ABB ACS880-107LC User manual

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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

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