ABB ACS880-204 User manual

—
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

247Main contactors ............................................................................
249Charging kits ................................................................................
251Varistor kit ACS880 for UL/CSA installations ..........................................
252AC connection of the LCL filter ..........................................................
254Busbars and quick connectors ...........................................................
255Quick connector ............................................................................
256DC-side components .........................................................................
256DC bus installation parts (for Rittal VX25 enclosures) ...............................
256DC busbars .................................................................................
257Module and common mode filter busbars ..............................................
257Common mode filters .....................................................................
258DC fuses ....................................................................................
260Cabinet ventilation ................................................................................
260Air inlet kits .....................................................................................
260Air inlet kits 400 mm cabinet .............................................................
261Air inlet kits 600 mm cabinet .............................................................
262Air inlet kits 800 mm cabinet .............................................................
263Air outlet kits ...................................................................................
263Air outlet kits 400 mm cabinet ............................................................
264Air outlet kits 600 mm cabinet ............................................................
265Air outlet kits 800 mm cabinet ............................................................
267Cooling fans (frames R1i…R4i) .............................................................
268Cooling fans (frame R6i) .....................................................................
269Cooling fans (frame R8i) .....................................................................
269Miscellaneous .....................................................................................
269BAMU voltage/current measurement unit .................................................
10 Technical data
271Contents of this chapter ..........................................................................
272Ratings .............................................................................................
273Definitions ......................................................................................
274Derating .........................................................................................
274Ambient temperature derating ...........................................................
274Altitude derating ............................................................................
275Type equivalence table ..........................................................................
276Fuses ...............................................................................................
276Fuses on BFPS board ........................................................................
276Fuses on CVAR board ........................................................................
276Fuses on BDFC board ........................................................................
276Charging kit contents .............................................................................
276IEC ..............................................................................................
279UL, CSA ........................................................................................
281Dimensions and weights .........................................................................
281IGBT supply module ..........................................................................
282LCL filter module ..............................................................................
284Free space requirements ........................................................................
285Allowable mounting orientations ................................................................
286Losses, cooling data and noise .................................................................
287Tightening torques ................................................................................
287Electrical connections ........................................................................
287Mechanical connections ......................................................................
287Insulation supports ............................................................................
Table of contents 11

288Cable lugs ......................................................................................
289Typical power cable sizes .......................................................................
291Electrical power network specification .........................................................
292DC connection data ..............................................................................
292Control unit connection data (ZCU/BCU) ......................................................
292Efficiency ...........................................................................................
293Protection classes ................................................................................
293Optical components ..............................................................................
294Ambient conditions ...............................................................................
295Materials ...........................................................................................
295Auxiliary circuit current consumption ...........................................................
296Cooling fans ....................................................................................
296Applicable standards .............................................................................
297Markings ...........................................................................................
297Disclaimer ..........................................................................................
297Generic disclaimer ............................................................................
297Cybersecurity disclaimer .....................................................................
11 Control units of the drive
299Contents of this chapter ..........................................................................
299General .............................................................................................
300ZCU-14 layout and connections ................................................................
301BCU-x2 control unit layout and connections ..................................................
303Default I/O diagram of the supply control unit ................................................
304External power supply for the control unit (XPOW) ..........................................
304The XD2D connector .............................................................................
305Safe torque off (XSTO, XSTO OUT) ...........................................................
305FSO-xx safety functions module connection (X12) ..........................................
305SDHC memory card slot .........................................................................
306Connector data ....................................................................................
308BCU-x2 ground isolation diagram ...........................................................
309ZCU-1x ground isolation diagram ...........................................................
12 Dimension drawings
311Contents of this chapter ..........................................................................
312IGBT supply module (frame R1i) ...............................................................
313IGBT supply module (frame R2i) ...............................................................
314IGBT supply module (frame R3i) ..............................................................
315IGBT supply module (frame R4i) ...............................................................
316IGBT supply module (frame R6i) ...............................................................
317IGBT supply module (frame R8i) ...............................................................
319Quick connectors of IGBT supply module (frame R8i) .....................................
320LCL filter module (filter for frames R1i and R2i) .............................................
321LCL filter module (filter for frame R3i) .........................................................
322LCL filter module (filter for frames R3i and R4i) .............................................
323LCL filter module (filter for frame R6i) .........................................................
324LCL filter module (filter for frame 1×R8i) ......................................................
325LCL filter module (filter for frame R8i multiples) .............................................
326WBCA-01 ..........................................................................................
327WBCA-11 ...........................................................................................
328WBCA-21 ..........................................................................................
12 Table of contents

