ABB ACS880-204 User manual

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ABB INDUSTRIAL DRIVES
ACS880-204 IGBT supply modules
Hardware manual

ACS880-204 IGBT supply modules
Hardware manual
Table of contents
5. Electrical installation
7. Start-up
© 2019 ABB Oy. All Rights Reserved. 3AUA0000131525 Rev H
EN
EFFECTIVE: 2019-06-30

Table of contents
1 Introduction to the manual
15Contents of this chapter ..........................................................................
15Applicability ........................................................................................
15Safety instructions ................................................................................
15Target audience ...................................................................................
16Categorization by frame size and option code ...............................................
16Use of component designations ................................................................
16Terms and abbreviations .........................................................................
17Related documents ...............................................................................
2 Operation principle and hardware description
19Contents of this chapter ..........................................................................
19Operation principle ................................................................................
20Simplified main circuit diagram ..............................................................
20Charging ........................................................................................
21Overview diagram of the drive system .........................................................
22Single-line circuit diagrams of the supply unit ................................................
22Frames R1i…R4i ..............................................................................
23Frame R6i ......................................................................................
24Frame 1×R8i ...................................................................................
25Frame R8i multiples ...........................................................................
26IGBT supply module hardware .................................................................
26Frame R1i layout ..............................................................................
27Frame R4i layout ..............................................................................
28Frame R6i layout ..............................................................................
29Frame R8i hardware ..........................................................................
31Connectors X50…X53 ........................................................................
33LCL filter module (filter for frames R1i…R4i) ..............................................
34Connectors X102 and X103 ..............................................................
35LCL filter module (type ALCL-05-5 for frame R6i) ........................................
36Connectors X50 and X1 ..................................................................
37LCL filter module (type BLCL-1x-x for frame 1×R8i) .....................................
38Connectors X30 and X55 .................................................................
39LCL filter module (type BLCL-2x-x for frame R8i multiples) .............................
40Connectors X30 and X55 .................................................................
41Control interfaces .................................................................................
41Overview of control connections of ZCU-14 control unit ................................
42Overview of the control connections of the BCU control unit ...........................
43Supply unit control devices ......................................................................
43Main disconnecting device ...................................................................
43Auxiliary voltage switch .......................................................................
43Operating switch ...............................................................................
43Emergency stop and emergency stop reset buttons .....................................
43The control unit ................................................................................
43ACX-AP-x control panel ......................................................................
44PC connection .................................................................................
Table of contents 5

44Fieldbus control ................................................................................
45Type designation labels of the supply module and LCL filter module .....................
46Type designation key .............................................................................
46IGBT supply module ..........................................................................
47LCL filter ........................................................................................
3 Moving and unpacking the module
49Contents of this chapter ..........................................................................
49Moving and lifting the transport package ......................................................
49Unpacking ..........................................................................................
49Frames R1i…R5i ..............................................................................
50Frames R6i…R8i ..............................................................................
50Lifting the modules ................................................................................
50Moving the modules ..............................................................................
4 Cabinet construction
51Contents of this chapter ..........................................................................
51Limitation of liability ...............................................................................
51Switching, disconnecting and protecting solution ............................................
51Frames R1i…R4i ..............................................................................
52Frame R6i ......................................................................................
52Frame R8i ......................................................................................
53Cabinet configuration overview .................................................................
53ACS880-204 configurations in Rittal VX25 enclosures ..................................
54ACS880-204 configurations in generic enclosures .......................................
55IGBT supply unit with frame R1i…R4i module ............................................
56IGBT supply unit with frame R6i module ...................................................
57IGBT supply unit with frame R8i module ...................................................
58IGBT supply unit with frame 2×R8i modules ..............................................
59Incoming cubicle ...............................................................................
59Example of the AC fuse cooling .........................................................
60RFI filter .........................................................................................
61Installation examples .............................................................................
61R1i…R4i module in a 400/600/800 mm wide Rittal VX25 enclosure ..................
61Installation stages ..........................................................................
62Kits for R1i…R4i modules ................................................................
63Example 1 ...................................................................................
64Example 2 ...................................................................................
65R6i module in a 600 mm wide Rittal VX25 enclosure ....................................
65Installation stages ..........................................................................
66Kits for R6i module in 600 mm Rittal VX25 enclosure ................................
67Stage 1: Installation of common parts ..................................................
68Stage 2: Rittal supports installation .....................................................
69Stage 3: DC kit installation ...............................................................
70Stage 4: Switching and charging installation ..........................................
71Stage 5: AC supply, varistor board location and EMC shield examples ...........
72Stage 6: Module installation parts .......................................................
73Stage 7: Cabling example for main cabling, charging cabling and ground cabling .
74Stage 8: Shroud installation parts .......................................................
751×R8i module in a 600 mm wide Rittal VX25 enclosure .................................
75Installation stages ..........................................................................
6 Table of contents

