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