—
ABB INDUSTRIAL DRIVES
ACS880-307LC diode supply units
Hardware manual
ACS880-307LC diode supply units
Hardware manual
3AXD50000579662 Rev A
EN
EFFECTIVE: 2020-06-30
Table of contents 5
Table of contents
Contents of this chapter ...........................................................................
Safety instructions .................................................................................
Target audience ....................................................................................
Terms and abbreviations .......................................................................... 10
Related documents ................................................................................ 11
Contents of this chapter ........................................................................... 13
Operation principle ................................................................................. 13
Layout drawings .................................................................................... 17
Supply unit control devices ....................................................................... 25
Control panel .................................................................................... 27
Fieldbus control ................................................................................. 28
Type designation labels ........................................................................... 28
Type designation keys ............................................................................ 30
6 Table of contents
Contents of this chapter ........................................................................... 35
Electrical safety precautions ..................................................................... 36
General notes ...................................................................................... 37
Static electricity ................................................................................. 37
Measuring the insulation .......................................................................... 38
Wiring the functional safety options ............................................................. 42
Connecting the control cables ................................................................... 42
Connecting a PC ................................................................................... 46
Contents of this chapter ........................................................................... 47
BCU-x2 layout ...................................................................................... 48
The X485 connector ............................................................................... 52
Connector data ..................................................................................... 54
Contents of this chapter ........................................................................... 57
Checklist ............................................................................................. 57
Contents of this chapter ........................................................................... 59
Start-up procedure ................................................................................. 60
Safety function validation ...................................................................... 62
Table of contents 7
Contents of this chapter ........................................................................... 63
Maintenance intervals ............................................................................. 63
Internal liquid-cooling system .................................................................... 65
Power connections ................................................................................ 65
Fans .................................................................................................. 65
Fuses ................................................................................................ 68
Supply module ..................................................................................... 70
Control panel ....................................................................................... 74
Control unit .......................................................................................... 75
LEDs and other status indicators ................................................................ 76
Control unit LEDs ............................................................................... 77
Contents of this chapter ........................................................................... 79
Applicability ......................................................................................... 79
Internal cooling system ............................................................................ 79
Connection to a cooling unit ...................................................................... 81
Filling up and bleeding the internal cooling circuit ............................................ 82
Draining the internal cooling circuit .............................................................. 84
Maintenance intervals ............................................................................. 84
Technical data ...................................................................................... 84
Coolant specification ........................................................................... 84
Temperature limits .............................................................................. 84
Pressure limits .................................................................................. 86
Coolant flow rate limits ........................................................................ 86
Cooling circuit materials ....................................................................... 86
8 Table of contents
Derating ............................................................................................. 90
Altitude derating ................................................................................ 91
Type equivalence table ............................................................................ 91
Fuses ................................................................................................ 92
Cooling data and noise ............................................................................ 95
Tightening torques ................................................................................. 98
Electrical connections .......................................................................... 98
Insulation supports ............................................................................. 98
Cable lugs ....................................................................................... 98
Typical power cable sizes ......................................................................... 99
Electrical power network specification ..........................................................101
Control unit (board) connection data ............................................................101
Auxiliary circuit current consumption ............................................................101
Efficiency ............................................................................................101
Protection classes .................................................................................101
Ambient conditions ................................................................................102
Materials .............................................................................................103
Color .................................................................................................103
Package .............................................................................................103
Vertical package ................................................................................103
Disposal .............................................................................................103
Applicable standards ..............................................................................103
Markings .............................................................................................104
Introduction to the manual 9
1
Introduction to the manual
Contents of this chapter
This chapter contains general information on the manual.
Applicability
The manual is applicable to the cabinet-installed ACS880-307LC…+A018 diode supply
units that form a part of an ACS880 multidrive 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.
10 Introduction to the manual
Categorization by frame size and option code
The frame size identifies information which concerns only a certain frame size of the drive.
The frame size is shown on the type designation label. All frame sizes are listed in the
technical data.
The option code (for example, option +E200) identifies information which concerns only a
certain optional selection. The options included in the drive are listed on the type designation
label.
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
Term
Description
ACU
Auxiliary control unit. Contains control electronics, auxiliary voltage circuitry, etc.
Type of control unit
BCU
CIO
I/O module for controlling cooling fans
Control board
Control unit
Cubicle
Circuit board in which the control program runs
Control board built in a housing (often rail-mountable)
One section of a cabinet-installed drive. A cubicle is typically behind a door of its own.
Frame size designation of the diode supply module
DC circuit between rectifier and inverter
D8T
DC link
DI
Digital input
Diode supply module
Diode rectifier and related components enclosed in a metal frame or enclosure. Inten-
ded for cabinet installation.
Diode supply unit
Drive
Diode supply modules under control of one control board, and related components.
Frequency converter for controlling AC motors
Diode supply unit
DSU
Frame, frame size
ICU
Physical size of the drive or power module
Incoming unit
Intermediate circuit
INU
DC circuit between rectifier and inverter
Inverter unit
Inverter module
Inverter bridge, related components and drive DC link capacitors enclosed in a metal
frame or enclosure. Intended for cabinet installation.
Inverter unit
Multidrive
Inverter module(s) under control of one control unit, and related components. One
inverter unit typically controls one motor.
Drive for controlling several motors which are typically coupled to the same machinery.
Includes one supply unit, and one or several inverter units.
Parameter
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.
Rectifier
Converts alternating current and voltage to direct current and voltage
Drive for controlling one motor
Single drive
Introduction to the manual 11
Related documents
Manual
Code
General manuals
ACS880 liquid-cooled multidrive cabinets and modules safety instructions
3AXD50000048633
ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions 3AXD50000048634
ACS880 liquid-cooled multidrive cabinets mechanical installation instructions
CIO-01 I/O module for distributed I/O bus control user's manual
Supply unit manuals
3AXD50000048635
3AXD50000126880
ACS880-207LC IGBT supply units hardware manual
ACS880 IGBT supply control program firmware manual
ACS880-307LC…+A018 diode supply units hardware manual
ACS880 diode supply control program firmware manual
Inverter unit manuals
3AXD50000174782
3AUA0000131562
3AXD50000579662
3AUA0000103295
ACS880-107LC inverter units hardware manual
3AXD50000196111
3AUA0000085967
3AUA0000098062
ACS880 primary control program firmware manual
ACS880 primary control program quick start-up guide
Manuals for application programs (Crane, Winder, etc.)
Brake unit and DC/DC converter unit manuals
ACS880-607LC 1-phase brake units hardware manual
ACS880 (3-phase) brake control program firmware manual
ACS880-1607LC DC/DC converter units hardware manual
ACS880 DC/DC converter control program firmware manual
Option manuals
3AXD50000481491
3AXD50000020967
3AXD50000431342
3AXD50000024671
ACS880-1007LC liquid cooling unit user's manual
ACS880 +C132 marine type-approved cabinet-built drives supplement
ACS-AP-x assistant control panels user’s manual
Drive composer start-up and maintenance PC tool user’s manual
Converter module lifting device for drive cabinets hardware manual
Manuals for I/O extension modules, fieldbus adapters, safety options etc.
3AXD50000129607
3AXD50000039629
3AUA0000085685
3AUA0000094606
3AXD50000210268
not available in the document library, contact your local ABB representative.
12
Operation principle and hardware description 13
2
Operation principle and hardware
description
Contents of this chapter
This chapter contains a description of the diode supply unit. The information is valid for the
ACS880-307LC…+A018 diode supply units.
Operation principle
The core of the diode supply unit is a diode-thyristor bridge. It rectifies three-phase AC
current to direct current for the intermediate DC link of the drive. The intermediate DC link
supplies the inverters that run the motors. There can be one inverter unit only (single drives)
or several inverter units (multidrives) connected to the intermediate circuit. The DSU modules
have inbuilt AC chokes. The AC chokes smoothen the current waveform in the power supply
network and voltage in the DC link of the drive.
The main difference between the ordinary diode-diode bridge and the controlled
diode-thyristor bridge is the controllability. You cannot control the operation of the diodes
but you can control the thyristors. By controlling the thyristors, you can limit the AC current
of the drive at the power up without additional charging circuit in the supply unit or in inverter
units.
