ABB ACS880-107LC User manual

—
ABB INDUSTRIAL DRIVES
ACS880-107LC inverter units
Hardware manual

ACS880-107LC inverter units
Hardware manual
Table of contents
3. Electrical installation
5. Start-up
3AXD50000196111 Rev B
EN
Original instructions
EFFECTIVE: 2021-07-09

Table of contents
1 Introduction to the manual
11Contents of this chapter ...........................................................................
11Applicability .........................................................................................
11Safety instructions .................................................................................
11Target audience ....................................................................................
12Categorization by frame size and option code .................................................
13Use of component designations .................................................................
13Related documents ................................................................................
14Terms and abbreviations ..........................................................................
2 Operation principle and hardware description
15Contents of this chapter ...........................................................................
15Overview diagram of the drive system ..........................................................
17Inverter unit hardware .............................................................................
17General ..........................................................................................
17Inverter module hardware ........................................................................
17Frame R8i and multiples ......................................................................
17BCU control unit of frame R8i and multiples ............................................
18Module layout ...............................................................................
18Coolant connectors .........................................................................
19Connectors X50…X59 .....................................................................
20Fiber optic connectors ......................................................................
20Cooling system .....................................................................................
21Control interfaces ..................................................................................
21Overview of the control connections of the BCU control unit ............................
21The ACx-AP-x control panel ..................................................................
22Control by PC tools .........................................................................
23Type designation labels ...........................................................................
23Inverter unit type designation label ..........................................................
23Inverter module type designation label ......................................................
23Inverter unit type designation key ...............................................................
3 Electrical installation
27Contents of this chapter ...........................................................................
27Electrical safety precautions .....................................................................
29General notes ......................................................................................
29Printed circuit boards ..........................................................................
29Optical components ............................................................................
30Checking the insulation of the assembly .......................................................
30Inverter unit ......................................................................................
30Measuring the insulation resistance of the motor and motor cable .....................
30Connecting the control cables ...................................................................
31Control cable connection procedure .........................................................
31Grounding the outer shields of the control cables at the cabinet entry .............
33Routing the control cables inside the cabinet ...........................................
Table of contents 5

33Connecting control cabling ................................................................
35
Connecting the motor cables (units without common motor terminal cubicle or sine output
filter) ..................................................................................................
35Motor connection diagram (without option +H366) ........................................
36Motor connection diagram (with option +H366) ............................................
36Procedure .......................................................................................
40
Connecting the motor cables (units with common motor terminal cubicle or sine output
filter) ..................................................................................................
40Output busbars .................................................................................
40Connection diagram ............................................................................
40Procedure .......................................................................................
42Connecting a PC ...................................................................................
43Panel bus (Control of several units from one control panel) .................................
45Installing option modules .........................................................................
45
Mechanical installation of I/O extension, fieldbus adapter and pulse encoder interface
modules ..........................................................................................
45Installation of an FSO-xx safety functions module onto BCU ............................
47Wiring of optional modules ....................................................................
4 Installation checklist
49Contents of this chapter ...........................................................................
49Checklist .............................................................................................
5 Start-up
51Contents of this chapter ...........................................................................
51Start-up procedure .................................................................................
6 Maintenance
55Contents of this chapter ...........................................................................
55Maintenance intervals .............................................................................
55Description of symbols ........................................................................
55Recommended maintenance intervals after start-up ......................................
57Retightening the power connections ............................................................
58Fans ..................................................................................................
58Inverter module fan replacement .............................................................
59Replacing the common motor terminal cubicle fan ........................................
60Inverter modules ...................................................................................
60Replacing a frame R8i inverter module .....................................................
60Removing the module ......................................................................
63Reinstalling the module ....................................................................
63Activating the reduced run of the inverter unit ..........................................
66Capacitors ...........................................................................................
66Reforming the capacitors ......................................................................
67DC fuse replacement ..............................................................................
69Control panel .......................................................................................
69Cleaning the control panel ....................................................................
69Replacing the battery ..........................................................................
70Control units ........................................................................................
70BCU control unit types .........................................................................
70Replacing the memory unit ...................................................................
70Replacing the BCU control unit battery .....................................................
6 Table of contents

