ABB ACS880-207LC User manual

—
ABB INDUSTRIAL DRIVES
ACS880-207LC IGBT supply units
Hardware manual

ACS880-207LC IGBT supply units
Hardware manual
Table of contents
3. Electrical installation
6. Start-up and operation
3AXD50000174782 Rev C
EN
Original instructions
EFFECTIVE: 2023-06-30

Table of contents
1 Introduction to the manual
11Contents of this chapter ........................................................................
11Applicability ........................................................................................
11Safety instructions ...............................................................................
11Target audience ...................................................................................
12Purpose of the manual ..........................................................................
12Categorization by frame size and option code ............................................
12Use of component designations ..............................................................
12Terms and abbreviations .......................................................................
14Related documents ..............................................................................
2 Operation principle and hardware description
15Contents of this chapter ........................................................................
15Operation principle ..............................................................................
16Simplified main circuit diagram ...........................................................
16Charging ........................................................................................
17Overview diagram of the drive .................................................................
18Layout drawings ..................................................................................
18Supply unit ......................................................................................
19Incoming cubicle ..............................................................................
19Incoming cubicle for frame R7i (door closed) .......................................
21Incoming cubicle for frame R7i (door open) .........................................
22Incoming cubicle for frame R8i (door closed) .......................................
23Incoming cubicle for frame R8i (door open) .........................................
24Supply module cubicle (frame R7i) ........................................................
25Supply module cubicle (frame R8i) ........................................................
25Door open ...................................................................................
26Filter cubicle (frame R8i) ....................................................................
26Door open ...................................................................................
27Auxiliary control cubicle (width 400 mm, frame R7i) ..................................
27Door open ...................................................................................
28Auxiliary control cubicle (width 600 mm) ................................................
28Door closed .................................................................................
29Door open ...................................................................................
30100 kA input cubicle (option +F274) ......................................................
31Overview of power and control connections ...............................................
32Overview of the control connections of the BCU control unit .......................
33Supply unit control devices .....................................................................
33Main disconnecting device [Q1] ............................................................
33Auxiliary voltage switch [Q21] ..............................................................
33Grounding switch [Q9] ......................................................................
33Charging switch [Q3] and DC switch/disconnector [Q40] ...........................
34Operating switch [S21] .......................................................................
34DC switch/disconnector [Q11], charging switch [Q10] and indicator lamp [P1] ..
34Operating instructions ...................................................................
35Local charging control switch [S4] ........................................................
Table of contents 5

35Emergency stop button [S61] and reset button [S62] .................................
36Control panel [A59] ...........................................................................
36PC connection .................................................................................
36Fieldbus control ...............................................................................
36Cooling system ....................................................................................
36Coolant connectors ...........................................................................
37Type designation label(s) .......................................................................
38Type designation key ............................................................................
42Weak supply networks ...........................................................................
3 Electrical installation
43Contents of this chapter ........................................................................
43Required tools .....................................................................................
43Electrical safety precautions ...................................................................
46Isolation from AC supply networks ...........................................................
47Isolation from common DC bus ...............................................................
47Checking the insulation of the assembly ....................................................
47Measuring the insulation resistance of the drive ......................................
47Measuring the insulation resistance of the input power cable . . . . . . . . . . . . . . . . . . . . . .
48Connecting the input power cables ..........................................................
48Connection diagram (frame R7i) ...........................................................
48Connection procedure (frame R7i) ........................................................
49Removing shrouds ........................................................................
49Connecting the cables ....................................................................
51Installing shrouds .........................................................................
52Connection diagram (frame R8i and multiples) ........................................
52Connection procedure (frame R8i and multiples) ......................................
53Removing shrouds ........................................................................
53Connecting the cables ....................................................................
55Installing shrouds .........................................................................
56Use of fasteners in cable lug connections ..................................................
57Connecting input power cables - cable entry in 100 kA input cubicle (option +F274) .
57Connection diagram ..........................................................................
57Connection procedure .......................................................................
57Removing shrouds and beams in front of the input cable terminals ...........
58Connecting the cables ....................................................................
60Replacing shrouds and beams in front of input power cable terminals .......
61Connecting the external power supply cable for the auxiliary circuit .................
61Connection diagram ..........................................................................
62Checking the settings of the auxiliary voltage transformer ([T21], option +G344) ..
62T21 tap settings (690 V units) ..............................................................
63Checking the settings of the cooling fan transformer ...................................
63T115 and T125 tap settings (690 V units) ................................................
63Connecting the power supply cable for the charging circuit ............................
64Connecting the control cables .................................................................
64General instructions on connecting the control cables to the drive ...............
64Control cable connection procedure ..................................................
68Powering the heating and lighting equipment (options +G300 and +G301) ........
68Connection diagram ..........................................................................
69Connecting a PC ..................................................................................
70Installing optional modules ....................................................................
6 Table of contents

