ABB ACS880-304 +A003 Series User manual

—
ABB INDUSTRIAL DRIVES
ACS880-304…+A003 diode supply modules
Hardware manual

ACS880-304…+A003 diode supply
modules
Hardware manual
Table of contents
4. Cabinet construction
5. Electrical installation
7. Start-up
3AUA0000102452 Rev G
EN
EFFECTIVE: 2020-03-18

Table of contents
1 Introduction to the manual
13Contents of this chapter ...........................................................................
13Applicability .........................................................................................
13Safety instructions .................................................................................
13Target audience ....................................................................................
14Categorization by frame size and option code .................................................
14Use of component designations .................................................................
14Terms and abbreviations ..........................................................................
14Related documents ................................................................................
2 Operation principle and hardware description
17Contents of this chapter ...........................................................................
17Operation principle .................................................................................
18Simplified main circuit diagram ...............................................................
18Overcurrent and short-circuit protection ....................................................
18Temperature supervision ......................................................................
19Overview diagrams ................................................................................
19Overview diagram of the drive system ......................................................
20Overview diagram of the supply unit ........................................................
20Diode supply unit with frame D6D or D7D module .....................................
21Diode supply unit with frame D8D module ..............................................
21Hardware of the supply modules ................................................................
22Layout drawings of the supply modules .....................................................
22D6D supply module .........................................................................
23D7D supply module .........................................................................
24D8D supply module .........................................................................
25Overview of control connections of ZCU-14 control unit .....................................
26Supply unit control devices .......................................................................
26Auxiliary voltage switch ........................................................................
26Operating switch ................................................................................
27Emergency stop and emergency stop reset buttons ......................................
27ACX-AP-x control panel .......................................................................
27PC connection ..................................................................................
27Fieldbus control .................................................................................
28Type designation label ............................................................................
29Type designation key ..............................................................................
3 Moving and unpacking the module
31Contents of this chapter ...........................................................................
31Moving and lifting the transport package .......................................................
31Unpacking ...........................................................................................
32Lifting the modules .................................................................................
32Moving the modules ...............................................................................
Table of contents 5

4 Cabinet construction
33Contents of this chapter ...........................................................................
33Limitation of liability ................................................................................
33Switching, disconnecting and protecting solution .............................................
33Frame sizes D6D and D7D ...................................................................
34Frame sizes D8D ...............................................................................
34Cabinet configuration overview ..................................................................
34ACS880-304…+A003 configurations in Rittal VX25 and generic enclosures .........
35Example of the AC fuse cooling .................................................................
36Installation examples ..............................................................................
37D6D module in a 400 mm wide Rittal VX25 enclosure ...................................
38Installation stages ...........................................................................
39Kits for D6D module in a 400 mm wide Rittal VX25 enclosure .......................
40Stage 1: Installation of common parts ...................................................
41Stage 2: Main switch-disconnector and main contactor installation .................
42Stage 3: D6D/D7D module installation parts ...........................................
43Stage 4: AC busbar installation ...........................................................
44Stage 5: Main circuit cabling ..............................................................
45Stage 6: Control unit installation ..........................................................
46Stage 7: Module installation ...............................................................
47Stage 8: D6D shroud installation .........................................................
48D7D module in a 400 mm wide Rittal VX25 enclosure ...................................
49Installation stages ...........................................................................
50Kits for D7D module in a 400 mm wide Rittal VX25 enclosure .......................
51Stage 1: Installation of common parts ...................................................
52Stage 2: Main switch-disconnector and main contactor installation .................
53Stage 3: D6D/D7D module installation parts ...........................................
54Stage 4: AC busbar installation ...........................................................
55Stage 5: Main circuit cabling ..............................................................
56Stage 6: Control unit installation ..........................................................
57Stage 7: Module installation ...............................................................
58Stage 8: Shroud installation ...............................................................
59D8D module in a 400 mm wide Rittal VX25 enclosure ...................................
60Installation stages ...........................................................................
61Kits for D8D module in a 400 mm wide Rittal VX25 enclosure .......................
62Stage 1: Installation of common parts ...................................................
63Stage 2: D8D/D8T module installation parts ............................................
64Stage 3: Quick connector installation ....................................................
65Stage 4: D8D DC busbar installation ....................................................
66Stage 5: D8D busbars to quick connector ..............................................
67Stage 6: D8D AC busbar installation .....................................................
68Stage 7: D8D module installation .........................................................
69Stage 8: D8D shroud installation .........................................................
5 Electrical installation
71Contents of this chapter ...........................................................................
71Safety and liability ..................................................................................
72Electrical safety precautions .....................................................................
73General notes ......................................................................................
73Static electricity .................................................................................
73Optical components ............................................................................
6 Table of contents