71Functional safety components ...................................................................
7 Control units of the drive
73Contents of this chapter ...........................................................................
73General ..............................................................................................
74BCU-x2 layout ......................................................................................
76Default I/O diagram of the inverter control unit (A41) .........................................
77Additional information on the connections .....................................................
77External power supply for the control unit (XPOW) .......................................
77DI6 as a PTC sensor input ....................................................................
78AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input .............................
78DIIL input ........................................................................................
79The XD2D connector ..........................................................................
79Safe torque off (XSTO, XSTO OUT) .........................................................
79FSO-xx safety functions module connection (X12) ........................................
79SDHC memory card slot .......................................................................
80Connector data .....................................................................................
82BCU-x2 ground isolation diagram ............................................................
8 The Safe torque off function
83Contents of this chapter ...........................................................................
83Description ..........................................................................................
84
Compliance with the European Machinery Directive and the UK Supply of Machinery
(Safety) Regulations ...........................................................................
85Wiring ................................................................................................
85Activation switch ................................................................................
85Cable types and lengths .......................................................................
85Grounding of protective shields ..............................................................
86Dual-channel connection with internal power supply .....................................
86Frame R8i and multiples ...................................................................
87Single-channel connection of activation switch ............................................
88Multiple drives ...................................................................................
88Internal power supply ......................................................................
89External power supply ......................................................................
90Operation principle .................................................................................
91Start-up including validation test .................................................................
91Competence .....................................................................................
91Validation test reports ..........................................................................
91Validation test procedure ......................................................................
93Use ...................................................................................................
95Maintenance ........................................................................................
95Competence .....................................................................................
96Fault tracing .........................................................................................
97Safety data ..........................................................................................
98Terms and abbreviations ......................................................................
98TÜV certificate ..................................................................................
9 Internal cooling circuit
99Contents of this chapter ...........................................................................
99Applicability .........................................................................................
99Internal cooling system ............................................................................
Table of contents 7

101Connection to a cooling unit ......................................................................
101Connection to an ACS880-1007LC cooling unit ...........................................
101Connection to a custom cooling unit .........................................................
101General requirements ......................................................................
101Coolant temperature control ...............................................................
102Filling up and bleeding the internal cooling circuit ............................................
102Drive line-ups with an ACS880-1007LC cooling unit ......................................
102Drive line-ups with a custom cooling unit ...................................................
104Draining the internal cooling circuit ..............................................................
104Maintenance intervals .............................................................................
104Technical data ......................................................................................
104Coolant specification ...........................................................................
104Coolant type .................................................................................
104Temperature limits ..............................................................................
106Pressure limits ..................................................................................
106Coolant flow rate limits ........................................................................
106Cooling circuit materials .......................................................................
10 Technical data
109Contents of this chapter ...........................................................................
110Ratings ..............................................................................................
110Definitions .......................................................................................
111Derating ..........................................................................................
111Surrounding air temperature derating ....................................................
111Coolant temperature derating .............................................................
111Antifreeze content derating ................................................................
111Altitude derating .............................................................................
111Switching frequency derating .............................................................
112Output frequency derating .................................................................
112Inverter unit frame sizes and modules used ...................................................
113Cooling data and noise ............................................................................
114DC fuses ............................................................................................
114Dimensions and weights ..........................................................................
114Free space requirements .........................................................................
116Typical power cable sizes .........................................................................
118Terminal and cable entry data for power cables ...............................................
118Terminal data for the inverter control unit ......................................................
118Input power (DC) connection .....................................................................
118Motor (AC) connection ............................................................................
118Efficiency ............................................................................................
119Energy efficiency data (ecodesign) ..............................................................
119Protection classes .................................................................................
119Optical components ...............................................................................
120Ambient conditions ................................................................................
121Materials .............................................................................................
121Applicable standards ..............................................................................
121Markings .............................................................................................
122Tightening torques .................................................................................
122Electrical connections ..........................................................................
122Mechanical connections .......................................................................
122Insulation supports .............................................................................
122Cable lugs .......................................................................................
8 Table of contents

123Disclaimers .........................................................................................
123Generic disclaimer .............................................................................
123Cybersecurity disclaimer ......................................................................
11 Dimensions
125Cabinet line-up dimensions .......................................................................
126Dimensions and weights ......................................................................
127Dimension drawing examples ................................................................
127Cabinet height and depth ..................................................................
129Location and size of output terminals ...........................................................
129Units without common motor terminal cubicle .............................................
129Inverter module cubicle with one R8i module, bottom cable exit ....................
130Inverter module cubicle with two R8i modules, bottom cable exit ...................
131Inverter module cubicle with three R8i modules, bottom cable exit .................
132Units with common motor terminal cubicle (+H359) ......................................
132Cubicle width 300 mm, bottom cable exit ...............................................
133Cubicle width 300 mm, top cable exit ....................................................
134Cubicle width 400 mm, bottom cable exit ...............................................
135Cubicle width 400 mm, top cable exit ....................................................
136Cubicle width 600 mm, bottom cable exit ...............................................
137Cubicle width 600 mm, top cable exit ....................................................
Further information
Table of contents 9

