ABB ACS880-207 User manual

Brand: ABB

Model: ACS880-207

Type: User manual

—

ABB INDUSTRIAL DRIVES

ACS880-207 IGBT supply units

Hardware manual

ACS880-207 IGBT supply units

Hardware manual

Table of contents

3. Electrical installation

5. Start-up

3AUA0000130644 Rev D

Original instructions

EFFECTIVE: 2020-12-22

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 .....................................................

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.

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).

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.



3 4

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.

~ 3

1310

1313

12 12

1212

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.

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

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ABB ACS880-207 User manual

ABB ACS880-207 User manual

ABB ACS880-207 User manual

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