There are two control modes for the upper leg thyristor firing: the charging mode and the
normal mode:
•
The charging mode is in operation a short period after the power switch on: the supply
control program controls the thyristor firing angle gradually towards zero while the
intermediate circuit capacitors located in the inverter module(s) get charged.
•
In the normal mode, the thyristor firing angle is 0 degrees: The thyristors operate as
diodes.
14 Operation principle and hardware description
￭ Overview diagram of the rectifier bridge
2
3
U
1
1
2
3
Diodes. The diodes connect the AC terminals in cyclic sequence to the lower DC busbar (-).
Thyristors. The thyristors connect the AC line terminals in cyclic sequence to the upper DC busbar (+).
AC chokes
￭ 6- and 12-pulse supply connections
The figure below illustrates the difference between 6-pulse and 12-pulse AC supply
connections. The 6-pulse connection is standard. If the drive has an even number of supply
modules, you can order it as a 12-pulse version (option +A004).
The 12-pulse supply connection eliminates the fifth and seventh harmonics, which
substantially reduces the harmonic distortion of the line current and the conducted emissions.
The 12-pulse connection requires a three-winding transformer, or two separate transformers.
There must be phase shift of 30-degrees between the two 6-pulse supply lines, which are
connected to different supply modules through electrically separate switching equipment.
Operation principle and hardware description 15
A
ꢂ
ꢀ
ꢁ
B
ꢂ
ꢀ
ꢁ
A
B
1
2
3
6-pulse connection
12-pulse connection
Supply transformer
Switching equipment
Diode supply modules
16 Operation principle and hardware description
Overview diagram of the drive system
The following figure shows an example drive with a diode supply unit and three inverter
units.
5
4
5
5
8
1
2
6
6
6
9
3
M
3~
M
3~
M
3~
7
1
2
3
4
5
6
7
8
9
Main circuit breaker [Q1]
AC fuses
Supply module [T01] (including choke and rectifier)
Supply module DC fuses
Inverter module DC fuses (with or without DC switches)
Inverter module [T11]
Motor
Auxiliary voltage switch [Q21] (option +G344 or +G451)
Auxiliary voltage transformer [T21] (option +G344)
18 Operation principle and hardware description
￭ Auxiliary control cubicle layout
1
3
2
4
5
8
6
7
1
2
3
4
5
Control panel [A59] (option +J400, or +J425)
Operating switch [S21], emergency stop button [S61], etc.
CIO-01 I/O module for cooling fan monitoring [A115.99]
BCU control unit [A51]
Auxiliary voltage transformers behind the assembly plates ([T21] option +G344, [T115] option +G451,
in some deliveries also [T125])
6
7
8
Cooling fan and heat exchanger [G115.99]
Inlet manifold with stop and drain valves
Outlet manifold with stop and drain valves
Operation principle and hardware description 19
￭ Incoming cubicle layout - bottom cable entry
1
2
6
7
3
4
8
5
9
10
11
12
14
13
1…4
5, 9 Main supply breaker [Q1.x] (option +F255)
1, 6 Auxiliary voltage supply breaker (switch fuse) [Q21]
4, 7 Grounding switch [Q9.x] (option +F259)
8
Not in use.
10 CIO-01 I/O module for cooling fan control [A115.x]
11 Cooling fan and heat exchanger [G115.x]
12 Input power cable terminals L1, L2, L3
13 Inlet manifold with stop and drain valves
14 Outlet manifold with stop and drain valves
20 Operation principle and hardware description
￭ Supply module cubicle layout – frame 1×D8T
Supply module cubicle layout – frame 1×D8T, electrical components
1
2
3
4
M
5
6
7
8
9
M
1
DC voltage measuring/testing points
1)
Cabinet light ([H310.10 ], option +G301)
2
3
4
5
6
Cabinet fan miniature circuit breaker [F115.10
]
CIO-01 I/O module for distributed I/O bus control [A115.10
]
Cabinet light switch ([S130.10 ], option +G301)
Module 1 AC fuses [F3.11…
]
]
Module 1 DC fuses [F2.11…
Supply module [T01.1]
7
8
Cabinet heater ([E95.10 ], option +G300)
9
Cabinet fan [G115.10
]
1)
Latter number is for the first supply module cubicle. The number increases in other cubicles (if any).
Supply module cubicle layout – frame 1×D8T, cooling circuit
Operation principle and hardware description 21
￭ Supply module cubicle layout – frame 2×D8T
Supply module cubicle layout – frame 2×D8T, electrical components
1
2
4
3
M
5
6
7
M
8
9
10
11
12
M
1
DC voltage measuring/testing points
1)
Cabinet light ([H310.10 ], option +G301)
2
3
4
5
6
Cabinet fan miniature circuit breaker [F115.10
]
CIO-01 I/O module for distributed I/O bus control [A115.10
]
Cabinet light switch ([S130.10 ], option +G301)
Module 1 AC fuses [F3.1…
]
Module 1 DC fuses [F2.11…
]
7
8
Supply module 1 [T01.1]
Module 2 AC fuses [F3.4 or F3.7…
]
9
Module 2 DC fuses [F2.21…
]
10 Supply module [T01.2]
11
Cabinet heater ([E95.10 ], option +G300)
22 Operation principle and hardware description
12
Cabinet fan [G115.10
]
1)
Latter number is for the first supply module cubicle. The number increases in other module cubicles (if any).
Supply module cubicle layout – frame 2×D8T, cooling circuit
6
4
5
6
4
2
1
5
4
7
3
7
5
1
2
3
4
5
6
7
Heat exchanger
Inlet manifold with stop and drain valves
Outlet manifold with stop and drain valves
Inlet pipes (cold coolant) from main pipe to modules and heat exchanger
Output pipes (warm coolant) to main pipe from modules and heat exchanger
Supply modules [T01.x]
Draining pipes (inlet draining pipe, and outlet draining pipe)
24 Operation principle and hardware description
Overview of the control connections of the BCU control
unit
The diagram shows the control connections and interfaces of the BCU control unit.
4
7
9
1
8
2
3
6
5
10
1
2
3
Analog and digital I/O extension modules and
fieldbus communication modules can be inserted
into slots 1, 2 and 3.
7
Control panel.
4
Memory unit
8
9
Fiber optic links to power modules (inverter,
supply, brake or converter)
5
6
Slot 4 for RDCO-0x
Terminal blocks.
Ethernet port. Not in use.
10 Safety option interface. Only in use for the invert-
er units.
Operation principle and hardware description 25
Supply unit control devices
￭ Overview of door switches and lights
This figure shows and example of the door control devices. The devices and their exact
locations varies depending on the options selected. The purpose of the devices is explained
in the following sections.
9
1
2
8
3
10
11
12
14
4
6
5
7
13
15
1…3 Not in use in multidrives
4
Operating switch [S21]. OFF: Opens main breaker (Q1.x), disables supply unit. ON (ENABLE/RUN):
Enables supply unit, closes main breaker (Q1.x).
5
6
7
8
9
Emergency stop reset button and indication lamp [S62] (option +G331)
Ground (earth) fault indicator light and reset button [S90] (option +Q954)
Reserved for application-engineered equipment
Emergency stop button [S61] (option +G331)
Control panel [A59] (option +J400, or +J412)
10 Auxiliary voltage supply breaker (switch fuse) [Q21]
11 Voltage meter [P5.x] (option +G334)
12 Selector switch for phase voltage meter [S5.x] (option +G334)
13 Phase current meter(s) [P2.x] (option +G335)
14 Grounding switch [Q9.x] (option +F259)
15 Main supply breaker [Q1.x] (option +F255)
￭ Main disconnecting device [Q1.x]
The supply unit is equipped with a main breaker ([Q1], option +F255) as standard. With this
device, you can isolate the main circuit of the drive from the power line. The main breaker
is withdrawable: to disconnect the drive, crank the breaker out with a separate loose handle
(included in the delivery). For the 12-pulse supply unit and power ratings higher than 3000 A
there are two main disconnecting devices ([Q1.1] and [Q1.2]).
26 Operation principle and hardware description
WARNING!
The main disconnecting device does not isolate the input power terminals, AC
voltage meters ([P5.x], option +G334) or the auxiliary circuit from the power line.