329Quick connector ..................................................................................
330Main switch-disconnector ........................................................................
330R1i…R4i ........................................................................................
330OS160GD03 (IEC) ........................................................................
331OT160E3 (UL, CSA) ......................................................................
332R6i ..............................................................................................
332OS400D03 (IEC) ..........................................................................
333OS400J03 (UL, CSA) .....................................................................
334R8i ...............................................................................................
334OT1000E03 (IEC), OT1200U03 (UL, CSA) ...........................................
335OT2000E12 (IEC) .........................................................................
336OT1250E12 (IEC) .........................................................................
337OT1200U12 (UL, CSA) ...................................................................
337Auxiliary contact OA1G10 .......................................................................
338Main contactor .....................................................................................
338R1i…R4i ........................................................................................
338AF09-30-10-13 (IEC, UL, CSA) .........................................................
339AF26-30-00-13 (IEC, UL, CSA) .........................................................
340AF96-30-22-13 (IEC, UL, CSA) ..........................................................
340R6i ..............................................................................................
340AF205-30-22-13 (IEC, UL, CSA) .......................................................
341R8i ...............................................................................................
341AF580-30-22-70 and AF750-30-22-70 (IEC, UL, CSA) .............................
342AF1250-30-22-70 (IEC, UL, CSA) ......................................................
343AF2050-30-22-70 (IEC, UL, CSA) .......................................................
344AF1650-30-22-70 (IEC, UL, CSA) ......................................................
345Charging switches ................................................................................
345OS30FAJ22F ...................................................................................
346OS60GJ22FP ..................................................................................
347OS100GJ22FP ................................................................................
348OS160GD04F ..................................................................................
349OS200J04FP ...................................................................................
350Resistors ...........................................................................................
350CBH 215 C H 414 5R0 .......................................................................
351Handles ............................................................................................
351OH45-275 ......................................................................................
352OHB150J12P ..................................................................................
353AC fuses ...........................................................................................
353R1i…R4i .......................................................................................
353170M1559D, 170M1562D, 170M1565D, 170M1566D, 170M1569D (IEC) .......
354DFJ-12, DFJ-25, DFJ-50, DFJ-70, DFJ-125 (UL, CSA) .............................
355R6i ..............................................................................................
355170M5808D (IEC) .........................................................................
355DFJ-300 (UL, CSA) ........................................................................
356R8i ...............................................................................................
3561170M6408, 170M6410, 170M6414, 170M6416 .....................................
357170M7059, 170M7062, 170M7063 ......................................................
358DC fuses ...........................................................................................
358R1i…R4i .......................................................................................
358Fuse, 14 × 51 mm (IEC, UL, CSA) .....................................................
358
Mersen (Ferraz-Shawmut) US141 (Z331153F) fuse disconnector (for 14 × 51 mm
fuses) (IEC, UL, CSA) ....................................................................
Table of contents 13

359Fuse, 27 × 60 mm (IEC, UL, CSA) .....................................................
359
Mersen (Ferraz-Shawmut) US271MI (R227600C) fuse disconnector (for 27 × 60
mm fuses) (IEC, UL, CSA) ...............................................................
360R6i ..............................................................................................
360170M4413 (IEC, UL, CSA) ...............................................................
361R8i ...............................................................................................
361170M6413, 170M6415, 170M6417, 170M6419 (IEC, UL, CSA) ....................
362170M6544, 170M6546, 170M6549 (IEC, UL, CSA) .................................
363Air circuit breakers ................................................................................
363E2.2S-A (UL/CSA/IEC) .......................................................................
364E4.2S (IEC) ....................................................................................
365E4.2S-A (UL/CSA/IEC) .......................................................................
366E6.2V-A (UL/CSA/IEC) .......................................................................
367ZCU control unit ...................................................................................
368BCU control unit ...................................................................................
369BAMU voltage/current measurement unit .....................................................
370ACS-AP-x control panel with DPMP-01 door mounting kit .................................
371Ramp ...............................................................................................
373CVAR board .......................................................................................
373Common mode filter ..............................................................................
374RFI filter and related accessories ..............................................................
374RFI filter .........................................................................................
375Oval toroid kit ..................................................................................
376Oval toroid ......................................................................................
13 Example circuit diagrams
377Contents of this chapter ..........................................................................
377Component designations used in the diagrams ..............................................
377Frames R1i…R4i ..............................................................................
378Frame R6i ......................................................................................
378Frame R8i and multiples .....................................................................
379Circuit diagram set contents .....................................................................
380Frames R1i…R4i ..................................................................................
385Frame R6i ..........................................................................................
390Frame 1×R8i .......................................................................................
396Frame 4×R8i .......................................................................................
Further information
14 Table of contents

Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
The manual is applicable to the ACS880-204 IGBT supply modules for user-defined cabinet
installations.
Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, use or service
the drive. The complete safety instructions are given in ACS880 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 service the
drive, or create instructions for the end user of the drive concerning the installation and
maintenance of the drive.
Read the manual before working on the drive. You are expected to know the fundamentals
of electricity, wiring, electrical components and electrical schematic symbols.
The manual is written for readers worldwide. Both SI and imperial units are shown.
1
Introduction to the manual 15