10

Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
This manual is applicable to ACS880-107LC inverter units that form a part of a drive system.
Safety instructions
Obey all safety instructions delivered with the drive.
•Read the complete safety instructions before you install, commission, use or service
the drive. The complete safety instructions are given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
•Read the software-function-specific warnings and notes before changing the default
settings of a function. For each function, the warnings and notes are given in the section
describing the related user-adjustable parameters.
•Read the task-specific safety instructions before starting the task. See the section
describing the task.
Target audience
This manual is intended for people who plan the installation, install, start up and do
maintenance work on the drive, or create instructions for the end user of the drive concerning
the installation and maintenance of the drive.
Read the manual before working on the drive. You are expected to know the fundamentals
of electricity, wiring, electrical components and electrical schematic symbols.
1
Introduction to the manual 11

Categorization by frame size and option code
Some descriptions, instructions, technical data and other information that concern only a
certain group of units may be marked with the frame size (such as "R8i", "4×R8i", etc.) The
marking derives from the quantity and basic construction of the modules that form the unit.
For example, the frame size "2×R8i" indicates that the unit consists of two frame size R8i
modules connected in parallel.
The frame size is marked on the type designation labels. The frame size of each unit is also
shown in the rating tables in chapter Technical data.
The information that concerns only certain optional selections is marked with option codes
(such as +E205). The options included in the unit can be identified from the type code visible
on the type designation label. The option selections are listed in section Inverter unit type
designation key (page 23).
12 Introduction to the manual

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.
Related documents
CodeManual
General manuals
3AXD50000048633
ACS880 liquid-cooled multidrive cabinets and modules safety instructions
3AXD50000048634
ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions
3AXD50000048635
ACS880 liquid-cooled multidrive cabinets mechanical installation instructions
3AXD50000126880
CIO-01 I/O module for distributed I/O bus control user's manual
Supply unit manuals
3AXD50000174782
ACS880-207LC IGBT supply units hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
3AXD50000579662
ACS880-307LC…+A018 diode supply units hardware manual
3AUA0000103295
ACS880 diode supply control program firmware manual
Inverter unit manuals
3AXD50000196111
ACS880-107LC inverter units hardware manual
3AUA0000085967
ACS880 primary control program firmware manual
3AUA0000098062
ACS880 primary control program quick start-up guide
Manuals for application programs (Crane, Winder, etc.)
Brake unit and DC/DC converter unit manuals
3AXD50000481491
ACS880-607LC 1-phase brake units hardware manual
3AXD50000581627
ACS880-607LC 3-phase dynamic brake units hardware manual
3AXD50000020967
ACS880 (3-phase) brake control program firmware manual
3AXD50000431342
ACS880-1607LC DC/DC converter units hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
3AXD50000752423
ACS880-7107LC DC feeder unit hardware manual
Option manuals
3AXD50000129607
ACS880-1007LC liquid cooling unit user's manual
3AUA0000085685
ACS-AP-x assistant control panels user’s manual
3AUA0000094606
Drive composer start-up and maintenance PC tool user’s manual
3AXD50000210268
Converter module lifting device for drive cabinets hardware manual
Manuals for I/O extension modules, fieldbus adapters, safety options etc.
You can find manuals on the Internet. See www.abb.com/drives/documents. For manuals
not available in the document library, contact your local ABB representative.
Introduction to the manual 13

Terms and abbreviations
DescriptionTerm
Type of control unitBCU
I/O module for controlling cooling fansCIO
Frequency converter for controlling AC motorsDrive
Electromagnetic compatibilityEMC
Electromagnetic interferenceEMI
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 analog I/O extension moduleFIO-11
Optional thermistor protection moduleFPTC-01
Optional ATEX-certified thermistor protection module for potentially explosive atmo-
spheres
FPTC-02
Physical size of the drive or power moduleFrame, frame size
Optional functional safety modulesFSO-12, FSO-21
Insulated gate bipolar transistorIGBT
Inverter module(s) under control of one control unit, and related components. One
inverter unit typically controls one motor.
Inverter unit
Common term for drive module, inverter module, supply module, brake chopper
module etc.
Power module
Radio-frequency interferenceRFI
Safe torque off (IEC/EN 61800-5-2)STO
Supply module(s) under control of one control unit, and related components.Supply unit
14 Introduction to the manual