To isolate auxiliary voltage, use the auxiliary voltage switch [Q21]. To isolate the
input power terminals and AC voltage meters, open the main breaker of the supply
transformer and lock it to the open position.
If the drive is equipped with a main breaker and has a charging circuit: The main
circuit breaker does not isolate the charging circuit. Use the charging switch [Q3].
￭ Auxiliary voltage switch [Q21]
The supply unit is equipped with an auxiliary voltage switch [Q21] as standard. Using the
switch, you can disconnect the auxiliary circuit from the power line. The switch has an
operating handle on the cabinet door.
￭ Grounding switch [Q9.x]
The supply unit can be equipped with an optional grounding switch ([Q9.x], option +F259).
Using the switch, you can temporarily ground the main AC busbars of the supply unit during
the maintenance work. The switch has an operating handle on the cabinet door.
WARNING!
The grounding switch does not ground the input power terminals of the drive or
the auxiliary (control) voltage circuits.
￭ Operating switch [S21]
The operating switch [S21] is a standard device.
By default, the operating switch controls the unit as follows:
•
•
The ENABLE/RUN position energizes digital input DI2 of the control unit: Control program
receives Run/Enable command and controls the supply unit power up via the control
unit I/O interface. The supply unit first charges the drive DC link and then starts normal
operation. The main breaker [Q1] closes.
The OFF position de-energizes digital input DI2 of the control unit: Control program
does not receive Run/Enable command and it opens the main breaker [Q1]. Supply
module stops rectifying.
Position ENABLE/RUN (1)
Position OFF (0)
ENABLE / RUN
0-1
ENABLE / RUN
0-1
Operation principle and hardware description 27
￭ Emergency stop button [S61]
The emergency stop button [S61] is an optional device (option +G331). Pressing the button
activates an emergency stop function of the supply unit. The button locks to open position
automatically. You must release the button before you can return to the normal operation.
Before the restart, you also need to reset the emergency stop circuit with a separate reset
button [S62].
￭ E-stop reset button [S62] and indication lamp [P62]
The emergency stop reset button [S62] is automatically installed on the door when the
supply unit is equipped with an emergency stop function (for example, options +Q951,
+Q952, etc). The button is illuminated, ie it includes an indication lamp [P62]. You can reset
the emergency stop circuit with the button.
Note: The emergency stop options are described in separate option manuals.
￭ Other optional door controls
•
•
•
A voltage meter is an optional device ([P5.x], option +G334). There is a meter on the
door and a switch [S5.x] with which you can select which phase voltage value to display.
An AC phase current meter is an optional device ([P2.x], option +G335). It is also possible
to have three meters on the door - one for each phase currents (option +3G335).
Tripping button for the supply breaker ([S22], option +Q959) is a push button on the
cabinet door for the user-defined use, for example, for tripping the breaker of the supply
transformer of the drive. The button is wired to a terminal block at the factory. The user
connects the external circuit to be controlled on site.
•
An electrical on/off push button ([S23], option +G332) on the cabinet door for tripping
the supply unit. The button is connected in series with the operating switch. The button
trips the Run enable signal and further the main contactor/breaker of the drive.
￭ Control panel
The control panel is the user interface of the unit. For the cabinet-installed drives, the panel
is optional (option +J400 or +J425). With the control panel, you can:
•
•
•
•
•
start and stop the unit
view and reset the fault and warning messages, and view the fault history
view actual signals
change parameter settings
change between local and external control.
To be able to start and stop the unit by the control panel, you must have the Run enable
signal and Start enable signal on (1) on the control board. Normally this means, that you
must have the operating switch on the cabinet door in ENABLE/RUN position. The control
panel must also be in local control mode. You can select the mode with the Loc/Rem key
on the panel.
For the instructions on the use of the panel, see ACX-AP-x Assistant control panels user's
manual (3AUA0000085685 [English]).
￭ PC connection
There is a USB connector on the front of the control panel that can be used to connect a
PC to the drive. When a PC is connected to the control panel, the control panel keypad is
disabled.
28 Operation principle and hardware description
￭ Fieldbus control
You can control the unit through a fieldbus interface if the unit is equipped with an optional
fieldbus adapter (for example, option +K454), and when you have configured the control
program for the fieldbus control with the parameters. For information on the parameters,
see the firmware manual.
Note: To be able to switch the main breaker [Q1] and the supply unit on and off (Run enable
signal) through the fieldbus, the Run enable command at digital input DI2 must be on (1).
That is the case when the operating switch [S21] is switched to the ENABLE/RUN position.
Type designation labels
Each diode supply module and unit has a type designation label. The type designation
stated on the label contains information on the specifications and configuration of the unit.
Supply unit
1
7
6
2
3
4
8
5
1
2
3
4
5
6
7
8
Type designation
Frame size
Cooling method
Degree of protection
UL/CSA data
Ratings
Valid markings
Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits
refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial
number so that there are no two units with the same number.
Operation principle and hardware description 29
Supply module
1
7
6
2
3
4
5
8
1
2
3
4
5
6
7
8
Type designation
Frame size
Cooling method
Degree of protection
UL/CSA data
Ratings
Valid markings
Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits
refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial
number so that there are no two units with the same number.
30 Operation principle and hardware description
Type designation keys
￭ Type designation key of the supply unit
The type designation describes the composition of the unit in short. The type designation
is visible on the label (sticker) which is attached to the cabinet. The complete designation
code is divided in subcodes:
•
The first 1…18 digits form the basic code. It describes the basic construction of the unit.
The fields in the basic code are separated by hyphens.
•
The option codes follow the basic code. Each option code starts with an identifying letter
(common for the whole product series), followed by descriptive digits. The option codes
are separated by plus signs.
Basic code
Code
Description
ACS880 Product series
307LC
Default configuration: liquid-cooled cabinet-installed diode supply unit, IP42 (UL Type 1), supply
frequency 50 Hz, control (auxiliary) voltage 230 V AC, half-controlled diode thyristor bridge, IEC
industrial cabinet construction, main switch type: air circuit breaker, degree of protection IP42 (UL
type 1), EMC filter (category 3, 2nd Environment), EN/IEC approved components, speed-controlled
module cooling fans, DC busbar material copper, cable supply conductors, standard wiring material,
power and control cabling through the bottom of the cabinet, ACS-AP-W assistant control panel,
ACS880 diode supply control program, coated circuit boards, lead-through-type cable entries,
multilingual door device label sticker, complete documentation in English in a USB memory stick.
Size
xxxxx
Refer to the rating table in the technical data.
Voltage range
525…690 V. This is indicated in the type designation label as typical input voltage levels
7
3~525/600/690 V AC.
Option codes
Code
A004
A012
A013
A018
B054
B055
C121
C129
Description
12-pulse supply connection
50 Hz supply frequency
60 Hz supply frequency
Half-controlled diode-thyristor bridge
IP42 (UL Type 1)
IP54 (UL Type 12)
Marine construction
UL Listed (evaluated to both U.S. and Canadian safety requirements)
Marine type approval. Refer to ACS880 +C132 marine type-approved cabinet-built drives supplement
(3AXD50000039629 [English]).
