ABB ACS880-104 User manual

—
ABB INDUSTRIAL DRIVES
ACS880-104 inverter modules
Hardware manual

ACS880-104 inverter modules
Hardware manual
Table of contents
4. Cabinet construction
5. Electrical installation
7. Start-up
© 2019 ABB Oy. All Rights Reserved. 3AUA0000104271 Rev H
EN
EFFECTIVE: 2019-06-29

Table of contents
1 Introduction to the manual
17Contents of this chapter ..........................................................................
17Applicability ........................................................................................
17Safety instructions ................................................................................
17Target audience ...................................................................................
18Categorization by frame size and option code ...............................................
18Use of component designations ................................................................
18Terms and abbreviations .........................................................................
19Related documents ...............................................................................
2 Hardware description
21Contents of this chapter ..........................................................................
22Overview diagram of the drive system .........................................................
22Inverter module hardware .......................................................................
22General .........................................................................................
23Frames R1i to R4i .............................................................................
23General ......................................................................................
23Frame R1i layout ...........................................................................
24Frame R4i layout ...........................................................................
25Overview circuit diagram of an inverter cubicle (frames R1i…R4i) .................
25Cabinet layout and cooling ...............................................................
26Frame R5i ......................................................................................
26General ......................................................................................
26Frame R5i layout ...........................................................................
27Overview circuit diagram of an inverter cubicle (frame R5i) .........................
27Cabinet layout and cooling ...............................................................
28Frames R6i and R7i ...........................................................................
28DC connection and capacitor charging .................................................
29Frame R6i and R7i layout ................................................................
30Overview circuit diagram of an inverter cubicle (frame R6i) .........................
31Overview circuit diagram of an inverter cubicle (frame R7i) .........................
31Cabinet layout and cooling ...............................................................
32Frame R8i and multiples .....................................................................
32DC connection and capacitor charging .................................................
33Frame R8i layout ...........................................................................
34Connectors X50…X53 ....................................................................
35Fiber optic connectors .....................................................................
36Overview circuit diagram of a frame R8i inverter unit ................................
37Overview circuit diagram of a frame 2×R8i inverter unit .............................
37Cabinet layout and cooling ...............................................................
38Inverter unit control interfaces ..................................................................
38Overview of control connections of the ZCU control unit ................................
39Overview of the control connections of the BCU control unit ...........................
40The ACx-AP-x control panel .................................................................
40Control by PC tools ........................................................................
41Type designation label ...........................................................................
Table of contents 5

3 Moving and unpacking the module
43Contents of this chapter ..........................................................................
43Moving and lifting the transport package ......................................................
43Unpacking ..........................................................................................
43Frames R1i…R5i ..............................................................................
44Frames R6i…R8i ..............................................................................
44Lifting the modules ................................................................................
44Moving the modules ..............................................................................
4 Cabinet construction
45Contents of this chapter ..........................................................................
45Limitation of liability ...............................................................................
45General .............................................................................................
45Installation examples .............................................................................
47R1i…R4i modules in a 400 mm wide Rittal VX25 enclosure ...........................
48Installation stages ..........................................................................
49Overview of kits ............................................................................
50Stage 1: Installation of common parts ..................................................
51Stage 2: Installation of bottom plate ....................................................
52Stage 3: Installation of mounting plate ..................................................
53Stage 4: Installation of DC busbars .....................................................
54Stage 5: Installation of mounting plate shrouds .......................................
55Stage 6: Installation of inverter modules and air guides .............................
56Stage 7: Installation of du/dt filters ......................................................
57R1i…R4i modules in a 600 mm wide Rittal VX25 enclosure ...........................
58Installation stages ..........................................................................
59Overview of kits ............................................................................
60Stage 1: Instalation of common parts ...................................................
61Stage 2: Installation of bottom plate ....................................................
62Stage 3: Installation of mounting plate ..................................................
63Stage 4: Installation of DC busbars .....................................................
64Stage 5: Installation of mounting plate shrouds .......................................
65Stage 6: Installation of inverter modules and air guides .............................
66Stage 7: Installation of du/dt filter ........................................................
67R1i…R4i modules in a 800 mm wide Rittal VX25 enclosure ...........................
68Installation stages ..........................................................................
69Overview of kits ............................................................................
70Stage 1: Installation of common parts ..................................................
71Stage 2: Installation of bottom plate ....................................................
72Stage 3: Installation of mounting plate ..................................................
73Stage 4: Installation of DC busbars .....................................................
74Stage 5: Installation of mounting plate shrouds .......................................
75Stage 6: Installation of inverter modules and air guides .............................
76Stage 7: Installation of du/dt filters ......................................................
77R5i modules in a 400 mm wide Rittal VX25 enclosure ..................................
78Installation stages ..........................................................................
79Overview of kits ............................................................................
80Stage 1: Installation of common parts ..................................................
81Stage 2: Installation of bottom plate ....................................................
82Stage 3: Installation of inverter module mounting plate ..............................
83Stage 4: Installation of DC busbars .....................................................
6 Table of contents