76Kits for R8i module in 600 mm Rittal VX25 enclosure ................................
77Stage 1: Installation of common parts ..................................................
78Stage 2: Module installation parts .......................................................
79Stage 3: BLCL AC busbars and quick connectors ....................................
80Stage 4: DC connection ...................................................................
81Stage 5: Common mode filter busbars and DC connection flanges ................
82Stage 6: BLCL AC connection ...........................................................
83Stage 7: Shroud installation parts .......................................................
84Stage 8: Module installation ..............................................................
851×R8i module in a 600 mm wide generic enclosure .....................................
85Parts to be installed .......................................................................
872×R8i modules in a 1000 mm wide Rittal VX25 enclosure ..............................
87Installation stages ..........................................................................
88Kits for 2×R8i modules in 1000 mm Rittal VX25 enclosure ..........................
89Stage 1: Installation of common parts ..................................................
90Stage 2: Module installation parts .......................................................
91Stage 3: Rear AC busbars and quick connectors .....................................
92Stage 4: BLCL AC busbars and AC flanges ...........................................
93Stage 5: DC connection ...................................................................
94Stage 6: Common mode filter busbars and DC connection flanges ................
95Stage 7: Shroud installation parts .......................................................
96Stage 8: Modules installation ............................................................
972×R8i modules in an 800 mm wide generic enclosure ..................................
97Parts to be installed .......................................................................
993×R8i modules in a 1600 mm wide Rittal VX25 enclosure ..............................
99Installation stages ..........................................................................
100Kits for 3×R8i modules in 1600 mm Rittal VX25 enclosure ..........................
101Stage 1: Installation of common parts ..................................................
102Stage 2: Module installation parts .......................................................
103Stage 3: BLCL rear AC busbars and quick connectors ..............................
104Stage 4: BLCL top AC busbars and AC flanges ......................................
105Stage 5: DC connection ...................................................................
106Stage 6: Common mode filter busbars and DC connection flanges ................
107Stage 7: Shroud installation parts .......................................................
108Stage 8: Modules installation ............................................................
1093×R8i modules in a 1400 mm wide generic enclosure ..................................
109Parts to be installed .......................................................................
5 Electrical installation
111Contents of this chapter ..........................................................................
111Safety and liability ................................................................................
112Electrical safety precautions ....................................................................
113General notes .....................................................................................
113Printed circuit boards .........................................................................
113Optical components ...........................................................................
113Checking the insulation of the assembly ......................................................
113Checking the insulation of the drive system ...............................................
113Checking the insulation of the input cable .................................................
113Checking the compatibility with IT (ungrounded) systems ..................................
114Connecting the input power cables ............................................................
114Connection diagram (frames R1i…R4i) ....................................................
115Connection diagram (frame R6i) ............................................................
Table of contents 7

116Connection diagram (frame 1×R8i) .........................................................
117Connection diagram (frame R8i multiples) ................................................
118Connection procedure (frames R1i…R4i) .................................................
120Frame R1i ...................................................................................
121Frame R2i ...................................................................................
122Frames R3i and R4i (connector covers removed) ...................................
124Connection procedure (frame R6i) ..........................................................
125Connection procedure (frame R8i) ..........................................................
130Connecting the LCL filter ........................................................................
131Connecting the WBCA adapter to the LCL filter (frames R1i…R4i) ...................
132Connecting WFU-xx LCL filter module (frames R1i…R4i) ..............................
133Internal circuit diagrams for LCL filters .....................................................
133WFU-01 and WFU-02 .....................................................................
134WFU-11 ......................................................................................
135WFU-21 and WFU-22 .....................................................................
136ALCL-05-5 ..................................................................................
137BLCL .........................................................................................
139Main contactor .....................................................................................
139Checking the charging capacity (frames R1i…R4i) ..........................................
140Single AC input ................................................................................
140Installing the charging circuit (frames R6i and R8i) ..........................................
140Connecting the external power supply cable for the auxiliary circuit ......................
140IGBT supply module (frames R1i…R4i, R6i) ..............................................
140IGBT supply module (frame R8i) and LCL filter module (frames R6i and R8i) .......
141Connecting the control cables ..................................................................
141Default I/O connection diagrams ............................................................
141Connection procedure ........................................................................
142Module fiber optic connectors (frame R8i) .................................................
144Connecting a PC ..................................................................................
145Installing optional modules ......................................................................
6 Installation checklist of the drive
147Contents of this chapter ..........................................................................
147Checklist ...........................................................................................
7 Start-up
149Contents of this chapter ..........................................................................
150Start-up procedure ................................................................................
153Switching the supply unit off .....................................................................
8 Maintenance
155Contents of this chapter ..........................................................................
155Maintenance intervals ............................................................................
157Maintenance timers and counters ..............................................................
157Cabinet .............................................................................................
157Cleaning the interior of the cabinet .........................................................
158Cleaning the door air inlets (IP22 and IP42) ..............................................
159Replacing the inlet door filters (IP54) .......................................................
159Cleaning the roof outlet filters (IP54) .......................................................
160Power connections ...............................................................................
160Retightening the power connections .......................................................
8 Table of contents