C132
C164
C176
C179
C205
C206
C207
Plinth height 100 mm
Door hinges on left
Plinth height 200 mm
Marine product certification issued by DNV GL
Marine product certification issued by the American Bureau of Shipping (ABS)
Marine product certification issued by Lloyd's Register (LR)
Operation principle and hardware description 31
Code
C209
C228
C229
E210
F255
F259
F274
G300
G301
G304
G307
G315
G316
G317
G320
G330
G331
G332
G333
G334
G335
G336
G337
G338
G339
G340
G341
G342
G343
G344
G426
H350
H351
H358
H364
H365
H367
H368
J410
Description
Marine product certification issued by Bureau Veritas
Marine product certification issued by China Classification Society (CCS)
Marine product certification issued by Russian Maritime Register of Shipping (RS)
EMC/RFI filter for 2nd environment TN (grounded) or IT (ungrounded) system, category C3
Main circuit breaker
Grounding (earthing) switch
100 kA short-circuit rating
Cabinet and module heating elements (external supply)
Cabinet lighting
Control (auxiliary) voltage 115 V AC
Terminals for connecting external control voltage (230 V AC or 115 V AC, eg. UPS)
Tin-plated copper DC busbars
Cable supply conductors
Supply connection by busbars
Control (auxiliary) voltage 230 V AC
Halogen-free wiring and materials
Emergency stop push button on the door (red)
Electrical disconnect push button on the door (black, opens main contactor / ACB)
kW-meter on door
V-meter with selector switch
A-meter in one phase
Arc monitoring
Arc monitoring with current monitoring unit
Additional wire markings
Corrosion indicator
Auxiliary voltage transformer
Arc monitoring extension unit
Bottom power cable entry
Top power cable entry
Cable gland plates (3 mm steel, undrilled)
Cable gland plates (3 mm aluminum, undrilled)
Cable gland plates (6 mm brass, undrilled)
Control cable entry through floor of cabinet
Control cabling through roof of cabinet
Control panel mounting platform
K450
K451
K454
Panel bus (control of several units from one control panel)
FDNA-01 DeviceNet™ adapter module
FPBA-01 PROFIBUS DP adapter module
32 Operation principle and hardware description
Code
K457
K458
K462
K469
K470
Description
FCAN-01 CANopen adapter module
FSCA-01 RS-485 (Modbus/RTU) adapter module
FCNA-01 ControlNet™ adapter module
FECA-01 EtherCat adapter module
FEPL-02 EtherPOWERLINK adapter module
FENA-21 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols,
2-port
K475
K480
K483
K490
K491
K492
L500
L501
L503
L508
L509
L525
L526
N8010
P913
P966
Q951
Q952
Q954
Q959
Q963
Q964
Ethernet switch for PC tool or control network (for max. 6 inverter units)
Ethernet switch with optical link for PC tool or control network (for max. 6 inverter units)
FEIP-21 Ethernet adapter module for EtherNet/IP™
FMBT-21 Ethernet adapter module for Modbus TCP
FPNO-21 Ethernet adapter module for PROFINET IO
FIO-11 analog I/O extension module
FIO-01 digital I/O extension module
FDCO-01 optical DDCS communication adapter module
FDCO-02 optical DDCS communication adapter module
RDCO-04 optical DDCS communication for BCU-xx (4xTransmitter/Receiver)
FAIO-01 analog I/O extension module
FDIO-01 digital I/O extension module
IEC 61131-3 application programmability
Special color (RAL Classic)
Special color (other than RAL Classic)
Emergency stop (category 0) with safety relays, by opening the main breaker/contactor
Emergency stop (category 1) with safety relays, by opening the main breaker/contactor
Earth fault monitoring for IT (ungrounded) systems
Supply transformer breaker disconnect push button (red, wired to terminals) on the door
Emergency stop (category 0) with safety relays, by activating the Safe torque off function
Emergency stop (category 1) with safety relays, by activating the Safe torque off function
Emergency stop (configurable for category 0 or 1) with FSO-xx safety functions module, by activating
the Safe torque off function
Q979
Q984
R700
Emergency stop button monitoring
Documentation/manuals in English
￭ Type designation key of the diode supply module
The type designation describes the composition of the module in short. The complete
designation code is divided in subcodes:
•
The first 1…18 digits form the basic code. It describes the basic construction of the unit.
The fields in the basic code are separated by hyphens.
•
The option codes follow the basic code. Each option code starts with an identifying letter
(common for the whole product series), followed by descriptive digits. The option codes
are separated by plus signs.
Code
Description
Basic codes
Operation principle and hardware description 33
Code
Description
ACS880 Product series
304LC
Construction: Liquid cooled diode supply module, IP00 (UL Open Type), AC-choke, circuit boards
with coating, CE approval
Size
0780A
Refer to the technical data.
Voltage range
7
525…690 V. This is indicated in the type designation label as typical input voltage levels
3~525/600/690 V AC.
Plus codes
A018
C132
C209
P904
P909
P911
Half-controlled diode-thyristor bridge (as standard)
Marine type approval
Marine product certification (only with +C132)
Extended warranty 24/30
Extended warranty 36/42
Extended warranty 60/66
34
Electrical installation 35
3
Electrical installation
Contents of this chapter
This chapter instructs how to check the insulation of the assembly and how to install the
input power cables and control cables. The information is valid for ACS880-307LC…+A018
diode supply units.
For more information on cable selection, protections, etc., see ACS880 multidrive cabinets
and modules electrical planning instructions (3AUA0000102324 [English]).
WARNING!
Obey the safety instructions given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
If you ignore the safety instructions, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
36 Electrical installation
Electrical safety precautions
These electrical safety precautions are for all personnel who do work on the drive, motor
cable or motor.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
Go through these steps before you begin any installation or maintenance work.
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that re-connection is not possible.
Lock out and tag out.
•
•
•
Open the main disconnecting device of the drive.
Open the charging switch if present.
Open the disconnector of the supply transformer. (The main disconnecting device
in the drive cabinet does not disconnect the voltage from the AC input power busbars
of the drive cabinet.)
•
•
Close the grounding switch or switches ([Q9], option +F259) if present. Do not use
excessive force as the switch has electromagnetic interlocking.
If the drive is equipped with a DC/DC converter unit (optional): Open the DC
switch-disconnector ([Q11], option +F286) of the DC/DC converter. Open the
disconnecting device of the energy storage connected to the DC/DC converter unit
(outside the drive cabinet).
•
•
•
Open the auxiliary voltage switch-disconnector (if present), and all other possible
disconnecting devices that isolate the drive from dangerous voltage sources.
In the liquid cooling unit (if present), open the switch-disconnector of the cooling
pumps.
If you have a permanent magnet motor connected to the drive, disconnect the motor
from the drive with a safety switch or by other means.
•
•
Disconnect all dangerous external voltages from the control circuits.
After you disconnect power from the drive, always wait 5 minutes to let the
intermediate circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
Electrical installation 37
5. Measure that the installation is de-energized. If the measurement requires removal or
disassembly of shrouding or other cabinet structures, obey the local laws and regulations
applicable to live working (including – but not limited to – electric shock and arc
protection).
•
•
•
•
Before and after measuring the installation, verify the operation of the voltage tester
on a known voltage source.
Make sure that the voltage between the drive input power terminals (L1, L2, L3)
and the grounding (PE) busbar is zero.
Make sure that the voltage between the drive output terminals (T1/U, T2/V, T3/W)
and the grounding (PE) busbar is zero.
Make sure that the voltage between the drive DC busbars (+ and -) and the
grounding (PE) busbar is zero.
WARNING!
The busbars inside the cabinet of liquid-cooled drives are partially coated.
Measurements made through the coating are potentially unreliable, so only
measure at uncoated portions. Note that the coating does not constitute a safe
or touch-proof insulation.
6. If the drive is not equipped with a grounding switch, install temporary grounding as
required by the local regulations.
7. Ask the person in control of the electrical installation work for a permit to work.
General notes
￭ Static electricity
WARNING!
Use a grounding wristband when you handle printed circuit boards. Do not touch
the boards unnecessarily. The boards contain components sensitive to electrostatic
discharge.
￭ Optical components
WARNING!
Obey these instructions. If you ignore them, damage to the equipment can occur.
•
•
•
Handle the fiber optic cables with care.
When you unplug the fiber optic cables, always hold the connector, not the cable itself.
Do not touch the ends of the fibers with bare hands as the ends are extremely sensitive
to dirt.
•
Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is
35 mm (1.4 in).
38 Electrical installation
Measuring the insulation
￭ Measuring the insulation of the drive
WARNING!
Do not do any voltage withstand or insulation resistance tests on any part of the
drive as testing can damage the drive. Every drive has been tested for insulation
between the main circuit and the chassis at the factory. Also, there are
voltage-limiting circuits inside the drive which cut down the testing voltage
automatically.
￭ Measuring the insulation of the input power cable
Before you connect the input power cable to the drive, measure its insulation according to
local regulations.
Connecting the input power cables
￭ Connection diagram – 6-pulse supply unit
This is a connection diagram for the 6-pulse supply unit. See also the delivery specific circuit
diagrams.
1
L1
L2
L3
PE
2
1
2
Fuses or other protection means for the short-circuit protection of the cable.
Grounding of the cable shield at the cable entry (360 degrees grounding).
Additional information:
• See the technical data for the dimensions of the cable entries, and the dimensions and tightening torques
of the terminals.
