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ABB INDUSTRIAL DRIVES
ACS880-207 IGBT supply units
Hardware manual
Table of contents
1 Introduction to the manual
9Contents of this chapter ...........................................................................
9Applicability .........................................................................................
9Safety instructions .................................................................................
9Target audience ....................................................................................
10Categorization by frame size and option code .................................................
10Use of component designations .................................................................
10Terms and abbreviations ..........................................................................
11Related documents ................................................................................
2 Operation principle and hardware description
13Contents of this chapter ...........................................................................
14Operation principle .................................................................................
14Simplified main circuit diagram ...............................................................
14Charging .........................................................................................
15Overview diagram of the drive ...................................................................
16Layout drawing of an IGBT supply unit 1×R8i (limited scope version) .....................
17Overview drawing of a drive ......................................................................
18Layout drawings of the cubicles in the supply unit ............................................
18Layout drawing of an auxiliary control cubicle .............................................
20Layout drawings of incoming cubicles .......................................................
20Layout drawing of a 400 mm incoming cubicle .........................................
22Layout drawing of a 600 mm incoming cubicle .........................................
24Layout drawing of a 1000 mm incoming cubicle .......................................
25Layout drawing of a supply module cubicle 2×R8i ........................................
26Layout drawings of supply and LCL filter modules ............................................
26IGBT supply module (frame R8i) .............................................................
27LCL filter module (type BLCL-1x-x for frame 1×R8i) ......................................
28LCL filter module (type BLCL-2x-x for frame R8i multiples) ..............................
29Overview of power and control connections ...................................................
30Overview of the control connections of the BCU control unit ............................
31Supply unit control devices ...................................................................
31Door switches and devices for frame R8i cabinet (limited scope version) .........
32Door switches and devices for frame R8i cabinet ......................................
33Main switch-disconnector / main circuit breaker .......................................
33Auxiliary voltage switch ....................................................................
33Grounding switch ...........................................................................
33Charging switch .............................................................................
34Operating switch ............................................................................
34Emergency stop button ....................................................................
34E-stop reset button .........................................................................
34Other door controls .........................................................................
35The ACS-AP-W control panel .............................................................
35PC connection ...............................................................................
35Fieldbus control .................................................................................
Table of contents 5
36Type designation labels ...........................................................................
36Type designation label of the supply unit ...................................................
37Type designation labels of the supply module and LCL filter module ..................
39Type designation keys ............................................................................
39Type designation key of the cabinet-installed IGBT supply unit .........................
43Type designation key of the IGBT supply module ........................................
44Type designation key of the filter module ...................................................
3 Electrical installation
45Contents of this chapter ...........................................................................
46Electrical safety precautions .....................................................................
47General notes ......................................................................................
47Printed circuit boards ..........................................................................
47Optical components ............................................................................
48Checking the insulation of the assembly .......................................................
48Measuring the insulation of the drive ........................................................
48Measuring the insulation of the input power cable ........................................
48Compatibility check - IT (ungrounded) earthing system ......................................
48Connecting the input power cables ..............................................................
48Connection diagram (frame 1×R8i, limited scope version) ...............................
49Connection diagram (frame R8i and multiples) ............................................
49Connection procedure (frame R8i, limited scope version) ...............................
52Connection procedure (frame R8i and multiples) ..........................................
55Checking the settings of transformers T21, T101 and T111 .................................
55T21 and T101 tap settings (400…500 V units) .............................................
56T21 and T101 tap settings (690 V units) ....................................................
56T111 tap settings ...............................................................................
57Checking the settings of the cooling fan transformer .........................................
57Connecting the control cables for the supply unit .............................................
57Default I/O connection diagram ..............................................................
57Connection procedure (frame R8i, limited scope version) ...............................
59Connection procedure (frame R8i and multiples) ..........................................
60Control cable connection procedure .....................................................
63Wiring the functional safety options +Q951, +Q952, +Q963, +Q964 or +Q979 ..........
64Connecting a PC ...................................................................................
4 Installation checklist
65Installation checklist ...............................................................................
65Contents of this chapter .......................................................................
65Checklist .........................................................................................
5 Start-up
67Contents of this chapter ...........................................................................
68Start-up procedure .................................................................................
70Electromagnetic interlocking ..................................................................
70Switching off the supply unit and the drive .....................................................