84Stage 5: Installation of front mounting plate ...........................................
85Stage 6: Installation of inverter modules ...............................................
86Stage 7: Installation of du/dt filters ......................................................
87R5i modules in a 600 mm wide Rittal VX25 enclosure ..................................
88Installation stages ..........................................................................
89Overview of kits ............................................................................
90Stage 1: Installation of common parts ..................................................
91Stage 2: Installation of bottom plate ....................................................
92Stage 3: Installation of inverter module mounting plate ..............................
93Stage 4: Installation of DC busbars .....................................................
94Stage 5: Installation of front mounting plate ...........................................
95Stage 6: Installation of inverter modules ...............................................
96Stage 7: Installation of du/dt filters ......................................................
97One R6i/R7i module in a 400 mm wide Rittal VX25 enclosure .........................
98Installation stages ..........................................................................
99Overview of kits ............................................................................
100Stage 1: Installation of common parts ..................................................
101Stage 2: Installation of bottom plate ....................................................
102Stage 3: Installation of support beams .................................................
103Stage 4 (R6i): Installation of DC busbars and charging components ..............
104Stage 4 (R7i): Installation of DC busbars and charging components ..............
105Stage 5: Installation of common mode filters ..........................................
106Stage 6 A: Installation of AC busbars (without du/dt filters) .........................
107Stage 6 B: Installation of AC busbars (with du/dt filters) .............................
108Stage 7: Installation of inverter module .................................................
109Stage 8: Installation of shrouding brackets ............................................
110One R8i module in a 400 mm wide Rittal VX25 enclosure ..............................
111Installation stages ..........................................................................
112Overview of kits ............................................................................
113Stage 1: Installation of common parts ..................................................
114Stage 2 A: Installation of DC busbars (1) (without DC switch/charging) ...........
115Stage 2 B: Installation of DC busbars (1) (with DC switch/charging) ..............
116Stage 3: Installation of module installation parts and lead-throughs ...............
117
Stage 4 A: Installation of quick connector and output (AC) busbars (cable
connection) .................................................................................
118
Stage 4 B: Installation of quick connector and output (AC) busbars (common AC
output busbar connection) ................................................................
119Stage 5 A: Installation of DC busbars (2) (without DC switch/charging) ...........
120Stage 5 B: Installation of DC busbars (2) (with DC switch/charging) ..............
121Stage 6: Installation of shrouding ........................................................
122Stage 7: Installation of inverter module .................................................
123Two R8i modules in a 600 mm wide Rittal VX25 enclosure .............................
124Installation stages ..........................................................................
125Overview of kits ............................................................................
126Stage 1: Installation of common parts ..................................................
127Stage 2 A: Installation of DC busbars (1) (without DC switch/charging) ...........
128Stage 2 B: Installation of DC busbars (1) (with DC switch/charging) ..............
129Stage 3: Installation of module installation parts and lead-throughs ...............
130
Stage 4 A: Installation of quick connector and output (AC) busbars (cable
connection) .................................................................................
131
Stage 4 B: Installation of quick connector and output (AC) busbars (cable
connection with bridging) .................................................................
Table of contents 7

