ABB ACS880-307LC User manual

—
ABB INDUSTRIAL DRIVES
ACS880-307LC diode supply units
Hardware manual

ACS880-307LC diode supply units
Hardware manual
Table of contents
3. Electrical installation
6. Start-up
3AXD50000579662 Rev A
EN
EFFECTIVE: 2020-06-30

Table of contents
1 Introduction to the manual
9Contents of this chapter ...........................................................................
9Applicability .........................................................................................
9Safety instructions .................................................................................
9Target audience ....................................................................................
10Categorization by frame size and option code .................................................
10Use of component designations .................................................................
10Terms and abbreviations ..........................................................................
11Related documents ................................................................................
2 Operation principle and hardware description
13Contents of this chapter ...........................................................................
13Operation principle .................................................................................
14Overview diagram of the rectifier bridge ....................................................
146- and 12-pulse supply connections .........................................................
16Overview diagram of the drive system ..........................................................
17Layout drawings ....................................................................................
17Overview layout drawing of the supply unit .................................................
18Auxiliary control cubicle layout ...............................................................
19Incoming cubicle layout - bottom cable entry ...............................................
20Supply module cubicle layout – frame 1×D8T .............................................
20Supply module cubicle layout – frame 1×D8T, electrical components ..............
20Supply module cubicle layout – frame 1×D8T, cooling circuit ........................
21Supply module cubicle layout – frame 2×D8T .............................................
21Supply module cubicle layout – frame 2×D8T, electrical components ..............
22Supply module cubicle layout – frame 2×D8T, cooling circuit ........................
23Supply module layout - frame D8T ..........................................................
24Overview of the control connections of the BCU control unit ................................
25Supply unit control devices .......................................................................
25Overview of door switches and lights ........................................................
25Main disconnecting device [Q1.x] ............................................................
26Auxiliary voltage switch [Q21] ................................................................
26Grounding switch [Q9.x] .......................................................................
26Operating switch [S21] ........................................................................
27Emergency stop button [S61] .................................................................
27E-stop reset button [S62] and indication lamp [P62] ......................................
27Other optional door controls ..................................................................
27Control panel ....................................................................................
27PC connection ..................................................................................
28Fieldbus control .................................................................................
28Type designation labels ...........................................................................
30Type designation keys ............................................................................
30Type designation key of the supply unit .....................................................
30Basic code ...................................................................................
30Option codes ................................................................................
32Type designation key of the diode supply module .........................................
Table of contents 5

3 Electrical installation
35Contents of this chapter ...........................................................................
36Electrical safety precautions .....................................................................
37General notes ......................................................................................
37Static electricity .................................................................................
37Optical components ............................................................................
38Measuring the insulation ..........................................................................
38Measuring the insulation of the drive ........................................................
38Measuring the insulation of the input power cable ........................................
38Connecting the input power cables ..............................................................
38Connection diagram – 6-pulse supply unit ..................................................
38Connection diagram – 12-pulse supply unit (option +A004) .............................
39Connection procedure – bottom cable entry ...............................................
42Connecting the external power supply cable for the auxiliary circuit (option +G307) ....
42Wiring the functional safety options .............................................................
42Connecting the control cables ...................................................................
42Control cable connection procedure .........................................................
42Grounding the outer shields of the control cables at the cabinet entry .............
44Routing the control cables inside the cabinet ...........................................
44Connecting control cabling ................................................................
46Connecting a PC ...................................................................................
4 The control unit
47Contents of this chapter ...........................................................................
48BCU-x2 layout ......................................................................................
50Default I/O diagram of the supply control unit .................................................
52External power supply for the control unit (XPOW) ...........................................
52The X485 connector ...............................................................................
53Safe torque off (XSTO, XSTO OUT) ............................................................
53FSO-xx safety functions module connection (X12) ...........................................
53SDHC memory card slot ..........................................................................
54Connector data .....................................................................................
56BCU-x2 ground isolation diagram ............................................................
5 Installation checklist
57Contents of this chapter ...........................................................................
57Checklist .............................................................................................
6 Start-up
59Contents of this chapter ...........................................................................
60Start-up procedure .................................................................................
60Basic checks with no voltage connected ....................................................
60Starting and checking the cooling system ..................................................
60Connecting voltage to input terminals and auxiliary .......................................
61Setting the supply unit parameters ..........................................................
61Powering up the drive ..........................................................................
62Safety function validation ......................................................................
62On-load checks .................................................................................
62Switching the supply unit off ......................................................................
62Disconnecting and temporary grounding the drive ............................................
6 Table of contents