70
Disconnecting the drive from AC power line (excluding the input power terminals), and
temporary grounding ..............................................................................
71Disconnecting and temporary grounding the drive (including the input power terminals) .
71Connecting the drive / supply unit to the power line ..........................................
72Powering-up the supply unit / drive ..............................................................
6 Table of contents
6 Maintenance
73Contents of this chapter ...........................................................................
73Maintenance intervals .............................................................................
75Maintenance timers and counters ...............................................................
75Cabinet ..............................................................................................
75Cleaning the interior of the cabinet ..........................................................
76Cleaning the door air inlets (IP22 and IP42) ...............................................
77Replacing the inlet door filters (IP54) ........................................................
77Replacing the outlet (roof) filters (IP54) .....................................................
77Cleaning the heatsink ..........................................................................
78Power connections and quick connectors ......................................................
78Retightening the power connections ........................................................
78Fans ..................................................................................................
79Replacing R8i module cooling fan (speed-controlled version) ...........................
80Replacing R8i module cooling fan (direct-on-line version) ...............................
82Replacing the circuit board compartment fan ..............................................
84Replacing the fan of the LCL filter (BLCL-1x-x) ............................................
85Replacing the fan of the LCL filter (BLCL-2x-x) ............................................
86Replacing the cooling fan in the incoming cubicle .........................................
86Replacing the fan in the auxiliary control cubicle ..........................................
87Replacing the roof fan for IP54 cabinet (option +B055) ..................................
88IGBT supply module ...............................................................................
88Reduced run ....................................................................................
89Starting reduced run operation ...........................................................
89Resuming normal operation ...............................................................
90Replacing the IGBT supply module (limited scope version) .............................
95Replacing the IGBT supply module (frame R8i and multiples) ..........................
101LCL filter .............................................................................................
101Replacing the LCL filter (limited scope version) ...........................................
104Replacing the LCL filter (frame R8i and multiples) ........................................
108Capacitors ...........................................................................................
108Reforming the capacitors ......................................................................
109Fuses ................................................................................................
109Checking and replacing the DC fuses (limited scope version) ..........................
110Checking and replacing the AC fuses (limited scope version) ...........................
111Checking and replacing the DC fuses (frame R8i and multiples) .......................
112Checking and replacing the AC fuses (frame R8i and multiples) .......................
113Control panel .......................................................................................
113Cleaning the control panel ....................................................................
113Replacing the battery ..........................................................................
114Memory unit .........................................................................................
114Replacing the memory unit ...................................................................
115LEDs and other status indicators ................................................................
115Control panel and panel platform/holder LEDs ............................................
115Functional safety components ...................................................................
7 Technical data
117Contents of this chapter ...........................................................................
118Ratings ..............................................................................................
118Definitions .......................................................................................
Table of contents 7
120Derating ..........................................................................................
120Surrounding air temperature derating ....................................................
120Altitude derating .............................................................................
121Derating for output voltage boosting .....................................................
122Fuses ................................................................................................
122Main circuit AC fuses ..........................................................................
123Main circuit DC fuses ..........................................................................
123Fuses on CVAR board .........................................................................
124LCL filters ...........................................................................................
125Dimensions .........................................................................................
126Free space requirements .........................................................................
128Losses, cooling data and noise ..................................................................
129Terminal and cable entry data for the input power cable .....................................
129600 mm incoming cubicle – main circuit breaker (+F255), top cable entry ............
1301000 mm incoming cubicle – main circuit breaker (+F255), top cable entry ...........
131Tightening torques .................................................................................
131Electrical connections ..........................................................................
131Mechanical connections .......................................................................
131Insulation supports .............................................................................
131Cable lugs .......................................................................................
132Electrical power network specification ..........................................................
132Control unit connection data (BCU) .............................................................
133Typical power cable sizes .........................................................................
135Protection classes .................................................................................
135Optical components ...............................................................................
135Ambient conditions ................................................................................
137Materials .............................................................................................
137Applicable standards ..............................................................................
137Markings .............................................................................................
138Disclaimers .........................................................................................
138Generic disclaimer .............................................................................
138Cybersecurity disclaimer ......................................................................
8 The control unit
139Contents of this chapter ...........................................................................
139General ..............................................................................................
140BCU-x2 layout ......................................................................................