132
Stage 4 C: Installation of quick connector and output (AC) busbars (common AC
output busbar connection) ................................................................
133Stage 5 A: Installation of DC busbars (2) (without DC switch/charging) ...........
134Stage 5 B: Installation of DC busbars (2) (with DC switch/charging) ..............
135Stage 6: Installation of shrouding ........................................................
136Stage 7: Installation of inverter modules ...............................................
137One R8i module in a 400 mm wide generic enclosure ..................................
139Two R8i modules in a 600 mm wide generic enclosure .................................
141Three R8i modules in a 800 mm wide generic enclosure ...............................
5 Electrical installation
143Contents of this chapter ..........................................................................
143Safety and liability ................................................................................
144Electrical safety precautions ....................................................................
145General notes .....................................................................................
145Printed circuit boards .........................................................................
145Optical components ...........................................................................
145Checking the insulation of the assembly ......................................................
145Checking the insulation of the drive system ...............................................
145Checking the insulation of the motor and motor cable ...................................
146Brake resistor assembly ......................................................................
147Power connections – Frames R1i…R5i .......................................................
147Power cable connection procedure .........................................................
147Frames R1i and R2i .......................................................................
148Frames R3i…R5i ..........................................................................
149Power connections – Frames R6i…R8i .......................................................
149R6i inverter module ...........................................................................
149R7i inverter module ...........................................................................
150Power connections - Frame R8i .............................................................
150R8i inverter module ........................................................................
1512×R8i inverter unit .........................................................................
152Connection procedure .....................................................................
154Replacing ACS800 R8i modules with ACS880 R8i modules ...............................
158Connecting the control cables - All frame sizes ..............................................
159Installing optional modules ......................................................................
159Installation of I/O extension and fieldbus adapter modules .............................
160Installation of an FSO-xx safety functions module .......................................
160Installation of an FSO-xx safety functions module onto ZCU .......................
161Installation of an FSO-xx safety functions module onto BCU .......................
163Installation of FSO-xx beside the control unit ..........................................
164Connecting a PC ..................................................................................
164Panel bus (Control of several units from one control panel) ................................
6 Installation checklist of the drive
167Contents of this chapter ..........................................................................
167Checklist ...........................................................................................
7 Start-up
169Contents of this chapter ..........................................................................
169Start-up procedure ................................................................................
8 Table of contents

8 Maintenance
173Contents of this chapter ..........................................................................
173Maintenance intervals ............................................................................
174Maintenance timers and counters ..............................................................
175Cleaning ............................................................................................
175Cleaning the interior of the cabinet .........................................................
175Cleaning the heatsink .........................................................................
176Cleaning the door air inlets ..................................................................
176Cleaning the door air inlets (IP20) .......................................................
176Cleaning the door air inlets (IP22 and IP42) ...........................................
177Replacing the inlet door filters (IP54) ...................................................
178Cooling fans .......................................................................................
178Replacing the module cooling fans .........................................................
178Replacing the R1i and R2i module cooling fan ........................................
179Replacing the R3i and R4i module cooling fan .......................................
180Replacing the R5i module main cooling fan ...........................................
180Replacing the R5i module auxiliary cooling fan .......................................
182Replacing the R6i and R7i module cooling fan ........................................
183Replacing R8i module cooling fan (speed-controlled version) ......................
184Replacing R8i module cooling fan (direct-on-line version) ...........................
186Replacing the circuit board compartment fan ..........................................
188Replacing the cabinet cooling fans .........................................................
188Cabinets with ABB air outlet kits .........................................................
188Cabinets with other fan types ............................................................
189Replacing R6i/R7i module .......................................................................
192Replacing R8i module ............................................................................
195Capacitors .........................................................................................
195Reforming the capacitors .....................................................................
195Control units .......................................................................................
195Replacing the memory unit ..................................................................
195Replacing the ZCU-14 control unit battery .................................................
196Replacing the BCU control unit battery ....................................................
197Control panel ......................................................................................
197Cleaning the control panel ...................................................................
197Replacing the control panel battery .........................................................
198LEDs and other status indicators ...............................................................
198Control panel and panel platform/holder LEDs ...........................................
198R8i module LEDs ..............................................................................
198Reduced run .......................................................................................
199Starting reduced run operation ..............................................................
199Resuming normal operation .................................................................
9 Ordering information
201Contents of this chapter ..........................................................................
202Kit code key ........................................................................................
204Frames R1i…R4i ..................................................................................
204Inverter modules ...............................................................................
206Control panel ...............................................................................
207DC-side components .........................................................................
208DC bus installation parts (for Rittal VX25 enclosures) ...............................
208Module-specific DC fuses (IEC, UL) ....................................................
Table of contents 9