73Measuring the insulation ..........................................................................
73Measuring the insulation of the drive ........................................................
73Measuring the insulation of the input power cable ........................................
74Connecting the input power cables ..............................................................
74Connection diagrams ..........................................................................
74D6D, D7D diode supply module ..........................................................
74D8D diode supply module .................................................................
75Connection procedure of the input power cables (D6D/D7D supply modules) ........
78Connection procedure of the input power cables (D8D supply modules) ..............
80Connecting power supply for the control unit ..................................................
80Connection diagram ............................................................................
80Connection procedure .........................................................................
81Connecting power supply for the module fan ..................................................
81Connection diagram ............................................................................
81Connecting the control cables ...................................................................
81Control cable connection procedure .........................................................
81Grounding the outer shields of the control cables at the cabinet entry .............
83Routing the control cables inside the cabinet ...........................................
83Connecting control cabling ................................................................
84Connecting a PC ...................................................................................
6 Installation checklist of the drive
87Contents of this chapter ...........................................................................
87Checklist .............................................................................................
7 Start-up
89Contents of this chapter ...........................................................................
90Start-up procedure .................................................................................
91Switching the supply unit off ......................................................................
91Disconnecting and temporary grounding the drive ............................................
8 Maintenance
93Contents of this chapter ...........................................................................
93Maintenance intervals .............................................................................
95Cabinet ..............................................................................................
95Cleaning the interior of the cabinet ..........................................................
95Cleaning the door air inlets (IP22 and IP42) ...............................................
96Power connections ................................................................................
96Retightening the power connections ........................................................
96Fuses ................................................................................................
96Checking and replacing the module DC fuses .............................................
97Checking and replacing the AC fuses .......................................................
98Checking and replacing the CVAR board fuses ............................................
98Fan ...................................................................................................
99Replacing the fan of the supply module .....................................................
100Replacing the cabinet cooling fan ............................................................
100Supply module .....................................................................................
101Replacing the D6D and D7D supply module ...............................................
104Lifting device for the D6D and D7D supply modules ..................................
105Replacing the D8D supply module ...........................................................
105Module handling ............................................................................
Table of contents 7

105Replacing the D8D supply module in the Rittal VX25 enclosure ....................
108Control panel .......................................................................................
108Cleaning the control panel ....................................................................
108Replacing the control panel battery ..........................................................
108Control unit ..........................................................................................
108Replacing the memory unit ...................................................................
109Replacing the ZCU-14 control unit battery ..................................................
110LEDs and other status indicators ................................................................
9 Ordering information
111Contents of this chapter ...........................................................................
112Kit code key .........................................................................................
113Frame D6D and D7D ..............................................................................
113Diode supply modules .........................................................................
115Control panel ....................................................................................
116Control electronics .............................................................................
116ZCU kit .......................................................................................
116Mechanical installation accessories and tools .............................................
116Module installation parts ...................................................................
117Main switch-disconnector and contactor mechanics kit ...............................
117Shrouds ......................................................................................
118X6X/X7X lifting device ......................................................................
119AC-side components ...........................................................................
119Main switch-disconnector kits .............................................................
119AC fuses .....................................................................................
120Main contactors .............................................................................
121Varistor kit ACS880 for UL/CSA installations ...........................................
122AC busbars ..................................................................................
122DC-side components ..........................................................................
122DC bus installation parts (for Rittal VX25 enclosures) ................................
123Ventilation kits ...................................................................................
123Air inlet kits 400 mm cabinet ..............................................................
124Air outlet kits 400 mm cabinet .............................................................
125Cooling fans .................................................................................
125Miscellaneous ...................................................................................
125Plug connectors .............................................................................
126Frame D8D .........................................................................................
126Diode supply modules .........................................................................
127Control panel ....................................................................................
128Control electronics .............................................................................
128ZCU kit .......................................................................................
128Mechanical installation accessories and tools .............................................
128Module installation parts ...................................................................
129Shrouds ......................................................................................
130Ramp .........................................................................................
130AC-side components ...........................................................................
130Bracket for Flat-PLS busbar holder (common AC) .....................................
130Main switch-disconnector kits .............................................................
131AC fuses .....................................................................................
131Main contactors .............................................................................
132Varistor kit ACS880 for UL/CSA installations ...........................................
132AC busbars ..................................................................................
8 Table of contents

