ABB ACS880-107 User manual

—
ABB INDUSTRIAL DRIVES
ACS880-107 inverter units
Hardware manual

ACS880-107 inverter units
Hardware manual
Table of contents
3. Electrical installation
6. Start-up
3AUA0000102519 Rev G
EN
Original instructions
EFFECTIVE: 2023-12-28

Table of contents
1 Introduction to the manual
11Contents of this chapter ........................................................................
11Applicability ........................................................................................
11Safety instructions ...............................................................................
11Target audience ...................................................................................
12Categorization by frame size, option code and item designation .....................
12Use of component designations ..............................................................
12Terms and abbreviations .......................................................................
13Related documents ..............................................................................
2 Operation principle and hardware description
15Contents of this chapter ........................................................................
15Overview diagramof the drivesystem .......................................................
17Inverter unit hardware ...........................................................................
17General ..........................................................................................
17Cabinet system ................................................................................
17Cooling ..........................................................................................
18Inverter module frame sizes R1i…R4i .....................................................
18General .......................................................................................
18Module layout examples .................................................................
19Standard cabinet layout .................................................................
20
Layout of cubicle with frame R1i…R4i modules in their own compartments
(option +C204) .............................................................................
23Inverter module frame size R5i .............................................................
23General .......................................................................................
23Module layout ..............................................................................
23Standard cabinet layout .................................................................
24
Layout of cubicle with frame R5i modules in their own compartments (option
+C204) .......................................................................................
26Inverter module frame sizes R6i and R7i .................................................
26Module layout ..............................................................................
26Cabinet layout ..............................................................................
27Motor cabling ..............................................................................
28Inverter module frame size R8i and multiples ..........................................
29Cooling fans ................................................................................
29Control electronics ........................................................................
29Cabinet layout ..............................................................................
31Motor cabling ..............................................................................
32Control interfaces ................................................................................
32Overview of control connections of the ZCU control unit ............................
33Overview of the control connections of the BCU control unit .......................
33The ACS-AP-W control panel ................................................................
34Control by PC tools ...........................................................................
34Fieldbus control ...............................................................................
34Other control devices ........................................................................
34DC switch-disconnector(option +F286) ..............................................
Table of contents 5

34Charging switch (frame R8i and multiples only) ....................................
35Type designation labels .........................................................................
35Inverter unit type designation label .......................................................
35Inverter module type designation label ..................................................
37Type designation key ............................................................................
37Type designation key of the inverter unit ................................................
37Option codes ...............................................................................
41Type designation key of the inverter module ...........................................
3 Electrical installation
43Contents of this chapter ........................................................................
43Warnings ...........................................................................................
44Electrical safety precautions ...................................................................
45General notes ......................................................................................
45Printed circuit boards ........................................................................
45Handling fiber optic cables .................................................................
46Measuring theinsulation ........................................................................
46Measuring the insulation resistance of the drive ......................................
46Measuring the insulation resistance of the motor and motor cable ...............
47Connecting the motor cable – Frame sizes R1i…R5i ......................................
47Connection diagram ..........................................................................
47Motor cable connection procedure .......................................................
49Connecting the motor cable – Frame sizes R6i and R7i ..................................
49Connection diagram ..........................................................................
49Motor cable connection procedure .......................................................
52
Connecting the motor cables – Frame size R8i and multiples without common
motor terminal cubicle or sine output filter ................................................
52Motor connection diagram (without option +H366) ..................................
52Motor connection diagram (with option +H366) .......................................
53Procedure .......................................................................................
53Removing an inverter module ...........................................................
54Removing the fan carriage of an inverter module ..................................
56Connecting the motor cables ...........................................................
58Installing the fan carriage of an inverter module ...................................
58Installing an inverter module ............................................................
59
Connecting the motor cables – Frame size R8i and multiples with common motor
terminal cubicle ...................................................................................
59Output busbars ................................................................................
59Connection diagram ..........................................................................
59Procedure .......................................................................................
61Use of fasteners in cable lug connections ...............................................
62Installing optional modules on the control unit ............................................
62Installing an FSO safety functions module (frame sizes R1i…R7i) ..................
63Installing an FSO safety functions module (frame sizes R8i and multiples) ......
65
Installation of I/O extension, fieldbus adapter and pulse encoder interface
modules .........................................................................................
66Connecting the control cables .................................................................
66Control cable connection procedure ......................................................
66Grounding the outer shields of the control cables 360° at the cabinet entry .
68Routing the control cables inside the cabinet .......................................
68Connecting control cabling .............................................................
69Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) ....
6 Table of contents