4 The control unit
71Contents of this chapter ........................................................................
71General ..............................................................................................
72BCU-x2 layout ......................................................................................
74Default I/O diagram of the supply control unit (BCU-x2) ................................
76Connecting motor temperature sensors to the drive ....................................
76Power supply for the control unit (XPOW) ..................................................
76The X485 connector ..............................................................................
77Safe torque off (XSTO, XSTO OUT) ...........................................................
77FSO safety functions module connection (X12) ............................................
77SDHC memory card slot .........................................................................
78Connector data ...................................................................................
81BCU-x2 ground isolation diagram .........................................................
5 Installation checklist
83Contents of this chapter ........................................................................
83Checklist ............................................................................................
6 Start-up and operation
85Contents of this chapter ........................................................................
86Start-up procedure ...............................................................................
88
Additional instructions for closing the DC switch-disconnector of the supply
module cubicle ([Q11], option +F286) .....................................................
7 Maintenance
89Contents of this chapter ........................................................................
89Maintenance intervals ...........................................................................
89Description of symbols ......................................................................
89Recommended maintenance intervals after start-up .................................
91Maintenance timers and counters ............................................................
92Cabinet .............................................................................................
92Cleaning the interior of the cabinet .......................................................
92Cleaning the exterior of the drive .........................................................
93Fuses ................................................................................................
93Replacing the supply unit AC fuses (frame R8i) ........................................
94Replacing AC fuses - 100 kA input cubicle (option +F274) ...........................
96Replacing the supply unit DC fuses (frame R7i) ........................................
98Replacing the supply unit DC fuses (frame R8i) ........................................
99Fans .................................................................................................
100Frame R7i – internal module fan replacement ..........................................
101Frame R8i fan replacement .................................................................
102Replacing the cabinet fan in the module cubicle (frame R7i) ........................
103Replacing the heat exchanger fan in the filter cubicle (frame R8i) .................
104Replacing the fan in the incoming cubicle (frame R7i) ................................
105Replacing the fan in the incoming cubicle (frame R8i) ................................
107Replacing the fan in the 400 mm wide auxiliary control cubicle (frame R7i) .....
108Replacing the fan in the 600 mm wide auxiliary control cubicle ....................
109Replacing the cooling fan in the 100 kA input cubicle .................................
Table of contents 7