• Use a separate PE conductor in addition if the conductivity of the shields does not meet the requirement for
the PE conductor.
• See ACS880 multidrive cabinets and modules electrical planning instructions [3AUA0000102324 (English)]
for the cable selection instructions.
￭ Connection diagram – 12-pulse supply unit (option +A004)
This is a connection diagram for the 12-pulse supply unit (option +A004). See also the
delivery specific circuit diagrams.
Electrical installation 39
1
1L1
1L2
1L3
PE
2L1
2L2
2L3
PE
2
1
2
Fuses or other protection means for the short-circuit protection of the cable.
Grounding of the cable shield at the cable entry (360 degrees grounding).
Additional information:
• See the technical data for the dimensions of the cable entries, and the dimensions and tightening torques
of the terminals.
• If the conductivity of the shields does not meet the requirement for the PE conductor, use a separate PE
conductor in addition.
• See ACS880 multidrive cabinets and modules electrical planning instructions (3AUA0000102324 [English])
for the cable selection instructions.
￭ Connection procedure – bottom cable entry
See the technical data for the dimensions of the cable entries, and the dimensions and
tightening torques of the terminals.
WARNING!
Apply grease to stripped aluminum conductors before attaching them to non-coated
aluminum cable lugs. Obey the grease manufacturer’s instructions.
Aluminum-aluminum contact can cause oxidation in the contact surfaces.
1. Disconnect the drive from the AC power line and make sure it is safe to start the work.
2. Open the door of the incoming cubicle.
3. Remove the shrouding covering the input terminals.
4. Peel off 3 to 5 cm of the outer insulation of the cables above the lead-through plate for
360° high-frequency grounding.
5. Prepare the ends of the cables.
6. Remove the rubber grommet from the cable entry plate for the cable to be connected.
Cut adequate hole into the rubber grommet. Slide the grommet onto the cable. Slide
the cable through the cable entry and attach the grommets to the holes.
7. Fasten the conductive sleeve of the cable entry to the cable shield with cable ties.
8. Tie up the unused conductive sleeves with cable ties.
9. Connect the twisted shield of the cable to the PE busbar of the cabinet. Tighten the
screw to the torque given in the technical data.
10. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals. Tighten
the screws to the torque given in the technical data.
40 Electrical installation
11. Reinstall the shrouding removed earlier.
12. Close the door.
3
PE
PE
Electrical installation 41
8
7
6
10
9
42 Electrical installation
Connecting the external power supply cable for the auxiliary
circuit (option +G307)
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death, or
damage to the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
For the connection diagram, see the delivery-specific circuit diagrams. For the auxiliary
circuit current consumption, see the delivery-specific technical documentation.
Wiring the functional safety options
The wiring instructions for the functional safety options such as +Q951, +Q952, etc are in
separate option manuals.
Connecting the control cables
See the chapter on control units for the default I/O connections. Note that the default I/O
connections can be affected by some options. See the circuit diagrams delivered with the
drive for the actual wiring.
￭ Control cable connection procedure
WARNING!
Obey the safety instructions given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
If you ignore the safety instructions, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
precautions (page 36) before you start the work.
Grounding the outer shields of the control cables at the cabinet entry
Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions
as follows (example constructions are shown below, the actual hardware may vary):
1. Loosen the tightening screws of the EMI conductive cushions and pull the cushions
apart.
2. Cut adequate holes to the rubber grommets in the entry plate and put the cables through
the grommets and the cushions.
Electrical installation 43
3. Strip off the cable plastic sheath above the entry plate just enough to ensure proper
connection of the bare shield and the EMI conductive cushions.
4. Tighten the two tightening screws so that the EMI conductive cushions press tightly
round the bare shield.
4
3
1
2
Note 1: Keep the shields continuous as close to the connection terminals as possible.
Secure the cables mechanically at the entry strain relief.
Note 2: If the outer surface of the shield is non-conductive:
•
Cut the shield at the midpoint of the bare part. Be careful not to cut the conductors or
the grounding wire (if present).
•
•
Turn the shield inside out to expose its conductive surface.
Cover the turned shield and the stripped cable with copper foil to keep the shielding
continuous.
A
B
C
A
B
C
1
2
3
4
Stripped cable
Conductive surface of the shield exposed
Stripped part covered with copper foil
Cable shield
2
2
1
3
4
Copper foil
Shielded twisted pair
Grounding wire
5
Note for top entry of cables: When each cable has its own rubber grommet, sufficient IP
and EMC protection can be achieved. However, if there is more than one cable per grommet,
plan the installation beforehand as follows:
1. Make a list of the cables coming to the cabinet.
2. Sort the cables going to the left into one group and the cables going to the right into
another group to avoid unnecessary crossing of cables inside the cabinet.
3. Sort the cables in each group according to size.
44 Electrical installation
4. Group the cables for each grommet as follows ensuring that each cable has a proper
contact to the cushions on both sides.
Cable diameter in mm
Max. number of cables per grommet
≤ 13
≤ 17
< 25
≥ 25
4
3
2
1
5. Arrange the bunches according to size from thickest to the thinnest between the EMI
conductive cushions.
6. If more than one cable go through a grommet, seal the grommet by applying Loctite
5221 inside the grommet.
Routing the control cables inside the cabinet
Use the existing trunking in the cabinet wherever possible. Use sleeving if cables are laid
against sharp edges. When running cables to or from a swing-out frame, leave enough
slack at the hinge to allow the frame to open fully.
Connecting control cabling
Connect the conductors to the appropriate terminals. Refer to the wiring diagrams delivered
with the drive.
Connect the inner twisted pair shields and all separate grounding wires to the grounding
clamps closest to the terminals.
The drawing below represents the grounding of the control cabling when connecting to a
terminal block inside the cabinet. The grounding is done in the same way when connecting
directly to a component such as the control unit.
Notes:
Electrical installation 45
•
•
Do not ground the outer shield of the cable here since it is grounded at the cable entry.
Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the
wire with its return wire reduces disturbances caused by inductive coupling.
At the other end of the cable, leave the shields unconnected or ground them indirectly via
a high-frequency capacitor with a few nanofarads, eg. 3.3 nF / 630 V. The shield can also
be grounded directly at both ends if they are in the same ground line with no significant
voltage drop between the end points.
46 Electrical installation
Connecting a PC
WARNING!
Do not connect the PC directly to the control panel connector of the control unit
as this can cause damage.
A PC (with eg, the Drive composer PC tool) can be connected as follows:
1. Connect an ACx-AP-x control panel to the unit either
•
•
by inserting the control panel into the panel holder or platform, or
by using an Ethernet (eg, Cat 5e) networking cable.
2. Remove the USB connector cover on the front of the control panel.
3. Connect an USB cable (Type A to Type Mini-B) between the USB connector on the
control panel (3a) and a free USB port on the PC (3b).
4. The panel will display an indication whenever the connection is active.
5. See the documentation of the PC tool for setup instructions.
USB connected
4
2
?
Stop
Start
Loc/Rem
?
Stop
Start
Loc/Rem
2
3b
3a
48 The control unit
BCU-x2 layout
Description
I/O
I/O terminals (see following diagram)
SLOT 1
I/O extension, encoder interface or fieldbus
adapter module connection. (This is the
sole location for an FDPI-02 diagnostics
and panel interface.)
SLOT 2
SLOT 3
I/O extension, encoder interface or fieldbus
adapter module connection
I/O extension, encoder interface, fieldbus
adapter or FSO-xx safety functions module
connection
SLOT 4
RDCO-0x DDCS communication option
module connection
X205
Memory unit connection
BATTERY
Holder for real-time clock battery (BR2032)
AI1
Mode selector for analog input AI1 (I =
current, U = voltage)
AI2
Mode selector for analog input AI2 (I =
current, U = voltage)
D2D TERM
Termination switch for drive-to-drive link
(D2D)
DICOM=
DIOGND
Ground selection. Determines whether
DICOM is separated from DIOGND (ie. the
common reference for the digital inputs
floats). See the ground isolation diagram.
7-segment display
Multicharacter indications are displayed as repeated se-
quences of characters
(“U” is indicated briefly before “o”.)
Control program running
Control program startup in progress
(Flashing) Firmware cannot be started.