209Module-specific DC fuse bases (IEC, UL) .............................................
209Main DC switch/disconnector kits .......................................................
209Main DC fuses (IEC, UL) .................................................................
210Busbars between main DC switch/disconnector and fuses .........................
212AC-side components ..........................................................................
212Output (du/dt) filters .......................................................................
213Mechanical installation accessories ........................................................
213Mounting plate shroud kits ...............................................................
214Air guide kits ................................................................................
215Frame R5i ..........................................................................................
215Inverter module ................................................................................
217Control panel ...............................................................................
218DC-side components .........................................................................
218DC bus installation parts (for Rittal VX25 enclosures) ...............................
218Module-specific DC fuses (IEC, UL) ....................................................
219Module-specific DC fuse bases (IEC, UL) .............................................
219Main DC switch/disconnector kits .......................................................
219Main DC fuses (IEC, UL) .................................................................
220DC busbars (IEC, UL) .....................................................................
221AC-side components ..........................................................................
221Output (du/dt) filters .......................................................................
221Mechanical installation accessories ........................................................
221Mounting plate shroud kits ...............................................................
222Fuse base shroud kit ......................................................................
223Frames R6i and R7i ..............................................................................
223Inverter modules ...............................................................................
224Control panel ...................................................................................
225DC-side components .........................................................................
225DC bus installation parts (for Rittal VX25 enclosures) ...............................
226DC fuses (IEC, UL) ........................................................................
226DC switch/disconnector kits ..............................................................
227Charging kit (R7i only) ....................................................................
228DC connection kit (for Rittal VX25 enclosures) ........................................
230DC busbars with common mode filter holder (for Rittal VX25 enclosures) ........
231DC busbars with fuse and common mode filter holders (for generic enclosures) .
231Common mode filters .....................................................................
232AC-side components ..........................................................................
232AC busbar kit ...............................................................................
232Output (du/dt) filters .......................................................................
233Mechanical installation accessories and tools ............................................
233Inverter module mounting parts ..........................................................
233Shrouding ...................................................................................
233Lifting device ................................................................................
235Frame R8i and multiples .........................................................................
235Inverter modules ...............................................................................
237Control panel ...............................................................................
238Control electronics ............................................................................
238Inverter control unit ........................................................................
238Fiber optic cables ..........................................................................
238Control circuit plug connectors ...........................................................
239Wire sets for use with the reduced run function .......................................
10 Table of contents