161Fans ................................................................................................
161Replacing the R1i and R2i module cooling fan ...........................................
162Replacing the R3i and R4i module cooling fan ...........................................
163Replacing the R6i module cooling fan ......................................................
164Replacing R8i module cooling fan (speed-controlled version) ..........................
165Replacing R8i module cooling fan (direct-on-line version) ..............................
167Replacing the circuit board compartment fan .............................................
170Replacing the fan of the LCL filter (filter for frames R1i…R4i) ..........................
171Replacing the fan of the LCL filter (filter for frame R6i) ..................................
172Replacing the fan of the LCL filter (BLCL-1x-x) ...........................................
173Replacing the fan of the LCL filter (BLCL-2x-x) ...........................................
174Replacing the cabinet cooling fans .........................................................
174Cabinets with ABB air outlet kits .........................................................
174Cabinets with other fan types ............................................................
175IGBT supply module ..............................................................................
175Cleaning the heatsink .........................................................................
176Replacing the R6i module ....................................................................
179Replacing R8i module ........................................................................
182LCL filter ............................................................................................
182Replacing the LCL filter (frame R6i) ........................................................
186Replacing the LCL filter (frame R8i) ........................................................
189Capacitors .........................................................................................
189Reforming the capacitors .....................................................................
190Replacing the LCL filter capacitor (frames R3i and R4i) ................................
191Control panel ......................................................................................
191Cleaning the control panel ...................................................................
191Replacing the control panel battery .........................................................
191Control units .......................................................................................
191BCU control unit types ........................................................................
191Replacing the memory unit ..................................................................
192Replacing the BCU control unit battery ....................................................
192LEDs and other status indicators ...............................................................
192Control panel and panel platform/holder LEDs ...........................................
193R8i module LEDs ..............................................................................
193Reduced run .......................................................................................
193Starting reduced run operation ..............................................................
194Resuming normal operation .................................................................
9 Ordering information
195Contents of this chapter ..........................................................................
195Kit code key ........................................................................................
197Frames R1i…R4i ..................................................................................
197IGBT supply modules .........................................................................
198LCL filters .......................................................................................
199Control panel ...................................................................................
200Mechanical installation accessories and tools ............................................
200Air guide kits for LCL filter modules .....................................................
201Air guide kits for IGBT supply modules .................................................
202WBCA-xx bottom connection adapters .................................................
203AC-side components ..........................................................................
203Main switch-disconnector kits ...........................................................
204AC fuses ....................................................................................
Table of contents 9

204Fuse bases for AC fuses (UL, CSA) ...................................................
205EMC/RFI filter ..............................................................................
206Main contactors ...........................................................................
206DC-side components .........................................................................
206DC bus installation parts (for Rittal VX25 enclosures) ...............................
207DC fuses ....................................................................................
208Fuse bases for DC fuses (IEC, UL, CSA) ..............................................
209Frame R6i ..........................................................................................
209IGBT supply modules ........................................................................
209LCL filters .......................................................................................
210LCL filters (+G304+A013) ....................................................................
211Control panel ...................................................................................
212Mechanical installation accessories and tools ............................................
212Module installation parts ..................................................................
212Shrouds .....................................................................................
212Lifting device ................................................................................
213AC-side components ..........................................................................
213AC bus installation parts (for Rittal VX25 enclosures) ................................
214Main switch-disconnector kits ............................................................
214AC fuses ....................................................................................
215RFI filters ....................................................................................
215Main contactors ............................................................................
216Switching and charging kit (mechanical parts) ........................................
217Charging kits ................................................................................
218Varistor kit ACS880 for UL/CSA installations ..........................................
218DC-side components .........................................................................
218DC bus installation parts (for Rittal VX25 enclosures) ...............................
219Module and common mode filter busbars ..............................................
219Common mode filters .....................................................................
220DC fuses ....................................................................................
221Frame R8i and multiples .........................................................................
221IGBT supply modules .........................................................................
223LCL filters (+C183+C188) ....................................................................
224LCL filters (+C183+C188 and +G304 or +G427) .........................................
225RFI filters .......................................................................................
226Control panel ...................................................................................
227Control electronics ............................................................................
227Control unit ..................................................................................
227Fiber optic cables ..........................................................................
228Control circuit plug connectors ...........................................................
229Mechanical installation accessories and tools ............................................
229Module installation parts .................................................................
231Shrouds .....................................................................................
232Ramp ........................................................................................
232AC-side components ..........................................................................
232AC bus installation parts (for Rittal VX25 enclosures) ................................
233Main switch-disconnector kits ............................................................
235Main circuit breakers and wagons .......................................................
243IEC bus bar shim kit .......................................................................
243Main circuit breaker and wagon cover ..................................................
244Main AC fuses in incoming cubicle ......................................................
246AC fuses in IGBT supply module cubicle or LCL filter cubicle ......................
10 Table of contents