69
Connecting the emergency stop push buttons (options +Q951, +Q952, +Q963,
+Q964, +Q978,+Q979) ....................................................................
70Connecting the emergency stop push buttons (option +Q951) .................
70Wiring the starter for auxiliary motor fan (options +M6xx) ......................
70
Wiring the PTC thermistor relay(s) (options +L505, +2L505, +L513 and
+2L513) .......................................................................................
70Wiring the Pt100 relays (option +nL506) .............................................
71Wiring the Pt100 relays (option +nL514) .............................................
71
Powering the heating and lighting equipment (options +G300, +G301 and
+G313) ........................................................................................
72Connecting a PC ..................................................................................
73Panel bus (control of several units from one control panel) .............................
4 Control units of the drive
77Contents of this chapter ........................................................................
77General ..............................................................................................
78ZCU-12 layout ......................................................................................
79ZCU-14 layout ......................................................................................
80Default I/O diagram of the inverter control unit (ZCU) ..................................
83BCU layout .........................................................................................
85Default I/O diagram of the inverter control unit (BCU) ..................................
89Additional information on the connections .................................................
89Power supply for the control unit (XPOW) ...............................................
89DIIL input ........................................................................................
89The XD2D connector ..........................................................................
90Safe torque off (XSTO, XSTO OUT) ........................................................
90FSO safety functions module connection (X12) ........................................
91SDHC memory card slot .....................................................................
92Connector data ...................................................................................
95BCU ground isolation diagram .............................................................
96ZCU ground isolation diagram .............................................................
5 Installation checklist
97Contents of this chapter ........................................................................
97Checklist ............................................................................................
6 Start-up
99Contents of this chapter ........................................................................
99Start-up procedure ...............................................................................
7 Maintenance
103Contents of this chapter ........................................................................
103Maintenance intervals ...........................................................................
103Description of symbols ......................................................................
103Recommended maintenance intervals after start-up .................................
104Maintenance timers and counters ............................................................
105Cabinet .............................................................................................
105Cleaning the interior of the cabinet .......................................................
105Cleaning the exterior of the drive .........................................................
106Cleaning the door air inlets (IP22 and IP42) .............................................
107Replacing the inlet door filters (IP54) .....................................................
Table of contents 7

107Replacing the roof outlet filters (IP54) ...................................................
107Cleaning the heatsink ........................................................................
108Cooling fans .......................................................................................
109Module cooling fans ..........................................................................
109Replacing the R1i and R2i module cooling fan .......................................
110Replacing the R3i and R4i module cooling fan ......................................
111Replacing the R5i module main cooling fan (without option +C204) ..........
112Replacing the R5i module main cooling fan (with option +C204) ...............
113Replacing the R5i module auxiliary cooling fan .....................................
113Replacing the R6i and R7i module cooling fan .......................................
115Replacing R8i module cooling fan (speed-controlled version) ...................
116Replacing R8i module cooling fan (direct-on-line version) .......................
118Replacing the circuit board compartment fan ......................................
119Cabinet cooling fans .........................................................................
119Replacing R1i…R5i cabinet fans ........................................................
121Replacing the control cubicle fan (Frame R8i and multiples) ....................
121Inverter modules ..................................................................................
121
Replacing R1i…R4i inverter module (with option +C204, modules in their own
compartments) ................................................................................
122Replacing R5i inverter module (without option +C204) ..............................
123
Replacing R5i inverter module (with option +C204, modules in their own com-
partments) .....................................................................................
124Replacing R6i and R7i inverter modules ..................................................
126Replacing R8i inverter modules ............................................................
126Removing an inverter module ...........................................................
131Installing an inverter module ............................................................
133Activating the reduced run function of the inverter unit ..........................
135Replacing DC fuses (frame R8i and multiples) .............................................
136Capacitors .........................................................................................
137Reforming the capacitors ...................................................................
137Functional safety components ................................................................
137Control units .......................................................................................
137Replacing the memory unit (ZCU or BCU control unit) ................................
138Replacing the ZCU-14 control unit battery ..............................................
139Replacing the BCU control unit battery ..................................................
140Control panel ...................................................................................
8 Technical data
141Contents of this chapter ........................................................................
141Ratings ..............................................................................................
144Definitions ......................................................................................
145Derating ............................................................................................
145Surrounding air temperature derating ...................................................
145Altitude derating ..............................................................................
146Inverter modules used, DC fuses, and DC capacitances .................................
150Noise andcooling characteristics .............................................................
153Sine output filter data ...........................................................................
154Input power (DC) connection ..................................................................
154Motor connection data ..........................................................................
155Typical power cable sizes .......................................................................
156Terminal and cable entry data for the power cables ......................................
156Output terminals (frames R1i…R5i) .......................................................
8 Table of contents