239DC-side components .........................................................................
240DC bus installation parts (for Rittal VX25 enclosures) ...............................
240DC connection parts 1 of 2 (for Rittal VX25 enclosures) .............................
243DC connection parts 1 of 2 (for generic enclosures) .................................
245DC connection parts 2 of 2 (for Rittal VX25 or generic enclosures) ................
246Common mode filters .....................................................................
247DC fuses (IEC, UL) ........................................................................
248DC switch/disconnector kits ..............................................................
250Charging kits ................................................................................
252Charging resistors .........................................................................
254AC-side components ..........................................................................
254Quick connector ............................................................................
254Output busbars/shrouds kit ...............................................................
258Cable entry kit ..............................................................................
258Mechanical installation accessories ........................................................
258Inverter module top/bottom guides ......................................................
260Ramp ........................................................................................
260Shrouding ...................................................................................
261Cabinet ventilation ................................................................................
261Air inlet kits .....................................................................................
261Air inlet kits 400 mm cabinet .............................................................
262Air inlet kits 600 mm cabinet .............................................................
263Air inlet kits 800 mm cabinet .............................................................
263Air outlet kits ...................................................................................
263Air outlet kits 400 mm cabinet ............................................................
265Air outlet kits 600 mm cabinet ............................................................
266Air outlet kits 800 mm cabinet ............................................................
268Cooling fans (frames R1i…R4i) .............................................................
271Cooling fans (frames R5i) ....................................................................
272Cooling fans (frames R6i…R7i) .............................................................
273Cooling fans (frames R8i) ....................................................................
10 Technical data
275Contents of this chapter ..........................................................................
275Ratings .............................................................................................
278Definitions ......................................................................................
279Derating ............................................................................................
279Ambient temperature derating ...............................................................
279Altitude derating ...............................................................................
280Switching frequency derating ................................................................
280Output frequency derating ...................................................................
280Cooling characteristics, noise, DC capacitance ..............................................
282Allowable mounting orientations ................................................................
283Dimensions and weights .........................................................................
284Free space requirements ........................................................................
285Typical power cable sizes .......................................................................
287Input power (DC) connection ....................................................................
287Motor (AC) connection ...........................................................................
289Control connections ..............................................................................
289Efficiency ...........................................................................................
289Degree of protection ..............................................................................
289Optical components ..............................................................................
Table of contents 11

290Ambient conditions ...............................................................................
291Materials ...........................................................................................
291Module housing ................................................................................
291Package ........................................................................................
291Disposal .........................................................................................
292Standards ..........................................................................................
292Markings ...........................................................................................
292Auxiliary power consumptions ..................................................................
292Control equipment .............................................................................
292Cabinet cooling fans ..........................................................................
293Definitions ......................................................................................
293Fuse data ..........................................................................................
293Ferrules used with 400 V and 500 V units .................................................
293Ferrules used with 690 V units ..............................................................
294Flush-end fuse blocks used with 400 V and 500 V units ................................
294Flush-end fuse blocks used with 690 V units .............................................
295Tightening torques ................................................................................
295Electrical connections ........................................................................
295Mechanical connections ......................................................................
295Insulation supports ............................................................................
295Cable lugs ......................................................................................
296Disclaimers ........................................................................................
296Generic disclaimer ............................................................................
296Cybersecurity disclaimer .....................................................................
11 Control units of the drive
297Contents of this chapter ..........................................................................
297General .............................................................................................
298ZCU-12 layout and connections ................................................................
299ZCU-14 layout and connections ................................................................
300Default I/O diagram of the inverter control unit (ZCU-14) ...................................
302BCU-x2 control unit layout and connections ..................................................
304Default I/O diagram of the inverter control unit (A41) ........................................
305External power supply for the control unit (XPOW) ..........................................
305DI6 as a PTC sensor input ......................................................................
306AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input ...............................
306DIIL input ...........................................................................................
306The XD2D connector .............................................................................
307Safe torque off (XSTO, XSTO OUT) ...........................................................
308FSO-xx safety functions module connection (X12) ..........................................
308SDHC memory card slot .........................................................................
309Connector data ....................................................................................
311BCU-x2 ground isolation diagram ...........................................................
312ZCU-1x ground isolation diagram ...........................................................
12 The Safe torque off function
313Contents of this chapter ..........................................................................
313Description .........................................................................................
314Compliance with the European Machinery Directive .....................................
315Wiring ...............................................................................................
315Activation switch ...............................................................................
12 Table of contents

