor [Q4] and resistors

15. Charging switch [Q3]

Doors closed Doors open

1

3

2

4

5

6

7

8

9

10

11

12

11

13

14

15

Operation principle and hardware description 17

Overview drawing of a drive

This drawing shows an example of a drive with an IGBT supply unit and an inverter unit.

Cables enter the cabinet through the bottom.

Description

A Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See

page 18.

B Incoming cubicle (ICU). Contains the power input cable terminals and switchgear. See page 20.

C Supply module cubicle. Contains IGBT supply modules. See page 23.

D Inverter module cubicle. Contains inverter modules.

E Inverter control cubicle. Contains inverter control unit.

A B C D E

Supply unit Inverter unit

18 Operation principle and hardware description

Layout drawings of the cubicles in the supply unit

This section contains layout drawings of cubicles that are included in a supply unit:

auxiliary control cubicle, incoming cubicle and supply module cubicle. The components,

layout and size of the cubicles vary depending on the supply unit size and options.

 Layout drawing of an auxiliary control cubicle

This is an example of a 600 mm wide auxiliary control cubicle. The control unit of the

supply unit, and auxiliary and control devices of the whole drive are located in the auxiliary

cubicle, as well as the auxiliary voltage transformer(s) that supply the auxiliary circuits.

The composition and size of the cubicle vary depending on the selected options.

Door closed Door open

5

32

4

14

7

8

9

10

11

12

13

16

15

17

18

19

6

1

Operation principle and hardware description 19

No. Desig. Description

1 S21, etc. Control panel and operating switches. See section Supply unit control devices on page

29.

2 F111 Fuses, direct-on-line cooling fans of the module (option +C188)

3 F101 Fuses, IP54 roof fans (option +B055)

4 F21 Fuses, auxiliary voltage transformer

5 A51 Control unit (BCU) for IGBT supply unit ACS880-207

6 T130 24 V DC power supply for cabinet lighting (option +G301)

7 Reserved space for customer-defined equipment

T21 At the backside of the assembly plate:

Auxiliary voltage transformer (option +G344).

Note: Connections are accessible from front. (Terminal block is at the lower part of

cubicle.)

T101 At the backside of the assembly plate:

Auxiliary voltage transformer, IP54 roof fans

(option +B055). Note: Connections are accessible from front. (Terminal block is at the

lower part of cubicle.)

8 A61 Main safety relay (optional)

A62 Safety relay (optional)

A63 Safety relay (optional)

9 A611 Safety relay (optional)

A612

A613

A614

A621

A622

A623

A624

10 K61…K66 Relays (optional)

11 X60 Terminal block, emergency stop circuit (optional)

12 T61 Power supply, safety circuit (optional)

T62 Power supply, safety circuit (optional)

F61 Protection switch, safety circuit (optional)

13 T21X1,

T101X1

Terminal blocks, auxiliary voltage transformers T21 and T101 connections

14 T111 Auxiliary voltage transformer. Supplies direct-on-line cooling fans (option +C188).

15 X22 Auxiliary circuit terminal block (on side plate)

16 T22, X21 24 V DC power supply (on side plate)

17 F20, F22 Circuit breakers, auxiliary voltage circuits (on side plate)

18 Q20 Connections and switches for external auxiliary voltage supplies (UPS), (option +G307,

on side plate)

Q95

Q130

19 X60, X61 Terminal blocks, emergency stop circuits (option, on side plate)

20 Operation principle and hardware description

 Layout drawings of incoming cubicles

This section shows examples of the incoming cubicle layouts. The input power cables are

connected to the incoming cubicle and it contains the main switching and disconnecting

devices. The components, layout and size vary depending on the supply unit size and

options.

Layout drawing of a 400 mm incoming cubicle

These layout drawings show a 400 mm wide incoming cubicle.

1

2

5

6

7

8

9

12

11

10

4

3

Door closed Door open

No. Description

1. Main switch-disconnector handle

2. Earthing/grounding switch handle

([Q9], option +F259)

3. Auxiliary voltage switch handle

4. Selector switch for V-meter (option

+G334)

5. Grounding busbar (PE)

6. Input power cable terminals [L1…L3]

7. Main switch-disconnector [Q1]

8. Earthing/grounding switch [Q9]

(option +F259)

9. Main AC fuses (F1…3)

10. Main contactor [Q2] (option +F250)

11. Auxiliary voltage switch [Q21]

12. Cubicle cooling fan

13. Charging switch handle

14. Charging switch [Q3]

15. Charging resistors

13

14

15

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