157Output terminals (frames R6i…R7i) .......................................................
158Output terminals (frame R8i) ...............................................................
158Connection capability (frame R8i) .........................................................
159Control connections .............................................................................
159Efficiency ...........................................................................................
160Energy efficiency data (ecodesign) ...........................................................
160Protection classes ................................................................................
160Ambient conditions ..............................................................................
161Cooling ..............................................................................................
161Colors ...............................................................................................
161Materials ............................................................................................
161Drive .............................................................................................
161Packaging of drive ............................................................................
162Packaging of options ........................................................................
162Manuals .........................................................................................
162Disposal ............................................................................................
162Applicable standards ............................................................................
163Markings ............................................................................................
163Tightening torques ...............................................................................
163Electrical connections ........................................................................
163Mechanical connections .....................................................................
163Insulation supports ...........................................................................
163Cable lugs .......................................................................................
164Disclaimers .........................................................................................
164Generic disclaimer ............................................................................
164Cyber security disclaimer ...................................................................
9 Dimensions and weights
165Contents of this chapter ........................................................................
165Frames R1i…R7i ...................................................................................
165Frames R1i…R5i ...............................................................................
165Weights ......................................................................................
166Frames R6i and R7i ............................................................................
167Dimension drawing – 400 mm wide cubicle .............................................
168Frame R8i and multiples ........................................................................
169Dimension drawing – R8i (without +C128 or +H353), bottom cable exit ..........
170Dimension drawing – R8i (without +C128 or +H353), top cable exit ...............
171Dimension drawing – 2×R8i (without +C128 or +H353), bottom cable exit .......
172Dimension drawing – 2×R8i (without +C128 or +H353), top cable exit ............
173Dimension drawing – 3×R8i (without +C128 or +H353), bottom cable exit .......
174Dimension drawing – 3×R8i (without +C128 or +H353), top cable exit ............
175Dimension drawing – drive control unit (DCU) (300 mm) ............................
176Location and size of output terminals ...................................................
176Units without common motor terminal cubicle .....................................
184Units with common motor terminal cubicle (+H359) ..............................
10 The Safe torque off function
191Contents of this chapter ........................................................................
191Description .........................................................................................
192
Compliance with the European Machinery Directive and the UK Supply of Ma-
chinery (Safety) Regulations ................................................................
Table of contents 9

193Wiring ...............................................................................................
193Activation switch ..............................................................................
193Cable types and lengths .....................................................................
193Grounding of protective shields ...........................................................
194Dual-channel connection with internal power supply .................................
194Frames R1i…R7i ............................................................................
195Frame R8i and multiples .................................................................
196Single-channel connection of activation switch ........................................
197Multiple inverter units ........................................................................
197Internal power supply ....................................................................
198External power supply ....................................................................
199Operation principle ..............................................................................
200Start-up including validation test .............................................................
200Competence ....................................................................................
200Validation test reports .......................................................................
200Validation test procedure ...................................................................
202Use ...................................................................................................
204Maintenance .......................................................................................
204Competence ....................................................................................
205Perfect proof test procedure ...............................................................
205Simplified proof test procedure ...........................................................
206Fault tracing .......................................................................................
207Safety data .........................................................................................
209Terms and abbreviations ....................................................................
210TÜV certificate .................................................................................
Further information
10 Table of contents

Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
This manual is applicable to air-cooled ACS880-107 inverter units.
Safety instructions
Obey all safety instructions of the drive.
• Read the complete safety instructions before you install, commission, use or
service the drive. The complete safety instructions are given in ACS880 multidrives
cabinets and modules safety instructions (3AUA0000102301 [English]).
• Read the warnings of the software function before you take the function in use
or change its default parameter settings. Read the warnings of the parameter
before you change its default setting. Refer to the firmware manual.
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.
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.
1
Introduction to the manual 11