315Cable types and lengths ......................................................................
315Grounding of protective shields .............................................................
316Dual-channel connection with internal power supply ....................................
316Frames R1i…R7i ..........................................................................
317Frame R8i and multiples ..................................................................
318Single-channel connection of activation switch ...........................................
319Multiple drives ..................................................................................
319Internal power supply .....................................................................
320External power supply .....................................................................
321Operation principle ................................................................................
322Start-up including acceptance test .............................................................
322Competence ...................................................................................
322Acceptance test reports ......................................................................
322Acceptance test procedure ..................................................................
324Use ..................................................................................................
325Maintenance .......................................................................................
325Competence ...................................................................................
326Fault tracing .......................................................................................
327Safety data .........................................................................................
328Abbreviations ..................................................................................
328TÜV certificate .................................................................................
13 Resistor braking using frames R1i…R4i inverter modules
329Contents of this chapter ..........................................................................
329Using R1i…R4i modules for resistor braking .................................................
329Planning the braking system ....................................................................
330Restrictions .....................................................................................
330Selecting the brake resistor ..................................................................
331Selecting and routing the brake resistor cables ...........................................
331Minimizing electromagnetic interference ...............................................
331Maximum cable length ....................................................................
331Placing custom brake resistors ..............................................................
331Protecting the system against thermal overload ..........................................
332Protecting the resistor cable against short circuit .........................................
332Mechanical installation ...........................................................................
332Electrical installation ..............................................................................
332Checking the insulation of the brake resistor assembly .................................
333Connection procedure ........................................................................
334Start-up .............................................................................................
335Technical data .....................................................................................
335Ratings ..........................................................................................
336Definitions ...................................................................................
337Resistor dimensions ..........................................................................
338Resistor connectors on inverter modules ..................................................
14 Dimension drawings
339Contents of this chapter ..........................................................................
340Frame R1i ..........................................................................................
341Frame R2i ..........................................................................................
342Frame R3i ..........................................................................................
343Frame R4i ..........................................................................................
Table of contents 13

344Frame R5i ..........................................................................................
345Frame R6i ..........................................................................................
346Frame R7i ..........................................................................................
347Frame R8i ..........................................................................................
349Frame R8i with option +P942 ...................................................................
352Control electronics ................................................................................
352ZCU control unit ...............................................................................
353BCU control unit ...............................................................................
354DPMP-01 door mounting kit .................................................................
355DC fuses and fuse bases ........................................................................
355Fuse, 14 × 51 mm .............................................................................
355Mersen US141 (Z331153F) fuse disconnector (for 14 × 51 mm fuses) ...............
356Fuse, 27 × 60 mm .............................................................................
356Mersen US271MI (R227600C) fuse disconnector (for 27 × 60 mm fuses) ...........
357
Mersen PS272PREMCPS (N220076) fuse disconnector (for R5i, 27 × 60 mm
fuses) ............................................................................................
358DC fuse blocks for frames R5i…R8i (Bussmann) ........................................
359Switchgear and charging components .........................................................
359OS_ switch fuses ..............................................................................
359OS100GJ04FP .............................................................................
360OS160GD04F ..............................................................................
361OS200DZ22F ...............................................................................
362OT_ switch/disconnectors ....................................................................
362OT200E11 ..................................................................................
363OT200U11 ..................................................................................
364OT400E11 ..................................................................................
365OT400E22 ..................................................................................
366OT400U11 ..................................................................................
367OT400U22 ..................................................................................
368OT600U11, OT630E11 ....................................................................
369OT1200U__, OT1600E__ ................................................................
370OT2500E22 .................................................................................
371OHB_ switch handles .........................................................................
371OHB65J6, OHB125J12, OHB145J12 ...................................................
371OHB150J12P ...............................................................................
372OHB274J12 .................................................................................
372OA1G10/OA3G01 auxiliary contact blocks ................................................
373AF190-30-00-13 contactor ...................................................................
374Charging controller ............................................................................
375CAV 120 C resistor ............................................................................
375ZRF 30/165 resistor ...........................................................................
376Miscellaneous components .....................................................................
376R3G225-RH17-23 / R2E225-RA92-17 cooling fan .......................................
376CRBB/4-400/188 cooling fan ................................................................
377Output (du/dt) filters for frames R1i…R5i ..................................................
378Common mode filters .........................................................................
378Quick connector for frame R8i ...............................................................
380Insertion/extraction ramp for frame R8i modules .........................................
15 Circuit diagrams
382Contents of this chapter ..........................................................................
14 Table of contents