112Supply modules ...................................................................................
112Replacing the supply module (frame R7i) ................................................
112Removing the module ....................................................................
114Reinstalling the module ..................................................................
114Replacing the supply module (frame R8i) ................................................
115Removing the module ....................................................................
117Reinstalling the module ..................................................................
118Assembling the service platform .......................................................
119LCL filters ..........................................................................................
119Replacing the capacitors of the LCL filter (frame R7i) ................................
120Replacing the capacitors of the LCL filter (frame R8i) ................................
121Lifting the inductor of the LCL filter ......................................................
122Charging resistors ................................................................................
122Replacing the charging resistors (frame R8i) ...........................................
123Capacitors of the DC circuit ....................................................................
123Reforming the capacitors ...................................................................
123Replacing the capacitors ....................................................................
123Control panel ......................................................................................
124Memory unit .......................................................................................
124Replacing the memory unit .................................................................
125LEDs .................................................................................................
125Control unit LEDs .............................................................................
125Control panel and panel platform/holder LEDs ........................................
125R7i and R8i module LEDs ....................................................................
126Reduced run .......................................................................................
126Starting reduced run operation ............................................................
127Resuming normal operation ................................................................
127Functional safety components ................................................................
8 Technical data
129Contents of this chapter ........................................................................
130Ratings ..............................................................................................
130Definitions ......................................................................................
131Derating .........................................................................................
131Surrounding air temperature derating ...............................................
131Altitude derating ..........................................................................
131Coolant temperature derating .........................................................
131Antifreeze content derating .............................................................
131Switching frequency derating ..........................................................
132Type equivalence table ..........................................................................
133Fuses ................................................................................................
133Main circuit AC fuses .........................................................................
134Main circuit AC fuses - 100 kA input cubicle (option +F274) .........................
135Main circuit DC fuses .........................................................................
136Dimensions and weights ........................................................................
137Free space requirements .......................................................................
137Losses, cooling data and noise ................................................................
138Internal cooling circuit data ....................................................................
138Terminal and lead-through data for the input power cable .............................
139400 mm wide input cubicle .................................................................
140600 mm wide incoming cubicle or input cubicle .......................................
1411000 mm wide input cubicle ................................................................
8 Table of contents

142100 kA input cubicle (option +F274) ......................................................
143Tightening torques ...............................................................................
143Electrical connections ........................................................................
143Mechanical connections .....................................................................
143Insulation supports ...........................................................................
143Cable lugs .......................................................................................
143Terminal data for the control cables .........................................................
144Typical power cable sizes .......................................................................
146Electrical power network specification ......................................................
147Control unit connection data (BCU) ..........................................................
147Efficiency ...........................................................................................
147Energy efficiency data (ecodesign) ...........................................................
147Protection classes ................................................................................
148Ambient conditions ..............................................................................
149Materials ............................................................................................
149Cabinet ..........................................................................................
149Package .............................................................................................
149Disposal ............................................................................................
150Applicable standards ............................................................................
150Markings ............................................................................................
150Disclaimers .........................................................................................
150Generic disclaimer ............................................................................
150Cyber security disclaimer ...................................................................
9 Internal cooling circuit
151Contents of this chapter ........................................................................
151Applicability ........................................................................................
151Internal cooling system .........................................................................
153Connection to a cooling unit ...................................................................
153Connection to an ACS880-1007LC cooling unit ........................................
153Connection to a custom cooling unit .....................................................
153General requirements ....................................................................
153Coolant temperature control ...........................................................
154Filling up and bleeding the internal cooling circuit ........................................
154Drive line-ups with an ACS880-1007LC cooling unit ...................................
154Drive line-ups with a custom cooling unit ...............................................
155Draining the internal cooling circuit ..........................................................
155Maintenance intervals ...........................................................................
156Technical data .....................................................................................
156Coolant specification ........................................................................
156Coolant type ................................................................................
156Temperature limits ...........................................................................
158Pressure limits .................................................................................
158Coolant flow rate limits ......................................................................
158Cooling circuit materials ....................................................................
Further information
Table of contents 9

10

Introduction to the manual
Contents of this chapter
This chapter describes the manual. It gives information on the markings and component
designations, and also the terms and abbreviations that are used in the manual. This
chapter also includes a list of related manuals.
Applicability
The manual is applicable to liquid-cooled, cabinet-installed ACS880-207LC IGBT 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, commission 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.
1
Introduction to the manual 11