Categorization by frame size and option code
The instructions and technical data which concern only certain module or frame sizes are
marked with the size identifier.
The module size can be identified from the basic code visible on the type designation label,
for example, ACS880-204-0420A-3 where 0420A is the module size. The option codes of
the module are listed after the plus sign.
The frame size of the IGBT supply module is, for example, R8i.
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 measurement unitBAMU
Type of control boardBCON
Type of control unitBCU
Control board for direct-on-line cooling fanBDFC
Internal power supply board in frame R8i modulesBDPS
Control and power supply board for speed-controlled cooling fanBFPS
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
Electromagnetic compatibilityEMC
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
Rittal Flat-PLS, a busbar system for standard, commercially available flat busbarsFlat-PLS
Optional PROFIBUS DP® adapter moduleFPBA-01
Physical size of the drive or power moduleFrame, frame size
Optional RS-485 (Modbus/RTU) adapterFSCA-01
See chapter Ordering information.
Generic enclosure
Incoming unitICU
IGBT bridge and related components enclosed inside a metal frame or enclosure.
Intended for cabinet installation.
IGBT supply module
16 Introduction to the manual

DescriptionTerm
IGBT supply module(s) under control of one control board, 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 board, 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
DDCS communication moduleRDCO-0x
Converts alternating current and voltage to direct current and voltageRectifier
Drive for controlling one motorSingle drive
Supply module(s) under control of one control board, and related components.Supply unit
Mounting adapter for WFU filters that enables supply cabling from below.WBCA
Series of LCL-filters, for example WFU-11WFU
Type of control boardZCON
Type of control unitZCU
Type of memory unit, attached to the control unitZMU
Related documents
CodeManual
General manuals
3AUA0000102301
ACS880 multidrive cabinets and modules safety instructions
3AUA0000102324
ACS880 multidrive cabinets and modules electrical planning instructions
3AUA0000107668
Drive modules cabinet design and construction instructions
3AUA0000113605
BCU-02/12/22 control units hardware manual
Supply module manuals
3AUA0000131525
ACS880-204 IGBT supply modules hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
3AXD50000220717
ACS880 multidrives, Optimal grid control (option +N8053) supplement
3AXD50000164745
Optimal grid control of ACS880 IGBT supply control program supplement
3AUA0000102452
ACS880-304 +A003 diode supply modules hardware manual
3AXD50000010104
ACS880-304…+A018 diode supply modules hardware manual
3AUA0000103295
ACS880 diode supply control program firmware manual
3AXD50000020457
ACS880-904 regenerative rectifier modules hardware manual
3AXD50000020827
ACS880 regenerative rectifier control program firmware manual
Inverter module manuals and guides
3AUA0000104271
ACS880-104 inverter modules hardware manual
3AUA0000085967
ACS880 primary control program firmware manual
3AUA0000098062
ACS880 primary control program quick start-up guide
Introduction to the manual 17

CodeManual
Brake module and DC/DC converter module manuals
3AUA0000106244
ACS880-604 1-phase brake chopper modules hardware manual
3AXD50000022033
ACS880-604 3-phase brake modules hardware manual
3AXD50000020967
ACS880 (3-phase) brake control program firmware manual
3AXD50000023642
ACS880-1604 DC/DC converter modules hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
Module package hardware manuals
3AUA0000138495
ACS880-04 module packages hardware manual
3AXD50000022021
ACS880-14 and -34 module packages hardware manual
Option manuals
3AXD50000037752
ACS880 +C132 marine type-approved drive modules and module packages supplement
3AUA0000085685
ACX-AP-x assistant control panels user’s manual
3AXD50000117840
BAMU-12C auxiliary measurement unit hardware manual
3AUA0000094606
Drive composer start-up and maintenance PC tool user’s manual
3AUA0000127808
Drive application programming (IEC 61131-3) manual
3AXD50000010531
Installation frames for ACS880 multidrive modules hardware manual
Manuals and quick guides for I/O extension modules, fieldbus adapters, safety functions modules, etc.
See www.abb.com/drives/documents for all manuals on the Internet.
You can find all documentation related to the multidrive modules on the Internet at
https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content.
18 Introduction to the manual

Operation principle and hardware
description
Contents of this chapter
This chapter describes how the IGBT supply unit works and also the hardware of the
ACS880-204 IGBT supply module.
Operation principle
IGBT supply unit rectifies three-phase AC current to direct current for the intermediate DC
link of the drive. The intermediate DC link supplies the inverters that run the motors. There
can be one inverter unit only (single drives) or several inverter units (multidrives) connected
to the intermediate circuit.
The LCL filter is an essential part of the IGBT supply unit. The supply module does not work
without the filter. It suppresses the AC voltage distortion and current harmonics. The high
AC inductance smooths the line voltage waveform distorted by the high-frequency switching
of the converter. Capacitive component of the filter effectively filters the high-frequency (over
1 kHz) harmonics.
2
Operation principle and hardware description 19

￭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.
Note:
Frames R1i…R4i IGBT supply modules have an inbuilt charging circuit and they do not
need external charging components.
The control program has a function for controlling the charging circuit. For further information,
see the firmware manual.
20 Operation principle and hardware description