142Default I/O diagram of the supply control unit .................................................
143External power supply for the control unit (XPOW) ...........................................
143Safe torque off (XSTO, XSTO OUT) ............................................................
143FSO-xx safety functions module connection (X12) ...........................................
143SDHC memory card slot ..........................................................................
144Connector data .....................................................................................
146BCU-x2 ground isolation diagram ............................................................
Further information
8 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 cabinet-installed ACS880-207 IGBT supply units that form
a part of an ACS880 multidrive system.
Safety instructions
Obey 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 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 do
maintenance work on 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 9
Categorization by frame size and option code
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 (page 39) explains the type
designation code in detail.
The frame size of the IGBT supply module is, for example, R8i. The ratings table lists the
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
Auxiliary control unit. Contains control electronics, auxiliary voltage circuitry, etc.ACU
Type of control boardBCON
Type of control unitBCU
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
Varistor boardCVAR
DC circuit between rectifier and inverterDC link
Digital inputDI
Frequency converter for controlling AC motorsDrive
Optional CANopen® adapter moduleFCAN
Optional ControlNet™ adapter moduleFCNA-01
DDCS communication module with two pairs of 10 Mbit/s DDCS channelsFDCO-01
Optional DeviceNet™ adapter moduleFDNA-01
Diagnostics and panel interface boardFDPI
Optional I/O extension adapterFEA-03
Optional EtherCAT® adapter moduleFECA-01
Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP® and PROFINET
IO® protocols
FENA-11
Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP® and PROFINET
IO® protocols, 2-port
FENA-21
Optional Ethernet POWERLINK adapter moduleFEPL-01
Optional digital I/O extension moduleFIO-01
Optional analog I/O extension moduleFIO-11
Optional PROFIBUS DP® adapter moduleFPBA-01
Physical size of the drive or power moduleFrame, frame size
Optional RS-485 (Modbus/RTU) adapterFSCA-01
Optional functional safety modulesFSO-12, FSO-21
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
10 Introduction to the manual
DescriptionTerm
IGBT supply module(s) under control of one control unit, and related components.IGBT supply unit
DC circuit between rectifier and inverterIntermediate circuit
Inverter unitINU
Converts direct current and voltage to alternating current and voltage.Inverter
Inverter bridge, related components and drive DC link capacitors enclosed in a metal
frame or enclosure. Intended for cabinet installation.
Inverter module
Inverter module(s) under control of one control unit, and related components. One
inverter unit typically controls one motor.
Inverter unit
IGBT supply unitISU
Inductor-capacitor-inductor filterLCL filter
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
Optical DDCS communication moduleRDCO
Converts alternating current and voltage to direct current and voltageRectifier
Drive for controlling one motorSingle drive
Related documents
CodeManual
General manuals
3AUA0000102301
ACS880 multidrive cabinets and modules safety instructions
3AUA0000102324
ACS880 multidrive cabinets and modules electrical planning instructions
3AUA0000101764
ACS880 multidrive cabinets mechanical installation instructions
Supply unit manuals
3AUA0000130644
ACS880-207 IGBT supply units 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
3AUA0000102453
ACS880-307 +A003 diode supply units hardware manual
3AXD50000011408
ACS880-307…+A018 diode supply units hardware manual
3AUA0000103295
ACS880 diode supply control program firmware manual
3AXD50000020546
ACS880-907 regenerative rectifier units hardware manual
3AXD50000020827
ACS880 regenerative rectifier control program firmware manual
Inverter unit manuals
3AUA0000102519
ACS880-107 inverter units hardware manual
3AUA0000085967
ACS880 primary control program firmware manual
3AUA0000098062
ACS880 primary control program quick start-up guide
Manuals for application programs (Crane, Winder, etc.)
Brake unit and DC/DC converter unit manuals
3AUA0000102559
ACS880-607 1-phase brake units hardware manual
3AXD50000022034
ACS880-607 3-phase dynamic brake units hardware manual
3AXD50000020967
ACS880 (3-phase) brake control program firmware manual
Introduction to the manual 11
CodeManual
3AXD50000023644
ACS880-1607 DC/DC converter units hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
Option manuals
3AXD50000039629
ACS880 +C132 marine type-approved cabinet-built drives supplement
3AUA0000085685
ACS-AP-x assistant control panels user’s manual
3AUA0000094606
Drive composer start-up and maintenance PC tool user’s manual
3AXD50000332588
Lifter for air-cooled drive modules user's guide
Manuals for I/O extension modules, fieldbus adapters, safety options etc.