133D8D AC busbars to quick connector .....................................................
133Quick connector .............................................................................
134DC-side components ..........................................................................
134DC bus installation parts (for Rittal VX25 enclosures) ................................
134DC busbars ..................................................................................
135DC connection flanges .....................................................................
135Ventilation kits ...................................................................................
135Air inlet kits 400 mm cabinet ..............................................................
136Air outlet kits 400 mm cabinet .............................................................
137Miscellaneous ...................................................................................
137Plug connectors .............................................................................
10 Technical data
139Contents of this chapter ...........................................................................
139Ratings ..............................................................................................
140Derating ..........................................................................................
140Surrounding air temperature derating ....................................................
140Altitude derating .............................................................................
141Fuses ................................................................................................
141AC fuses .........................................................................................
141IEC ............................................................................................
142IEC/UL ........................................................................................
142UL .............................................................................................
143Internal DC fuses ...............................................................................
143Fuses on CVAR board .........................................................................
143Dimensions and weights ..........................................................................
144Free space requirements .........................................................................
144Allowable mounting orientations .................................................................
145Losses, cooling data and noise ..................................................................
146Auxiliary current consumption ....................................................................
146Tightening torques .................................................................................
146Electrical connections ..........................................................................
146Mechanical connections .......................................................................
146Insulation supports .............................................................................
147Cable lugs .......................................................................................
148Typical power cable sizes .........................................................................
150Electrical power network specification ..........................................................
150DC connection data ................................................................................
150Efficiency ............................................................................................
150Control unit connection data .....................................................................
150Protection classes .................................................................................
151Ambient conditions ................................................................................
152Materials .............................................................................................
152Standards ...........................................................................................
152Markings .............................................................................................
152Disclaimers .........................................................................................
152Generic disclaimer .............................................................................
152Cybersecurity disclaimer ......................................................................
11 Control units of the drive
153Contents of this chapter ...........................................................................
Table of contents 9