Categorization by frame size, option code and item
designation
Some descriptions, instructions, technical data and dimensional drawings which
concern only a certain group of units may be marked with the symbol of the frame
size (such as “R2i”, “4×R8i”, etc.). The marking derives from the quantity and basic
construction of the inverter modules that form the inverter unit. For example, the
frame size “2×R8i” indicates that the inverter unit consists of two frame size R8i inverter
modules connected in parallel.
The frame size is marked on the type designation labels. The frame size of each inverter
module is also shown in the rating tables. See the technical data.
The instructions and technical data which concern only 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.
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
Type of control unitBCU
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 rectifier and inverterDC link
Frequency converter for controlling AC motorsDrive
Analog I/O extension moduleFAIO-01
Optional CANopen® adapter moduleFCAN
Optional ControlNet™ adapter moduleFCNA
Optical DDCS communication moduleFDCO
Optional digital I/O extension moduleFDIO-01
Optional DeviceNet™ adapter moduleFDNA
Diagnostics and panel interface boardFDPI
Optional EtherCAT® adapter moduleFECA
Optional Ethernet adapter moduleFEIP
Optional TTL incremental encoder interface moduleFEN-01
Optional absolute encoder interface moduleFEN-11
Optional resolver interface moduleFEN-21
Optional HTL incremental encoder interface moduleFEN-31
Optional Ethernet adapter moduleFENA
Optional Ethernet POWERLINK adapter moduleFEPL
Optional digital I/O extension moduleFIO-01
Optional analog I/O extension moduleFIO-11
Optional Ethernet adapter module for Modbus TCP protocolFMBT
Optional PROFIBUS DP adapter moduleFPBA
Optional PROFINET IO adapter moduleFPNO
Optional thermistor protection moduleFPTC-01
12 Introduction to the manual

DescriptionTerm
Optional ATEX-certified thermistor protection module for potentially explosive
atmospheres
FPTC-02
Physical size of the drive or power moduleFrame, frame size
Optional Modbus RTU adapter moduleFSCA
Optional pulse encoder interface module for safety encoderFSE-31
Optional functional safety modulesFSO-12, FSO-21
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 unit, and related components.
One inverter unit typically controls one motor.
Inverter unit
Drive for controlling several motors which are typically coupled to the same
machinery. Includes one supply unit, and one or several inverter units.
Multidrive
In the drive control program, user-adjustable operation instruction to the
drive, or signal measured or calculated by the drive.
In some (for example fieldbus) contexts, a value that can be accessed as an
object. For example, variable, constant, or signal.
Parameter
Programmable logic controllerPLC
Prevention of unexpected start-upPOUS
Optical DDCS communication moduleRDCO
Radio-frequency interferenceRFI
Safety integrity level (1…3) (IEC 61508, IEC 62061, IEC 61800-5-2)SIL
Safe torque off (IEC/EN 61800-5-2)STO
Supply module(s) under control of one control unit, and related components.Supply unit
Uninterruptible power supplyUPS
Type of control unitZCU
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
Introduction to the manual 13

14

Operation principle and hardware
description
Contents of this chapter
This chapter describes a typical drive system and the hardware of the inverter unit.
The information is valid for all ACS880-107 inverter units.
Overview diagram of the drive system
The diagram that follows shows an example of a multidrive. The supply unit connects
the drive to the AC supply network. It converts the AC voltage into DC. The DC voltage
is distributed through the DC bus to all inverter units and optional brake units. The
inverter unit converts the DC back to AC that rotates the motor. The brake unit
(optional) conveys energy to brake resistors whenever needed.
2
Operation principle and hardware description 15

1
3
4
6
5
88
7
9
10
12
1113
7
2
A
B C C D
7 7
Incoming unitA
Supply unitB
Inverter unitC
Brake unit (optional)D
AC supply1
Main breaker, or main contactor and main switch-disconnector2
Input (AC) fuses3
Supply module4
DC bus5
Supply and inverter module DC fuses6
DC switch/disconnector (optional)7
Inverter modules8
Brake chopper fuses9
3-phase brake chopper module (optional)10
Brake resistors (optional or acquired by the customer)11
Fuses for the brake resistors12
Motor(s) (acquired by the customer)13
16 Operation principle and hardware description