Memory unit missing or corrupted
Firmware download from PC to control unit
in progress
At power-up, the display may show short
indications of eg. “1”, “2”, “b” or “U”. These
are normal indications immediately after
power-up. If the display ends up showing
any other value than those described, it in-
dicates a hardware failure.
The control unit 49
Description
XAI
Analog inputs
Analog outputs
XAO
XDI
Digital inputs, Digital input interlock (DIIL)
Digital input/outputs
XRO3
XRO2
XRO1
XD24
XDIO
XPOW
XAO
XDIO
XD2D
XD24
XETH
XPOW
XRO1
XRO2
XRO3
XSTO
Drive-to-drive link
+24 V output (for digital inputs)
Ethernet port – Not in use
External power input
Relay output RO1
XDI
XAI
Relay output RO2
X485
Relay output RO3
Safe torque off connection (input signals)
XSTO OUT Safe torque off connection (to inverter mod-
ules)
XSTO
OUT
XD2D
XSTO
X12
(On the opposite side) Connection for FSO-
xx safety functions module (optional)
X13
Control panel / PC connection
Not in use
X485
V1T/V1R,
V2T/V2R
Fiber optic connection to modules 1 and 2
(VxT = transmitter, VxR = receiver)
V3T/V3R
…
Fiber optic connection to modules 3…7 (BCU-
12/22 only)
V7T/V7R
(VxT = transmitter, VxR = receiver)
V8T/V8R
…
Fiber optic connection to modules 8…12
(BCU-22 only)
V12T/V12R (VxT = transmitter, VxR = receiver)
SD CARD Data logger memory card for inverter module
communication
BATT OK
Real-time clock battery voltage is higher than
2.8 V. If the LED is off when the control unit
is powered, replace the battery.
FAULT
The control program has generated a fault.
See the firmware manual of the supply/invert-
er unit.
PWR OK
WRITE
Internal voltage supply is OK
Writing to memory card in progress. Do not
remove the memory card.
50 The control unit
Default I/O diagram of the supply control unit
The diagram below shows the default I/O connections on the supply control unit (A51), and
describes the use of the connections in the supply unit. Under normal circumstances, the
factory-made wiring should not be changed.
The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …
2.5 mm2 (24…12 AWG). The torque is 0.5 N·m (5 lbf·in).
Terminal
Description
XD2D
Drive-to-drive link
1
B
1
2
3
4
2
3
4
A
Not in use by default
BGND
Shield
1)
D2D.TERM
Drive-to-drive link termination switch
RS485 connection
X485
5
6
7
8
B
5
6
7
8
A
Cooling fan monitoring (CIO module)
BGND
Shield
XRO1, XRO2, XRO3
Relay outputs
Norm. closed
Common
11
12
13
21
22
NC
2)
XRO1: Running (Energized = running)
COM
NO
250 V AC / 30 V DC, 2 A
Norm. open
Norm. closed
Common
11
12
13
21
22
23
31
32
33
NC
XRO2: Fault (-1) (Energized = no fault)
250 V AC / 30 V DC, 2 A
COM
Note: If drive is equipped with a liquid cool-
ing unit, the relay output controls the cooling
unit start signal. Then the selection Fault(-
1) may also be changed to Started by bit
12 of parameter 195.12. See ACS880 diode
supply control program firmware manual
(3AUA0000103295 [English]).
23
NO
Norm. open
31
32
33
NC
Norm. closed
Common
3)
XRO3: MCB ctrl (Energized = closes
COM
NO
main contactor/breaker) 250 V AC /
30 V DC, 2 A
Norm. open
4)
XSTO, XSTO OUT
Safe torque off
1
2
3
4
5
6
7
8
OUT
1
2
3
4
5
6
7
8
SGND
IN1
XSTO: Factory connection. Both circuits must be closed for the drive to start
(IN1 and IN2 must be connected to OUT).
IN2
IN1
SGND
IN2
XSTO OUT: Not in use.
Digital inputs
SGND
XDI
The control unit 51
Terminal
Description
1
DI1
DI2
DI3
DI4
DI5
DI6
DIIL
Temp fault (0 = overtemperature)
1
2
3
4
5
6
7
2
3
4
5
6
7
Run enable (1 = run enable)
MCB feedback (0 = main contactor/breaker open)
Auxiliary circuit breaker fault
Not in use by default. Can be used for eg. earth fault monitoring.
Reset (0 -> 1 = fault reset)
Not in use by default. Can be used for eg. emergency stop.
Digital input/outputs
XDIO
1
2
3
4
DIO1
Not in use by default
1
2
3
4
DIO2
Not in use by default
DIOGND
DIOGND
Digital input/output ground
Digital input/output ground
Auxiliary voltage output
XD24
5)
1
2
3
4
+24VD
DICOM
+24VD
DIOGND
+24 V DC 200 mA
5
6
7
8
Digital input ground
+24 V DC 200 mA
Digital input/output ground
6)
DICOM=DIOGND
Ground selection switch
XAI
Analog inputs, reference voltage output
10 V DC, RL 1…10 kohm
-10 V DC, RL 1…10 kohm
Ground
1
2
3
4
5
6
7
+VREF
-VREF
AGND
AI1+
1
2
3
4
5
6
7
7)
Not in use by default. 0(2)…10 V, Rin > 200 kohm
AI1-
AI2+
8)
Not in use by default. 0(4)…20 mA, Rin = 100 ohm
AI2-
AI1
AI2
AI1 current/voltage selection switch
AI2 current/voltage selection switch
Analog outputs
XAO
1
2
3
4
AO1
1
2
3
4
Zero (no signal indicated) 0…20 mA, RL < 500 ohm
AGND
AO2
Zero (not signal indicated) 0…20 mA, RL < 500 ohm
AGND
XPOW
External power input
1
2
3
4
+24VI
GND
+24VI
GND
1
2
3
4
24 V DC, 2.05 A
X12
X13
Not in use in supply units
Control panel connection
52 The control unit
Terminal
Description
X205
Memory unit connection
1)
Must be set to ON when the supply unit is the first or last unit on the drive-to-drive (D2D) link. On intermediate units, set
termination to OFF.
Default use of the signal in the control program. The use can be changed by a parameter. See also the delivery-specific
circuit diagrams.
2)
3)
4)
Use of the signal in the control program (fixed). See also the delivery-specific circuit diagrams.
This input only acts as a true Safe torque off input in inverter units. In other applications (such as a supply or brake unit),
de-energizing the IN1 and/or IN2 terminal will stop the unit but not constitute a true safety function.
5)
6)
Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and DIO2.
Determines whether DICOM is separated from DIOGND (ie, common reference for digital inputs floats). ON: DICOM
connected to DIOGND. OFF: DICOM and DIOGND separate.
7)
8)
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected by switch AI1. Change of
setting requires reboot of control unit.
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected by switch AI2. Change of
setting requires reboot of control unit.
External power supply for the control unit (XPOW)
The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW. With
a type BCU control unit, a second supply can be connected to the same terminal block for
redundancy.
Using an external supply is recommended if
•
the control unit needs to be kept operational during input power breaks, for example,
because of continuous fieldbus communication
•
immediate restart is needed after a power break (that is, no control unit power-up delay
is allowed).
The X485 connector
The X485 provides a connection for optional CIO-01 I/O module. The following diagram
shows the wiring for the CIO module.
BCU
CIO
CIO
X485
B
X485
B
X485
B
A
A
A
GND
SHIELD
BGND
SHIELD
GND
SHIELD
The control unit 53
Safe torque off (XSTO, XSTO OUT)
Note: The XSTO input only acts as a true Safe torque off input on the inverter control unit.
De-energizing the IN1 and/or IN2 terminals of other units (supply, DC/DC converter, or brake
unit) will stop the unit but not constitute a true safety function.
FSO-xx safety functions module connection (X12)
See the user manual of the FSO-xx module. Note that the FSO-xx safety functions module
is not in use in supply, DC/DC converter or brake units.
SDHC memory card slot
The BCU-x2 has an on-board data logger that collects real-time data from the power modules
to help fault tracing and analysis. The data is stored onto the SDHC memory card inserted
into the SD CARD slot and can be analyzed by ABB service personnel.