153General ..............................................................................................
154ZCU-14 layout ......................................................................................
155ZCU-14 default I/O connection diagram ........................................................
157External power supply for the control unit (XPOW) ...........................................
157Safe torque off (XSTO) ............................................................................
157FSO-xx safety functions module connection (X12) ...........................................
158Connector data .....................................................................................
160ZCU-1x ground isolation diagram ............................................................
12 Dimension drawings
161Contents of this chapter ...........................................................................
162Diode supply module (frame D6D) ..............................................................
163Diode supply module (frame D7D) ..............................................................
164Diode supply module (frame D8D) ..............................................................
166Quick connector ....................................................................................
167Main switch-disconnectors .......................................................................
167OS250D03 .......................................................................................
168OS400J03 .......................................................................................
169OS630D12 and OS600J12 ...................................................................
170OT1000E03, OT1250E03 and OT1200U03 ................................................
171Main switch-disconnector handles ...........................................................
171OHB65J6, OHB145J12 ....................................................................
171OHB274J12 ..................................................................................
172Auxiliary contact OA1G10 .....................................................................
172Main contactors ....................................................................................
172AF146-30-22B-13 ..............................................................................
173AF460-30-22-70 ................................................................................
174AF750-30-22-70 ................................................................................
175AF1250-30-22-70 ...............................................................................
176AC fuses .............................................................................................
176170M3814D, 170M3817D, 170M6809D, 170M6812D ....................................
177170M6415 and 170M6419 ....................................................................
178DFJ-250 ..........................................................................................
178DFJ-500 ..........................................................................................
179KTU-700 .........................................................................................
1806,9 URD 33 TT F 1100 and 6,9 URD 73 TT F 1600 .......................................
181ZCU-14 control unit ................................................................................
182Support plate for ZCU-14 .........................................................................
183ACS-AP-x control panel with door mounting kit ...............................................
184Ramp ................................................................................................
186D6D/D7D cabinet cooling fan ....................................................................
187CVAR board ........................................................................................
13 Example circuit diagrams
188Contents of this chapter ...........................................................................
188Component designations used in the diagrams ...............................................
188D8D circuit diagrams ...........................................................................
188Differences of the DSU DxD circuit diagrams ..............................................
188
Frames D6D and D7D – Main supply, auxiliary voltage transformer, DSU module (sheet
001) ..................................................................................................
189Frame D6D – Auxiliary voltage distribution (sheet 020) ......................................
10 Table of contents

190Frames D7D – Auxiliary voltage distribution (sheet 020) ....................................
191Frames D6D and D7D – ZCU-14 control unit, control panel (sheet 050) ..................
192Frame D8D – Main supply, auxiliary voltage transformer, DSU module (sheet 001) ....
193Frame D8D – Auxiliary voltage distribution (sheet 020) ......................................
194Frame D8D – ZCU-14 control unit, control panel (sheet 050) ...............................
195Frame D8D – Emergency stop safety circuit (sheet 060) ....................................
Further information
Table of contents 11

12

Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
The manual is applicable to the ACS880-304…+A003 diode supply modules.
Safety instructions
Obey all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, use or service
the drive. The complete safety instructions are given in ACS880 multidrive cabinets and
modules safety instructions (3AUA0000102301 [English]).
•Read the software-function-specific warnings and notes before changing the default
settings of a function. For each function, the warnings and notes are given in the section
describing the related user-adjustable parameters.
• Read the task-specific safety instructions before starting the task. See the section
describing the task.
Target audience
This manual is intended for people who plan the installation, install, start up and do
maintenance work on the drive, or create instructions for the end user of the drive concerning
the installation and maintenance of the drive.
Read the manual before working on the drive. You are expected to know the fundamentals
of electricity, wiring, electrical components and electrical schematic symbols.
1
Introduction to the manual 13

Categorization by frame size and option code
The information which concerns only certain supply module frame sizes is marked with the
frame size identifier. The frame sizes of the diode supply modules are D6D, D7D and D8D.
The module size can be identified from the basic code visible on the type designation label,
for example, ACS880-304-0070A-5+A003 where 0070A is the module size. The option
codes of the module are listed after the plus sign. The codes are listed in section Type
designation key (page 29).
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
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
Diode rectifier and related components enclosed in a metal frame or enclosure. Inten-
ded for cabinet installation.
Diode supply module
Diode supply modules under control of one control board, and related components.Diode supply unit
Frequency converter for controlling AC motorsDrive
Diode supply unitDSU
Rittal Flat-PLS, a busbar system for standard, commercially available flat busbarsFlat-PLS
Physical size of the drive or power moduleFrame, frame size
DC circuit between rectifier and inverterIntermediate circuit
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
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
Converts alternating current and voltage to direct current and voltageRectifier
Drive for controlling one motorSingle drive
Enclosure system by Rittal (www.rittal.com)VX25
Type of control unitZCU
Related documents
CodeManual
General manuals
3AUA0000102301
ACS880 multidrive cabinets and modules safety instructions
3AUA0000102324
ACS880 multidrive cabinets and modules electrical planning instructions
14 Introduction to the manual