382Component designations used in the diagrams ..............................................
382Frames R1i…R5i ..............................................................................
382Frame R6i ......................................................................................
382Frame R7i ......................................................................................
382Frame R8i and multiples .....................................................................
384Frames R1i…R4i – Sheet 001 (Main circuit, control unit) ..................................
385Frames R1i…R4i – Sheet 020 (Auxiliary voltage distribution) .............................
386Frames R1i…R4i – Sheet 026 (Cabinet cooling fan control) ...............................
387Frame R5i – Sheet 001 (Main circuit, control unit) ...........................................
388Frame R5i – Sheet 020 (Auxiliary voltage distribution) ......................................
389Frame R5i – Sheet 026 (Cabinet cooling fan control) .......................................
390Frame R6i – Sheet 001 (Main circuit, control unit) ...........................................
391Frame R6i – Sheet 020 (Auxiliary voltage distribution) ......................................
392Frame R7i – Sheet 001 (Main circuit, control unit) ...........................................
393Frame R7i – Sheet 020 (Auxiliary voltage distribution) ......................................
394Frame R8i (with DC switch/disconnector) – Sheet 001 (DC circuit) .......................
395Frame R8i (with DC switch/disconnector) – Sheet 005 (Inverter module) ................
396Frame R8i (with DC switch/disconnector) – Sheet 020 (Auxiliary voltage distribution) ..
397Frame R8i (with DC switch/disconnector) – Sheet 040 (Control unit) .....................
398Frame R8i (with DC switch/disconnector) – Sheet 061 (STO) .............................
399Frame 2×R8i – Sheet 001 (DC circuit) .........................................................
400Frame 2×R8i – Sheet 005 (Inverter modules) ................................................
401Frame 2×R8i – Sheet 020 (Auxiliary voltage distribution) ..................................
402Frame 2×R8i – Sheet 040 (Control unit) ......................................................
403Frame 2×R8i – Sheet 061 (STO) ...............................................................
Further information
Table of contents 15

16

Introduction to the manual
Contents of this chapter
This chapter gives the basic information on the manual.
Applicability
The manual applies to ACS880-104 inverter modules intended for user-defined cabinet
installations.
Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, use or service
the drive. The complete safety instructions are given in ACS880 multidrive cabinets and
modules safety instructions (3AUA0000102301 [English]).
•Read the software-function-specific warnings and notes before changing the default
settings of a function. For each function, the warnings and notes are given in the section
describing the related user-adjustable parameters.
• Read the task-specific safety instructions before starting the task. See the section
describing the task.
Target audience
This manual is intended for people who plan the installation, install, start up and service 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 17