Operation principle and hardware
description
Contents of this chapter
This chapter describes a typical drive system and the hardware of the inverter unit.
Overview diagram of the drive system
This diagram 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
2
Operation principle and hardware description 15

back to AC that rotates the motor. The brake unit (optional) conveys energy to brake resistors
whenever needed.
1
3
4
6
5
88
7
9
10
12
1113
7
2
A
B C C D
Incoming unitA
Supply unitB
Inverter unitC
Brake unitD
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 user)11
Fuses for the brake resistors12
Motor(s) (acquired by user)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.
ACS880-107LC inverter units range from 355 to 6000 kW in power. The units employ
ACS880-104LC (frame R8i) modules. Up to approximately 800 kW, inverter units consist
of one module only; higher power ratings are achieved by connecting multiple modules in
parallel.
All inverter modules have coated circuit boards as standard.
Inverter module hardware
￭Frame R8i and multiples
Frame R8i modules are used to achieve output powers from approximately 350 kW upwards
in single or parallel configurations.
The DC connection of the module is by busbars and located at the top. The motor connection
is via a quick connector at the back of the module that couples when the module is inserted
into the cubicle. Each parallel-connected module is cabled separately to the motor, or
connected by busbars to adjacent modules to reduce the number of cables. It is also possible
to build an AC bus from each module to a separate output cubicle.
Internal du/dt filtering is mandatory with all 690 volt units and all parallel-connected modules.
690 volt modules have internal du/dt filtering as standard.
BCU control unit of frame R8i and multiples
Inverter units consisting of one or several R8i modules employ a separate control unit (BCU)
that contains the BCON board with basic I/Os and slots for optional I/O modules. A fiber
optic link connects the BCU to each inverter module. Any safety circuits utilizing the built-in
Safe torque off functionality are connected to the BCU. The forwarding connector of the
BCU is wired to the inverter module(s).
Operation principle and hardware description 17

Module layout
2a
2b
6
3b
5
3a
4
10
9
7
1a
8
1b
11
DescriptionNo.
DC input busbars1.
Lifting eyes, front (a) and back (b)2.
Coolant in (a) and out (b) connectors. See section Coolant connectors.
3.
Handle4.
Fiber optic connectors. See section Fiber optic connectors.
5.
Quick connector (AC output) (the counterpart fastened to the cabinet behind the module)6.
Terminal block X50 (auxiliary power input for internal boards). See section Connectors X50…X59.
7.
Terminal block X51 and X52 (Safe torque off). See section Connectors X50…X59.
8.
Terminal block X53 (24 V DC power output). See section Connectors X50…X59.
9.
Auxiliary voltage selector (115 or 230 V). See section Connectors X50…X59.
10.
Unpainted fastening hole. The grounding point (PE) between module frame and cabinet frame.11.
Coolant connectors
The coolant pipe inlet and outlet connectors are located at the bottom front of the module.
The connectors are for 16/13 millimeter PA (polyamide) pipe.
18 Operation principle and hardware description

WARNING!
For a reliable connection, the end of the pipe entering the connector must be
completely intact for a length of at least 5 cm (2”). Make sure the pipe is perfectly
round where it enters the connector, and not deformed eg. by any bends nearby.
The piping must not exert any tension or torque on the connector.
Connectors X50…X59
R8i modules contain a power supply (BDPS) that provides 24 V DC for the circuit boards
of the module. The 24 V DC voltage provided by the BDPS is also available on X53, and
can be used to power the BCU control unit of a single R8i inverter module.
Note: With an inverter unit consisting of parallel-connected R8i modules, it is strongly
recommended to use an external 24 V DC supply to power the BCU control unit.
The BDPS is powered internally from the DC link. An auxiliary voltage of 230 V AC or 115
V AC (selectable) can optionally be fed to terminal block X50 to power the BDPS even when
the DC link is not live. The selection between 115 V and 230 V is made with selector plug
X59. The setting can be changed by removing the two screws, turning the plug 180 degrees,
and reinstalling the screws.
If the Safe torque off (STO) function is not used, the “24V” inputs on X52 must be connected
to +24 V (on connector X53, for example) on each inverter module. On a new module, a
jumper wire set installed at the factory makes this connection.
If the STO function is to be implemented, the jumper wire set must be removed – a
mechanical interlocking device is factory-installed on connectors X51 and X52 to this effect.
For STO, X52 (STO IN) is wired to the STO OUT connector on the BCU control unit.
Connector X51 on the module is wired to connector X52 on the next module (if present).
For details, see chapter The Safe torque off function.
Operation principle and hardware description 19

Auxiliary voltage inputs for internal power supply (BDPS)
AC IN
X50
L N
POWER
24 V DC output (for eg. BCU control unit)
24V OUT
X53
GND +24V GND +24V FE
STO signals from BCU control unit
STO IN
X52
+24V GND +24V GND FE
STO signal forwarding output to next inverter module (if
present)
STO OUT
X51
+24V GND +24V GND FE
Auxiliary voltage: 230 V AC
Auxiliary voltage: 115 V AC
Fiber optic connectors
DescriptionName
Reserved.BSFC
Control unit connection. Must be connec-
ted by the installer.
BCU
V50←BSFC
V60→
V10←BCU
V20→
Cooling system
See chapter Internal cooling circuit (page 99).
20 Operation principle and hardware description