CodeManual
3AUA0000107668
Drive modules cabinet design and construction instructions
Supply module manuals
3AUA0000131525
ACS880-204 IGBT supply modules hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
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
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 single drive module packages (560 to 2200 kW) hardware manual
3AXD50000022021
ACS880-14 and -34 single drive module packages hardware manual
Option manuals
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
3AXD50000210268
Converter module lifting device for drive cabinets hardware 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.
Introduction to the manual 15

16

Operation principle and hardware
description
Contents of this chapter
This chapter contains a description of the diode supply unit. The information is valid for the
units with ACS880-304…+A003 diode supply modules.
Operation principle
The diode supply module uses a six-pulse diode bridge to rectify three-phase alternating
current to direct current for the DC bus of the drive. The DC bus supplies electrical power
to the inverters, which control the motors. There can be one inverter unit (single drives) or
several inverter units (multidrives) connected to the intermediate circuit. The AC choke
smoothens the current waveform in the power supply network and voltage in the DC link of
the drive.
The rectifier bridge in the ACS880-304…+A003 diode supply module is uncontrolled: it
cannot control the DC link voltage and limit the charging current of the DC link capacitors
at the power up. Thus you can only use the bridge with inverters that have internal charging
circuits, or you must equip the supply unit with a separate, external charging circuit. The
control program allows the use of an external charging circuit, but ABB does not offer
components for its connection. ABB inverters with frame sizes R1…R4i have internal charging
circuits as standard. An internal charging circuit is available for frames R6i…R7i as an option
(+F272).
ABB also offers a half-controlled diode bridge. See ACS880-304…+A018 diode supply
modules hardware manual (3AXD50000010104 [English]).
2
Operation principle and hardware description 17

￭Simplified main circuit diagram
The following figure shows the simplified main circuit diagram of the rectifier.
UU
13
1
2
3
Diodes1
AC choke2
DC fuses3
￭Overcurrent and short-circuit protection
The main circuit of the supply unit is equipped with AC and DC fuses. The fuses protect the
unit against overcurrent and short-circuits.
￭Temperature supervision
Thermal switch(es) supervise the temperature inside the diode supply module. Wire the
switch to a digital input (DI) of the ZCU control unit (1 = OK, 0 = overtemperature). In case
of overtemperature, the switch opens and the control program generates first a warning,
and then, if the overtemperature indication remains over a predefined delay, trips the supply
unit on a fault. You can adjust the delay time with parameters.
A temperature sensor integrated into the ZCU control unit supervises the board operating
temperature. In case of overtemperature, the control program generates a warning or trips
the supply unit on a fault.
18 Operation principle and hardware description

Overview diagrams
￭Overview diagram of the drive system
The following figure shows a simplified diagram of a common DC bus drive system. More
details of the diode supply unit are shown in the module-specific single-line diagrams in
section Overview diagram of the supply unit (page 20).
M
3~
M
3~
M
3~
7
3
2
4
5
6 6
5
6
5
1
Main switch-disconnector [Q1]1
AC fuses2
Main contactor [Q2]3
Supply module [T01] (including choke, rectifier and DC fuses)4
Inverter DC fuses5
Inverter modules [T11…]6
Motors7
Operation principle and hardware description 19

￭Overview diagram of the supply unit
The following figures are examples of possible diode supply unit configurations.
Diode supply unit with frame D6D or D7D module
The following figure shows a connection example of a supply unit with a D6D or D7D module.
The table gives explanations for the numbers and letters used in the diagram. It also indicates
if the components can be ordered from ABB or if they must be acquired separately by the
customer.
Diode supply unit cubicle (DSU)A
AC supply network1
Main switch-disconnector [Q1] 1)
2
Main contactor [Q2] 1)
3
Diode supply module [T01] 2)
4
DC link5
1) Available from ABB or third party.
2) Available from ABB.
20 Operation principle and hardware description