The manual is written for readers worldwide. Both SI and imperial units are shown.
Categorization by frame size and option code
The instructions and technical data which concern only certain module or frame sizes are
marked with the size identifier.
The module size can be identified from the basic code visible on the type designation label,
for example, ACS880-104-0100A-3 where 0100A is the module size. The option codes of
the module are listed after the plus sign.
The frame size of a module can be, for example, R1i, R4i, R7i, R8i or 3×R8i (the latter
describing an inverter unit consisting of three parallel-connected R8i inverter modules). See
the technical data for the units and frame sizes.
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
Type of control boardBCON
Type of control unitBCU
Internal power supply board in frame R8i modulesBDPS
Control and power supply board for speed-controlled cooling fanBFPS
Conducts the surplus energy from the intermediate circuit of the drive to the brake
resistor when necessary. The chopper operates when the DC link voltage exceeds a
certain maximum limit. The voltage rise is typically caused by deceleration (braking)
of a high inertia motor.
Brake chopper
Common mode filteringCMF
One section of a cabinet-installed drive. A cubicle is typically behind a door of its own.Cubicle
DC circuit between rectifier and inverterDC link
Energy storage which stabilizes the intermediate circuit DC voltageDC link capacitors
Distributed drives communication system protocolDDCS
Frequency converter for controlling AC motorsDrive
Embedded fieldbusEFB
Electromagnetic compatibilityEMC
Electromagnetic interferenceEMI
Optional analog I/O extension moduleFAIO
Fieldbus adapterFBA
Optional CANopen® adapter moduleFCAN
Optional ControlNet™ adapter moduleFCNA
DDCS communication moduleFDCO
Diagnostics and panel interface boardFDPI
Optional EtherCAT adapter moduleFECA
Optional TTL incremental encoder interface moduleFEN-01
Optional TTL absolute encoder interface moduleFEN-11
Optional resolver interface moduleFEN-21
Optional HTL incremental encoder interface moduleFEN-31
Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP® and PROFINET
IO® protocols
FENA-11
18 Introduction to the manual

DescriptionTerm
Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP® and PROFINET
IO® protocols, 2-port
FENA-21
Optional Ethernet POWERLINK adapter moduleFEPL
Optional digital I/O extension moduleFIO-01
Optional analog I/O extension moduleFIO-11
Operation of a machine in both the forward and reverse directions in both motoring
and generating modes. Also used as an attribute of a drive; a regenerative drive can
operate the electric machine in all four modes, while a non-regenerative drive can
only operate the machine in motoring mode.
Four-quadrant operation
Optional PROFIBUS DP adapter moduleFPBA
Physical size of the drive or power moduleFrame, frame size
Optional Modbus RTU adapter moduleFSCA
Optional functional safety modulesFSO-12, FSO-21
See chapter Ordering information.
Generic enclosure
High-threshold logicHTL
Insulated gate bipolar transistorIGBT
DC circuit between rectifier and inverterIntermediate circuit
Inverter unitINU
Converts direct current and voltage to alternating current and voltage.Inverter
Inverter bridge, related components and drive DC link capacitors enclosed in a metal
frame or enclosure. Intended for cabinet installation.
Inverter module
Inverter module(s) under control of one control board, 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
Series of optional brake chopper modulesNBRA
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
Programmable logic controllerPLC
Radio-frequency interferenceRFI
Safety integrity level (1...3) (IEC 61508)SIL
Safe torque off (IEC/EN 61800-5-2)STO
Total harmonic distortionTHD
Enclosure system by Rittal (www.rittal.com)TS 8
Transistor-transistor logicTTL
Uninterruptible power supplyUPS
Type of control boardZCON
Type of control unitZCU
Type of memory unit, attached to the control unitZMU
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CodeManual
General manuals
3AUA0000102301
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3AUA0000102324
ACS880 multidrive cabinets and modules electrical planning instructions
3AUA0000107668
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Supply module manuals
Introduction to the manual 19

CodeManual
3AUA0000131525
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Module package hardware manuals
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Option manuals
3AXD50000037752
ACS880 +C132 marine type-approved drive modules and module packages supplement
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ACX-AP-x assistant control panels user’s manual
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BAMU-12C auxiliary measurement unit hardware manual
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3AXD50000010531
Installation frames for ACS880 multidrive modules hardware manual
Manuals and quick guides for I/O extension modules, fieldbus adapters, safety functions modules, etc.
See www.abb.com/drives/documents for all manuals on the Internet.
You can find all documentation related to the multidrive modules on the Internet at
https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content.
20 Introduction to the manual