Read the manual before you work on the drive. You are expected to know the
fundamentals of electricity, wiring, electrical components and electrical schematic
symbols.
Purpose of the manual
This manual helps in installing, commissioning, using and maintaining a multidrive
with an IGBT supply unit.
Categorization by frame size and option code
Some instructions and technical data which concern only certain unit or frame sizes
are marked with the size identifier. The frame size indicates the number of power
modules that form the supply unit.
The unit size can be identified from the basic code visible on the type designation
label, for example, ACS880-207LC-4360A-7 where 4360A is the unit size. The option
codes of the unit are listed after the plus sign. Section Type designation key (page 38)
explains the type designation code in detail.The frame size is marked on the type
designation label, and can also be determined from the type code.
The instructions and technical data which only concern certain optional selections are
marked with option codes (such as +E205). The options included in the drive can be
identified from the option codes visible on the type designation label. The option
selections are listed in section Type designation key (page 38).
Use of component designations
Some device names in the manual include the component designation in brackets (for
example, [Q20]). This will help you to identify the components in the circuit diagrams
of the drive.
Terms and abbreviations
DescriptionTerm/
Abbreviation
Assistant control panelACS-AP-…
Type of control boardBCON
Type of control unitBCU
An enclosure that consists of one or more cubiclesCabinet
I/O module for controlling cooling fansCIO
The part in which the control program runs.Control unit
One section of a cabinet-installed drive. A cubicle is typically behind a door of
its own.
Cubicle
DC circuit between line-side converter and motor-side converterDC link
Distributed drives communication system protocolDDCS
Digital inputDI
Frequency converter for controlling AC motorsDrive
Electromagnetic compatibilityEMC
Electromagnetic interferenceEMI
Analog I/O extension moduleFAIO-01
Optional CANopen® adapter moduleFCAN
Optional ControlNet™ adapter moduleFCNA-01
12 Introduction to the manual

DescriptionTerm/
Abbreviation
Optional digital I/O extension moduleFDIO-01
Optional DeviceNet™ adapter moduleFDNA-01
Diagnostics and panel interface boardFDPI
Optional I/O extension adapterFEA-03
Optional EtherCAT® adapter moduleFECA-01
Optional TTL incremental encoder interface moduleFEN-01
Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP® and
PROFINET IO® protocols
FENA-11
Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP and
PROFINET IO protocols, 2-port
FENA-21
Optional Ethernet POWERLINK adapter moduleFEPL-02
Optional digital I/O extension moduleFIO-01
Optional analog I/O extension moduleFIO-11
Optional PROFIBUS DP® adapter moduleFPBA-01
Physical size of the drive or power moduleFrame, frame size
Optional RS-485 (Modbus/RTU) adapterFSCA-01
Optional functional safety modulesFSO-12, FSO-21
Insulated gate bipolar transistorIGBT
IGBT supply module(s) under control of one control unit, and related compon-
ents.
IGBT supply unit
DC circuit between rectifier and inverterIntermediate circuit
Inverter module(s) under control of one control unit, and related components.
One inverter unit typically controls one motor.
Inverter unit
IGBT supply unitISU
Inductor-capacitor-inductor filterLCL filter
Drive for controlling several motors which are typically coupled to the same
machinery. Includes one supply unit, and one or several inverter units.
Multidrive
In the drive control program, user-adjustable operation instruction to the
drive, or signal measured or calculated by the drive.
In some (for example fieldbus) contexts, a value that can be accessed as an
object. For example, variable, constant, or signal.
Parameter
Protective earth (ground)PE
Programmable logic controllerPLC
Common term for drive module, inverter module, supply module, brake
chopper module etc.
Power module
Positive temperature coefficientPTC
Optical DDCS communication moduleRDCO
Safe torque off (IEC/EN 61800-5-2)STO
Introduction to the manual 13

Related documents
You can find manuals on the Internet. See below for the relevant code/link. For more
documentation, go to www.abb.com/drives/documents.
Manuals for ACS880 multidrives cabinets
14 Introduction to the manual

Operation principle and hardware
description
Contents of this chapter
This chapter describes the operation basics and the hardware of the IGBT supply unit
(ACS880-207LC).
Operation principle
IGBT supply unit rectifies three-phase AC current to direct current for the intermediate
DC link of the drive. The intermediate DC link supplies the inverters that run the motors.
There can be one inverter unit only (single drives) or several inverter units (multidrives)
connected to the intermediate circuit.
The LCL filter is an essential part of the IGBT supply unit. The supply module does not
work without the filter. It suppresses the AC voltage distortion and current harmonics.
The high AC inductance smooths the line voltage waveform distorted by the
high-frequency switching of the converter. Capacitive component of the filter effectively
filters the high-frequency (over 1 kHz) harmonics.
A grid converter is an IGBT supply unit equipped with optimal grid control functionality.
The grid converter can be used to produce an island AC grid. It is also possible to use
grid converters in parallel with generators to support the operation of a distributed
power system. The grid converter produces sinusoidal three-phase AC voltages from
the DC link voltage of the system. AC voltage magnitude and frequency can be defined
by the user. A grid converter can be used in eg. marine applications where ordinary
power grid connection is not available. For further details, see Optimal grid control
of ACS880 IGBT supply control program supplement (3AXD50000164745 [English]).
Optimal grid control functionality is in use only when the license key N8053 has been
activated on the memory unit. This has been done at the factory for a unit with the
option +N8053. You can see the license information with the Drive Composer PC tool
2
Operation principle and hardware description 15