7 Maintenance
63Contents of this chapter ...........................................................................
63Maintenance intervals .............................................................................
65Maintenance timers and counters ...............................................................
65Internal liquid-cooling system ....................................................................
65Power connections ................................................................................
65Retightening the power connections ........................................................
65Fans ..................................................................................................
65Replacing the fan in the 600 mm wide incoming cubicle .................................
67Replacing the cooling fan of a D8T supply module .......................................
68Fuses ................................................................................................
68Checking and replacing the AC fuses .......................................................
69Checking and replacing the DC fuses .......................................................
70Supply module .....................................................................................
70Replacing the D8T supply module ...........................................................
74Control panel .......................................................................................
74Cleaning the control panel ....................................................................
74Replacing the control panel battery ..........................................................
75Control unit ..........................................................................................
75Replacing the memory unit ...................................................................
75Replacing the BCU control unit battery .....................................................
76LEDs and other status indicators ................................................................
76Control panel and panel platform/holder LEDs ............................................
77Control unit LEDs ...............................................................................
8 Internal cooling circuit
79Contents of this chapter ...........................................................................
79Applicability .........................................................................................
79Internal cooling system ............................................................................
81Connection to a cooling unit ......................................................................
81Connection to an ACS880-1007LC cooling unit ...........................................
81Connection to a custom cooling unit .........................................................
81General requirements ......................................................................
81Coolant temperature control ...............................................................
82Filling up and bleeding the internal cooling circuit ............................................
82Drive line-ups with an ACS880-1007LC cooling unit ......................................
82Drive line-ups with a custom cooling unit ...................................................
84Draining the internal cooling circuit ..............................................................
84Maintenance intervals .............................................................................
84Technical data ......................................................................................
84Coolant specification ...........................................................................
84Coolant type .................................................................................
84Temperature limits ..............................................................................
86Pressure limits ..................................................................................
86Coolant flow rate limits ........................................................................
86Cooling circuit materials .......................................................................
9 Technical data
89Contents of this chapter ...........................................................................
89Ratings ..............................................................................................
Table of contents 7

90Derating .............................................................................................
90Surrounding air temperature derating .......................................................
91Coolant temperature derating ................................................................
91Antifreeze content derating ...................................................................
91Altitude derating ................................................................................
91Type equivalence table ............................................................................
92Fuses ................................................................................................
92Main circuit AC fuses ..........................................................................
93Main circuit DC fuses ..........................................................................
94Dimensions, weights and free space requirements ...........................................
95Cooling data and noise ............................................................................
95Terminal and cable entry data for the input power cable .....................................
96400 mm wide input cubicle ....................................................................
97600 mm wide incoming cubicle or input cubicle ...........................................
98Tightening torques .................................................................................
98Electrical connections ..........................................................................
98Mechanical connections .......................................................................
98Insulation supports .............................................................................
98Cable lugs .......................................................................................
99Typical power cable sizes .........................................................................
101Electrical power network specification ..........................................................
101Control unit (board) connection data ............................................................
101Auxiliary circuit current consumption ............................................................
101Efficiency ............................................................................................
101Protection classes .................................................................................
102Ambient conditions ................................................................................
103Materials .............................................................................................
103Color .................................................................................................
103Package .............................................................................................
103Vertical package ................................................................................
103Disposal .............................................................................................
103Applicable standards ..............................................................................
104Markings .............................................................................................
104Disclaimers .........................................................................................
104Generic disclaimer .............................................................................
104Cybersecurity disclaimer ......................................................................
Further information
8 Table of contents

