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