Inverter unit hardware
￭General
An inverter unit contains the components required to control one motor. These include
one or more inverter modules connected in parallel, together with the necessary
auxiliary equipment such as control electronics, fusing, cabling and switchgear.
ACS880-107 inverter units range from 1.5 to 5600 kW in power. ACS880-107 inverter
units employ inverter modules from frame size R1i to R8i. Up to approximately 500 kW,
inverter units consist of one module only; higher powers are achieved by connecting
multiple R8i modules in parallel.
All inverter modules have coated circuit boards as standard.
￭Cabinet system
An inverter unit is built into one or more adjoining cubicles and contains the
components that are required to control one motor. At smaller inverter sizes, a single
cubicle can contain several inverter units, each controlling a different motor. Large
inverter units consist of parallel-connected modules and can occupy several cubicles.
Examples of the cabinet configurations are included below as well as in the dimensions
and weights chapter. The motor cabling direction is optionally up or down – see below
under each module frame size for specific information.
￭Cooling
Each inverter module has its own cooling fan(s). Control cubicles can have additional
cooling fans.
The inverter cubicles have the air intake at the lower part of the door. The intake can
optionally be through the floor, adding 130 mm (5.12”) to the standard depth of 600
mm (23.62”) of the cabinet.
The cooling air outlets are on the roof of each cubicle. Some configurations have
exhaust fans fitted inside the top compartment of the cubicle. A channeled air outlet
is optional.
Operation principle and hardware description 17

￭Inverter module frame sizes R1i…R4i
General
The motor (output) cables are connected to either detachable or non-detachable screw
terminal blocks at the bottom of the cubicle. The modules have a built-in ZCU drive
control unit, which contains the basic I/Os and slots for optional I/O modules.
The modules have an internal capacitor precharge circuit.
External optional equipment is primarily installed on mounting plates in the same
cubicle.
Module layout examples
Frame R1i (Frame R2i has a similar layout)
ExplanationItem

8
3
4
1
2
7
7
7
5
6
9
Power unit1
DC (input) connections2
Motor (output) connection (obscured). This has
been wired to a separate terminal block in the
lower part of the cubicle.
3
ZCU-14 control unit mounted on top of the power
unit
4
Grounding/strain relief rail for control cables5
I/O terminal blocks6
3 slots for optional modules7
Memory unit8
Connection for FSO safety functions module9
18 Operation principle and hardware description

Frame R4i (Frame R3i has a similar layout)
ExplanationItem
8
3
4
1
2
7
7
7
5
6
9
Power unit1
DC (input) connections (under connector cover)2
Motor (output) connection (under connector cov-
er). This has been wired to a separate terminal
block in the lower part of the cubicle.
3
ZCU-14 control unit mounted on top of the power
unit
4
Grounding/strain relief rail for control cables5
I/O terminal blocks6
3 slots for optional modules7
Memory unit8
Connection for FSO safety functions module9
Standard cabinet layout
Several inverter modules of frame sizes R1i…R4i can be installed in one cubicle. The
standard cubicle width is 400, 600, 800 or 1000 mm depending on the size and number
of inverter modules installed.
Each module has dedicated DC fuse disconnectors. The motor (output) connections
are located at the lower part of the cubicle; depending on the power of the inverter
module, these are either detachable or non-detachable terminal blocks.
The cubicle is equipped with cable entries for the motor cables in the floor.
This illustration shows an example of a 600 mm wide cubicle with three R1i, one R3i
and two R4i modules.
Operation principle and hardware description 19

ExplanationItem
1
3
2
3
45
5
6
7
8
Main DC switch fuse for all units in the cubicle
(optional) or main DC fuses
1
DC fuse disconnectors for each individual module2
Three frame R1i inverter modules3
Frame R3i inverter module4
Two frame R4i inverter modules5
Output connections6
Cable entries7
Air outlet compartment with cabinet cooling fan
(not shown)
8
Layout of cubicle with frame R1i…R4i modules in their own compartments (option
+C204)
If option +C204 is selected, each inverter module is installed into its own compartment
behind a door. Up to three inverter modules of frame sizes R1i…R4i can be installed
in one 400 mm wide cubicle.
At the top of the cubicle, there is another compartment which contains the common
DC switch-disconnector and fuses for all the modules in the cubicle.
The inverter modules are installed in an inclined position so that the cooling air flows
from the cool area at the front of the cubicle through the modules into the hot area
at the back. The hot air is exhausted through the roof of the cubicle.
20 Operation principle and hardware description