Introduction to the manual
Contents of this chapter
This chapter contains general information on the manual.
Applicability
The manual is applicable to the cabinet-installed ACS880-307LC…+A018 diode supply
units that form a part of an ACS880 multidrive system.
Safety instructions
Obey all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, use or service
the drive. The complete safety instructions are given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [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 9

Categorization by frame size and option code
The frame size identifies information which concerns only a certain frame size of the drive.
The frame size is shown on the type designation label. All frame sizes are listed in the
technical data.
The option code (for example, option +E200) identifies information which concerns only a
certain optional selection. The options included in the drive are listed on the type designation
label.
Use of component designations
Some device names in the manual include the item designation in brackets, for example
[Q20], to make it possible to identify the components in the circuit diagrams of the drive.
Terms and abbreviations
DescriptionTerm
Auxiliary control unit. Contains control electronics, auxiliary voltage circuitry, etc.ACU
Type of control unitBCU
I/O module for controlling cooling fansCIO
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
Frame size designation of the diode supply moduleD8T
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
Physical size of the drive or power moduleFrame, frame size
Incoming unitICU
DC circuit between rectifier and inverterIntermediate circuit
Inverter unitINU
Inverter bridge, related components and drive DC link capacitors enclosed in a metal
frame or enclosure. Intended for cabinet installation.
Inverter module
Inverter module(s) under control of one control unit, and related components. One
inverter unit typically controls one motor.
Inverter unit
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
10 Introduction to the manual

Related documents
CodeManual
General manuals
3AXD50000048633
ACS880 liquid-cooled multidrive cabinets and modules safety instructions
3AXD50000048634
ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions
3AXD50000048635
ACS880 liquid-cooled multidrive cabinets mechanical installation instructions
3AXD50000126880
CIO-01 I/O module for distributed I/O bus control user's manual
Supply unit manuals
3AXD50000174782
ACS880-207LC IGBT supply units hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
3AXD50000579662
ACS880-307LC…+A018 diode supply units hardware manual
3AUA0000103295
ACS880 diode supply control program firmware manual
Inverter unit manuals
3AXD50000196111
ACS880-107LC inverter units hardware manual
3AUA0000085967
ACS880 primary control program firmware manual
3AUA0000098062
ACS880 primary control program quick start-up guide
Manuals for application programs (Crane, Winder, etc.)
Brake unit and DC/DC converter unit manuals
3AXD50000481491
ACS880-607LC 1-phase brake units hardware manual
3AXD50000020967
ACS880 (3-phase) brake control program firmware manual
3AXD50000431342
ACS880-1607LC DC/DC converter units hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
Option manuals
3AXD50000129607
ACS880-1007LC liquid cooling unit user's manual
3AXD50000039629
ACS880 +C132 marine type-approved cabinet-built drives supplement
3AUA0000085685
ACS-AP-x assistant control panels user’s manual
3AUA0000094606
Drive composer start-up and maintenance PC tool user’s manual
3AXD50000210268
Converter module lifting device for drive cabinets hardware manual
Manuals for I/O extension modules, fieldbus adapters, safety options etc.
You can find manuals on the Internet. See www.abb.com/drives/documents. For manuals
not available in the document library, contact your local ABB representative.
Introduction to the manual 11

12

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
ACS880-307LC…+A018 diode supply units.
Operation principle
The core of the diode supply unit is a diode-thyristor bridge. It 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 DSU modules
have inbuilt AC chokes. The AC chokes smoothen the current waveform in the power supply
network and voltage in the DC link of the drive.
The main difference between the ordinary diode-diode bridge and the controlled
diode-thyristor bridge is the controllability. You cannot control the operation of the diodes
but you can control the thyristors. By controlling the thyristors, you can limit the AC current
of the drive at the power up without additional charging circuit in the supply unit or in inverter
units.
There are two control modes for the upper leg thyristor firing: the charging mode and the
normal mode:
• The charging mode is in operation a short period after the power switch on: the supply
control program controls the thyristor firing angle gradually towards zero while the
intermediate circuit capacitors located in the inverter module(s) get charged.
• In the normal mode, the thyristor firing angle is 0 degrees: The thyristors operate as
diodes.
2
Operation principle and hardware description 13