54 The control unit
Connector data
Power supply (XPOW)
Connector pitch 5 mm, wire size 2.5 mm2
24 V (±10%) DC, 2 A
External power input.
Two supplies can be connected for redundancy.
Relay outputs RO1…RO3
(XRO1…XRO3)
Connector pitch 5 mm, wire size 2.5 mm2
250 V AC / 30 V DC, 2 A
Protected by varistors
+24 V output (XD24:2 and XD24:4)
Connector pitch 5 mm, wire size 2.5 mm2
Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus
the power taken by DIO1 and DIO2.
Digital inputs DI1…DI6 (XDI:1…XDI:6) Connector pitch 5 mm, wire size 2.5 mm2
24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP (DI1…DI5), NPN (DI6)
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
DI6 (XDI:6) can alternatively be used as an input for a PTC sensor.
“0” > 4 kohm, “1” < 1.5 kohm.
Imax: 15 mA (DI1…DI5), 5 mA (DI6)
Start interlock input DIIL (XDI:7)
Connector pitch 5 mm, wire size 2.5 mm2
24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Input type: NPN/PNP
Hardware filtering: 0.04 ms, digital filtering up to 8 ms
Digital inputs/outputs DIO1 and DIO2
(XDIO:1 and XDIO:2)
Connector pitch 5 mm, wire size 2.5 mm2
As inputs: 24 V logic levels: “0” < 5 V, “1” > 15 V. Rin: 2.0 kohm. Fil-
Input/output mode selection by paramet- tering: 1 ms.
ers.
As outputs: Total output current from +24VD is limited to 200 mA
DIO1 can be configured as a frequency
input (0…16 kHz with hardware filtering
of 4 microseconds) for 24 V level square
wave signal (sinusoidal or other wave
form cannot be used). DIO2 can be con-
figured as a 24 V level square wave fre-
quency output. See the firmware manual,
parameter group 111/11.
+24VD
DIOx
RL
DIOGND
Reference voltage for analog inputs
+VREF and -VREF (XAI:1 and XAI:2)
Connector pitch 5 mm, wire size 2.5 mm2
10 V ±1% and –10 V ±1%, Rload 1…10 kohm
Maximum output current: 10 mA
Analog inputs AI1 and AI2
(XAI:4 … XAI:7).
Connector pitch 5 mm, wire size 2.5 mm2
Current input: –20…20 mA, Rin = 100 ohm
Voltage input: –10…10 V, Rin > 200 kohm
Differential inputs, common mode range ±30 V
Sampling interval per channel: 0.25 ms
Hardware filtering: 0.25 ms, adjustable digital filtering up to 8 ms
Resolution: 11 bit + sign bit
Current/voltage input mode selection by
switches
Inaccuracy: 1% of full scale range
The control unit 55
Analog outputs AO1 and AO2 (XAO)
Connector pitch 5 mm, wire size 2.5 mm2
0…20 mA, Rload < 500 ohm
Frequency range: 0…500 Hz
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
XD2D connector
Connector pitch 5 mm, wire size 2.5 mm2
Physical layer: RS-485
Transmission rate: 8 Mbit/s
Cable type: Shielded twisted-pair cable with a twisted pair for data
and a wire or another pair for signal ground (nominal impedance
100 … 165 ohm, for example Belden 9842)
Maximum length of link: 50 m (164 ft)
Termination by switch
RS-485 connection (X485)
Connector pitch 5 mm, wire size 2.5 mm2
Physical layer: RS-485
Safe torque off connection (XSTO)
Connector pitch 5 mm, wire size 2.5 mm2
Input voltage range: -3…30 V DC
Logic levels: “0” < 5 V, “1” > 17 V.
Note: For the unit to start, both connections must be “1”. This applies
to all control units (including drive, inverter, supply, brake, DC/DC
converter etc. control units), but true Safe torque off functionality is
only achieved through the XSTO connector of the drive/inverter
control unit.
EMC (immunity) according to IEC 61326-3-1
Safe torque off output (XSTO OUT)
Control panel connection (X13)
Ethernet connection (XETH)
Connector pitch 5 mm, wire size 2.5 mm2
To STO connector of inverter module.
Connector: RJ-45
Cable length < 3 m
Connector: RJ-45
This connection is not supported by the firmware.
SDHC memory card slot (SD CARD)
Memory card type: SDHC
Maximum memory size: 4 GB
The terminals of the control unit fulfill the Protective Extra Low Voltage (PELV) requirements. The PELV re-
quirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output.
56 The control unit
￭ BCU-x2 ground isolation diagram
XPOW
+24VI
GND
+24VI
GND
1
2
3
4
XAI
+VREF
-VREF
AGND
AI1+
AI1-
AI2+
1
2
3
4
5
6
7
**
AI2-
XAO
AO1
AGND
AO2
1
2
3
4
AGND
XD2D
B
A
1
2
3
4
BGND
SHIELD
XRO1, XRO2, XRO3
NC
COM
NO
NC
COM
NO
NC
COM
NO
11
12
13
21
22
23
31
32
33
XD24
+24VD
DICOM
+24VD
5
6
7
8
DIOGND
XDIO
DIO1
DIO2
DIOGND
DIOGND
1
2
3
4
XDI
*
DI1
DI2
DI3
DI4
DI5
DI6
DIIL
1
2
3
4
5
6
7
XSTO
OUT
SGND
IN1
1
2
3
4
IN2
XSTO OUT
IN1
SGND
IN2
5
6
7
8
SGND
*Ground selector (DICOM=DIOGND) settings
DICOM=DIOGND: ON
All digital inputs share a common ground (DICOM connected to DIOGND). This is the default setting.
DICOM=DIOGND: OFF
Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from DIO signal ground (DIOGND). Isolation
voltage 50 V.
**Common mode voltage between each AI input and AGND is +30 V
Installation checklist 57
5
Installation checklist
Contents of this chapter
This chapter contains a checklist of the mechanical and electrical installation of the drive.
Checklist
Examine the mechanical and electrical installation of the drive before start-up. Go through
the checklist together with another person.
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death, or
damage to the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
WARNING!
Stop the drive and do the steps in section Electrical safety precautions (page 36)
before you start the work.
Make sure that …
The ambient operating conditions meet the drive ambient conditions specification, and enclosure rating
(IP code or UL enclosure type).
The supply voltage matches the nominal input voltage of the drive. See the type designation label.
The insulation resistance of the input power cable, motor cable and motor is measured according to
local regulations and the manuals of the drive.
The drive cabinet is attached to the floor, and if necessary due to vibration etc, also by its top to the
wall or roof.
The drive module is fastened properly to the cabinet.
58 Installation checklist
Make sure that …
If the drive is connected to a network other than a symmetrically grounded TN-S system: You have
done all the required modifications (for example, you may need to disconnect the EMC filter or ground-
to-phase varistor). See the electrical installation instructions in the supply unit manual.
Appropriate DC fuses are installed.
There is an adequately sized protective earth (ground) conductor(s) between the drive and the
switchboard, the conductor is connected to correct terminal, and the terminal is tightened to the correct
torque.
Proper grounding has also been measured according to the regulations.
If the drive is equipped with a DC/DC converter unit: There is an adequately sized protective earth
(ground) conductor between the energy storage and the DC/DC converter, the conductor has been
connected to appropriate terminal, and the terminal has been tightened to the proper torque. Proper
grounding has also been measured according to the regulations.
If the drive is equipped with a DC/DC converter unit: The energy storage cable has been connected to
the correct terminals of the DC/DC converter and energy storage, and the terminals have been tightened
to the proper torque.
If the drive is equipped with a DC/DC converter unit: The energy storage has been equipped with fuses
for protecting energy storage cable in a cable short-circuit situation.
If the drive is equipped with a DC/DC converter unit: The energy storage has been equipped with a
disconnecting device.
The input power cable is connected to the correct terminals, the phase order is correct, and the terminals
are tightened to the correct torque.
There is an adequately sized protective earth (ground) conductor between the motor and the drive,
and the conductor is connected to the correct terminal, and the terminal is tightened to the correct
torque.
Proper grounding has also been measured according to the regulations.
The motor cable is connected to the correct terminals, the phase order is correct, and the terminals
are tightened to the correct torque.
The motor cable is routed away from other cables.
No power factor compensation capacitors are connected to the motor cable.