You can find manuals on the Internet. See www.abb.com/drives/documents. For manuals
not available in the document library, contact your local ABB representative.
12 Introduction to the manual
Operation principle and hardware
description
Contents of this chapter
This chapter describes the operation basics and the hardware of the IGBT supply unit
(ACS880-207).
2
Operation principle and hardware description 13
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.
￭ 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.
In cabinet-installed 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 control program has a function for controlling the charging circuit. For further information,
see the firmware manual.
14 Operation principle and hardware description
Overview diagram of the drive
The following figure shows a single-line diagram of a drive with an IGBT supply unit.
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
Auxiliary voltage transformer ([T21], option +G344)1
Auxiliary voltage switch [Q21]2
Main switch-disconnector ([Q1], option +F253) (standard, always with +F250)3
AC fuses [F1]4
Main contactor ([Q2], option +F250) (standard, always with +F253)5
Charging switch fuse [Q3]6
Charging contactor [Q4]7
Charging resistors [R1]8
LCL filter [R03]9
IGBT supply module [T01]10
Common mode filter [R1]11
DC fuses [F2]12
Inverter modules [T11]13
Motor(s)14
Operation principle and hardware description 15
Layout drawing of an IGBT supply unit 1×R8i (limited scope
version)
Limited scope means 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.
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.
1
3
2
4
5
6
7
8
9
10
11
12
11
13
14
15
Door closed
Door open
Incoming cubicle1
IGBT supply module cubicle2
BCU control unit [A51] with optional modules3
AC fuses [F1]4
Main switch-disconnector ([Q1], option +F253)5
Input power cable connections [L1, L2, L3]6
Location of PE busbar and input power cable lead-throughs7
LCL filter module [R03]8
DC fuses [F2]9
IGBT supply module [T01]10
Module cooling fan11
Cabinet cooling fan12
Auxiliary voltage switch [Q21]13
Charging assembly plate containing charging contactor [Q4] and resistors14
16 Operation principle and hardware description
Charging switch [Q3]15
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.
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
Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections.A
Incoming cubicle (ICU). Contains the power input cable terminals and switchgear.B
Supply module cubicle. Contains IGBT supply modules.C
Inverter module cubicle. Contains inverter modules.D
Inverter control cubicle. Contains inverter control unit.E
Operation principle and hardware description 17
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
Control panel and operating switches.S21, etc.1
Fuses, direct-on-line cooling fans of the module (option +C188)F111.12
Fuses, IP54 roof fans (option +B055)F1013
Fuses, auxiliary voltage transformerF214
18 Operation principle and hardware description
Control unit (BCU)A515
24 V DC power supply for cabinet lighting (option +G301)T1306
Reserved space for customer-defined equipment7
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.)
T21
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.)
T101
Main safety relay (optional)A618
Safety relay (optional)A62
Safety relay (optional)A63
Safety relay (optional)A6119
A612
A613
A614
A621
A622
A623
A624
Relays (optional)K61…K6610
Terminal block, emergency stop circuit (optional)X6011
Power supply, safety circuit (optional)T6112
Power supply, safety circuit (optional)T62
Protection switch, safety circuit (optional)F61
Terminal blocks, auxiliary voltage transformers T21 and T101 connectionsT21X1,13
T101X1
Auxiliary voltage transformer. Supplies direct-on-line cooling fans (option +C188).T11114
Auxiliary circuit terminal block (on side plate)X2215
24 V DC power supply (on side plate)T22, X2116
Circuit breakers, auxiliary voltage circuits (on side plate)F20, F2217
Connections and switches for external auxiliary voltage supplies (UPS), (option
+G307, on side plate)
Q2018
Q95
Q130
Terminal blocks, emergency stop circuits (option, on side plate)X60, X6119
Operation principle and hardware description 19
￭ 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, size and appearance vary depending on the supply unit
size and selected options.
Layout drawing of a 400 mm incoming cubicle
These layout drawings show a 400 mm wide incoming cubicle with cabling through the
bottom (option +H350).
Door open
Door closed
Main switch-disconnector handle1
20 Operation principle and hardware description
/