￭Overview diagram of the rectifier bridge
UU
1
2
3
Diodes. The diodes connect the AC terminals in cyclic sequence to the lower DC busbar (-).1
Thyristors. The thyristors connect the AC line terminals in cyclic sequence to the upper DC busbar (+).2
AC chokes3
￭6- and 12-pulse supply connections
The figure below illustrates the difference between 6-pulse and 12-pulse AC supply
connections. The 6-pulse connection is standard. If the drive has an even number of supply
modules, you can order it as a 12-pulse version (option +A004).
The 12-pulse supply connection eliminates the fifth and seventh harmonics, which
substantially reduces the harmonic distortion of the line current and the conducted emissions.
The 12-pulse connection requires a three-winding transformer, or two separate transformers.
There must be phase shift of 30-degrees between the two 6-pulse supply lines, which are
connected to different supply modules through electrically separate switching equipment.
14 Operation principle and hardware description


 

A
 

B
6-pulse connectionA
12-pulse connectionB
Supply transformer1
Switching equipment2
Diode supply modules3
Operation principle and hardware description 15

Overview diagram of the drive system
The following figure shows an example drive with a diode supply unit and three inverter
units.
M
3~
M
3~
M
3~
7
1
2
9
8
4
3
5
66
5
5
6
Main circuit breaker [Q1]1
AC fuses2
Supply module [T01] (including choke and rectifier)3
Supply module DC fuses4
Inverter module DC fuses (with or without DC switches)5
Inverter module [T11]6
Motor7
Auxiliary voltage switch [Q21] (option +G344 or +G451)8
Auxiliary voltage transformer [T21] (option +G344)9
16 Operation principle and hardware description

Layout drawings
￭Overview layout drawing of the supply unit
This drawing shows an example of a diode supply unit.
123
6
10
8
11
5 4
7
9
Auxiliary control cubicle1
Incoming cubicle2
Supply module cubicle3
Control devices. See section Supply unit control devices.
4…11
Operation principle and hardware description 17

￭Auxiliary control cubicle layout
2
1
4
3
5
6
78
Control panel [A59] (option +J400, or +J425)1
Operating switch [S21], emergency stop button [S61], etc.2
CIO-01 I/O module for cooling fan monitoring [A115.99]3
BCU control unit [A51]4
Auxiliary voltage transformers behind the assembly plates ([T21] option +G344, [T115] option +G451,
in some deliveries also [T125])
5
Cooling fan and heat exchanger [G115.99]6
Inlet manifold with stop and drain valves7
Outlet manifold with stop and drain valves8
18 Operation principle and hardware description

￭Incoming cubicle layout - bottom cable entry
5
4
1
2
3
12
11
10
9
8
7
6
14
13
See Supply unit control devices (page 25).
1…4
Main supply breaker [Q1.x] (option +F255)5, 9
Auxiliary voltage supply breaker (switch fuse) [Q21]1, 6
Grounding switch [Q9.x] (option +F259)4, 7
Not in use.8
CIO-01 I/O module for cooling fan control [A115.x]10
Cooling fan and heat exchanger [G115.x]11
Input power cable terminals L1, L2, L312
Inlet manifold with stop and drain valves13
Outlet manifold with stop and drain valves14
Operation principle and hardware description 19

￭Supply module cubicle layout – frame 1×D8T
Supply module cubicle layout – frame 1×D8T, electrical components
8
7
6
5
M4
23
1
9
DC voltage measuring/testing pointsM
Cabinet light ([H310.101) ], option +G301)
1
Cabinet fan miniature circuit breaker [F115.101) ]
2
CIO-01 I/O module for distributed I/O bus control [A115.101) ]
3
Cabinet light switch ([S130.101) ], option +G301)
4
Module 1 AC fuses [F3.11…1) ]
5
Module 1 DC fuses [F2.11…1) ]
6
Supply module [T01.1]7
Cabinet heater ([E95.101) ], option +G300)
8
Cabinet fan [G115.101) ]
9
1) Latter number is for the first supply module cubicle. The number increases in other cubicles (if any).
Supply module cubicle layout – frame 1×D8T, cooling circuit
20 Operation principle and hardware description