or ACS-AP-x control panel in System info -Licenses. If the license key for the optimal
grid control is missing, the converter indicates fault 6E1F Licensing fault. Auxiliary
code in the event logger indicates the plus code of missing license, in this case N8053.
For further assistance, contact your local ABB representative.
￭Simplified main circuit diagram
The following figure shows the simplified main circuit diagram of the rectifier.
1
2
3 4 5
6
AC voltage1.
AC fuses2.
LCL filter3.
IGBT supply module4.
DC fuses5.
DC voltage6.
￭Charging
A charging circuit powers up the DC link capacitors of the drive system smoothly.
Discharged capacitors cannot be directly connected to the full supply voltage. The
charging current must be limited until the capacitors are charged and ready for normal
use.
In cabinet-installed units, a resistive charging circuit consisting of fuses, a contactor
and charging resistors is used. The resistive charging circuit is in use after power-up
as long as DC voltage has risen to a predefined level.
The control program has a function for controlling the charging circuit. For further
information, see the firmware manual.
16 Operation principle and hardware description

Overview diagram of the drive
This diagram shows a simplified diagram of a drive with IGBT supply unit (frame R7i)
and inverter unit.
M
3
M
3
M
3
3~
1
2
10
12
4
8
7
11
9
6
5
3
999
10 10 10
11 11
Auxiliary voltage transformer ([T21], option +G344)1.
Auxiliary voltage switch [Q21]2.
Main switch-disconnector ([Q1], option +F253) (standard, always with +F250)3.
AC fuses [F1]4.
Main contactor ([Q2], option +F250) (standard, always with +F253)5.
Charging circuit6.
LCL filter [R03]7.
IGBT supply module [T01]8.
Common mode filter [R1]9.
DC fuses [F2]10.
Inverter modules [T11]11.
Motor(s)12.
Operation principle and hardware description 17

Layout drawings
This section contains layout drawings of cubicles that are included in a supply unit.
The components, layout and size of the cubicles vary depending on the supply unit
size and selected options.
￭Supply unit
This drawing shows an example of an IGBT supply unit. Cables enter the cabinet
through the bottom.
1 2 3 4
Incoming cubicle (ICU). Contains the power input cable terminals and switchgear.1.
LCL filter cubicle. Contains LCL filter(s).2.
Supply module cubicle. Contains IGBT supply module(s) of frame size R8i.3.
Auxiliary control cubicle. Contains control electronics and customer I/O connections.4.
18 Operation principle and hardware description

￭Incoming cubicle
This section shows examples of incoming cubicle layout. The cubicle contains the
main switching and disconnecting devices. The input power cables are connected to
the incoming cubicle through cabinet bottom. The components, layout and size vary
depending on the supply unit size and selected options. The top cable entry (option
+H351) increases the cubicle height.
Input cubicle (IPU) does not contain main disconnecting device (main
switch-disconnector or main circuit breaker), but is otherwise similar.
Supply units with high power can contain two incoming cubicles. Then only one of
them contains charging components, otherwise the cubicles are similar.
Incoming cubicle for frame R7i (door closed)
1
3
4
6
5
2
7
Meters1.
V-meter selector switch [S5]2.
DC link charging switch [Q40]3.
Auxiliary voltage switch4.
Charging switch5.
Operation principle and hardware description 19

Grounding switch (option +F259)6.
Main switch-disconnector7.
20 Operation principle and hardware description