If an external brake resistor is connected to the drive: There is an adequately sized protective earth
(ground) conductor between the brake resistor and the drive, and the conductor is connected to the
correct terminal, and the terminals are tightened to the correct torque. Proper grounding has also been
measured according to the regulations.
If an external brake resistor is connected to the drive: The brake resistor is connected to the correct
terminals, and the terminals are tightened to the correct torque.
If an external brake resistor is connected to the drive: The brake resistor cable is routed away from
other cables.
The control cables are connected to the correct terminals, and the terminals are tightened to the correct
torque.
The voltage setting of the auxiliary voltage transformers (if any) is correct. See the electrical installation
instructions.
If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive output
contactor are either mechanically and/or electrically interlocked, that is, they cannot be closed at the
same time. A thermal overload device must be used for protection when bypassing the drive. Refer to
local codes and regulations.
There are no tools, foreign objects or dust from drilling inside the drive.
Cover(s) of the motor connection box are in place. Cabinet shrouds are in place and doors are closed.
The motor and the driven equipment are ready for power-up.
The coolant connections between cubicles (if any) and to the cooling circuit are tight.
If the drive is equipped with a cooling unit: Refer to the cooling unit documentation for specific tasks.
Start-up 59
6
Start-up
Contents of this chapter
This chapter contains start-up instructions of the diode supply unit.
The underlined tasks are necessary only for certain cases. The symbols in brackets, for
example [Q1], refer to the item designations used in the circuit diagrams. If a task is valid
only for a certain option device or feature, the option code is given in brackets, for example,
(option +F259).
Note: The instructions do not cover all possible supply unit configurations. Always refer to
the delivery-specific circuit diagrams when proceeding with the start-up. This default start-up
procedure is valid for a supply unit equipped with a main breaker ([Q1], option +F255) and
an external auxiliary voltage supply (option +G307).
Note: For the functional safety options, the start-up instructions are given in separate option
manuals. Reserve the necessary option manuals at hand before the supply unit start-up.
Obey their start-up instructions.
WARNING!
Obey the safety instructions during the start-up procedure. See ACS880
liquid-cooled multidrive cabinets and modules safety instructions
(3AXD50000048633 [English]). If you ignore the safety instructions, injury
or death, or damage to the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
60 Start-up
Start-up procedure
￭ Basic checks with no voltage connected
Action
Disconnect the drive from the AC power line and make sure it is safe to start the work. See section
Set the current trip limits of the main breaker. The trip limits have been preset to generic values by the
breaker manufacturer. The generic limits do not correspond the protection requirements of the applic-
ation.
General rule
Make sure that the selectivity condition is fulfilled, that is the breaker trips at the lower current than the
protection device of the supplying network, and that the limit is high enough to cause unnecessary
trips during the intermediate DC circuit load peak at start.
Long term current limit
Rule of thumb: Set to the rated AC current of the drive.
Peak current limit
Rule of thumb: Set to a value 3…4 times the rated AC current of the drive.
Make sure that the mechanical and electrical installation of the drive is completed. See Installation
Check the settings of breakers/switches in the auxiliary circuits.
Make sure that the voltage settings of the auxiliary voltage transformers (option +G344) are according
to the actual power line voltage. See the delivery-specific circuit diagrams.
Transformer [T21] is selected by option +G344; [T101] and [T111] are present if required by the options
specified by the customer.
￭ Starting and checking the cooling system
Action
Fill up and bleed the internal cooling circuit. Start the cooling unit up. See Internal cooling cir-
Check the cooling system for leaks.
Make sure that cooling circuit joints at the shipping split joining cubicles are tight and that all drain
valves have been closed.
Make sure that the coolant can flow freely in all cubicles.
Install all shrouds (if removed) and close the cabinet doors.
￭ Connecting voltage to input terminals and auxiliary
Action
Remove the temporary grounding system (if installed).
Drive with voltage meters (option +G334): Close the circuit breaker for the voltage meters [F5].
Close the circuit breakers supplying the auxiliary circuits [F20, F22.x].
Drive with an external control voltage supply (option +G307): Close the circuit breaker of the external
control voltage supply.
Start-up 61
Action
Make sure that it is safe to connect voltage:
• nobody is working on the unit or circuits that are wired from outside into the cabinets
• covers of the motor terminal boxes are on
• cabinet doors are closed
• the disconnecting device [Q1] is open.
Drive with the earthing/grounding switch [Q9] (option +F259): Open the earthing/grounding switch.
Close the auxiliary voltage switch [Q21].
￭ Setting the supply unit parameters
Action
If the supply unit includes one supply module:
• Check the correct voltage ranges by parameter 195.01 Supply voltage.
• Reboot the control unit by parameter 196.08 Control board boot.
If the supply unit includes more than one supply module: Make sure that the value of parameter 195.31
Parallel connection rating id corresponds to the actual number of parallel-connected diode supply
modules:
• Select the correct voltage range with parameter 195.30 Parallel type filter.
• Select the correct supply unit type with parameter 195.31 Parallel connection rating id.
• Reboot the control unit by parameter 196.08 Control board boot.
• Check the correct voltage range, parameter 195.01 Supply voltage.
• Reboot the control unit by parameter 196.08 Control board boot.
If you need more information on the use of the control panel, see ACX-AP-x assistant control panels
user's manual (3AUA0000085685 [English]).
￭ Powering up the drive
Action
Close the disconnecting device of the supply unit.
Drive with main breaker [Q1] (option +F255): Unlock the withdrawn breaker, and crank it in.
WARNING!
Never use the start button of the air circuit breaker to close it. Start button bypasses normal
start-up procedure and may damage the module.
Make sure that the control panel [A59] is in the remote mode (Loc/Rem key of the panel).
Switch the Run enable and Start signals at digital input DI2 on (1) to start the operation of the supply
unit.
Turn the operating switch [S21] on the cabinet door to ENABLE/RUN (1) position.
Run enable starts the supply unit power up sequence. After the program has stepped through it (ap-
proximately 3 seconds), the drive DC link is charged, the main breaker is closed and the supply unit
is in operation and ready to the supply inverters.
Turn the operating switch [S21] to on (1) position to activate the Run enable signal and to close the
main breaker [Q1].
62 Start-up
￭ Safety function validation
Action
Validate the operation of safety functions (for example, emergency stop).
WARNING!
The safety functions are not safe before they are validated according to the instructions.
See the function-specific manual for the validation tasks.
Safety functions are optional. See the function-specific manual for the validation tasks.
￭ On-load checks
Action
Make sure that the cooling operates properly (no overtemperature related warnings or faults).
Switching the supply unit off
1. Stop the motors connected to inverter units. See the inverter unit hardware and firmware
manuals.
2. Turn the operating switch [S21] to the OFF (0) position to deactivate the Run enable
signal and to switch off the main disconnecting device (main breaker [Q1]).
ENABLE / RUN
0-1
Disconnecting and temporary grounding the drive
Maintenance 63
7
Maintenance
Contents of this chapter
This chapter instructs how to maintain the diode supply unit and how to interpret its fault
indications. The information is valid for ACS880-307LC…+A018 diode supply units.
WARNING!
Obey the safety instructions given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
If you ignore the safety instructions, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
Maintenance intervals
The table below shows the maintenance tasks which can be done by the end user. The
For more information, consult your local ABB Service representative
64 Maintenance
Years from start-up
Component
1
2
3
4
5
6
7
8
9
10 11 12
…
Coolant
Coolant draining and refill
Checking coolant quantity
R
P
P
R
P
P
P
P
P
P
P
P
P
P
Checking coolant antifreeze con-
centration
P
P
P
P
P
P
P
External circuit of main heat ex-
changer (temperature, flow, pres-
sure)
I
I
I
I
I
I
Cabinet fans and fan control board
Cooling fans 230 V AC 50/60 Hz
R
R
CIO-module for fan control
(230 V AC)
Cooling fans 115 V AC 50/60 Hz
R
R
R
R
I/R
CIO-module for fan control
1)
(115 V AC)
Batteries
Control panel battery
Control unit battery
Control unit
R
R
R
R
P
BCU Control unit
Connections and environment
Quality of supply voltage
Inspections
P
P
P
P
P
P
P
P
P
P
P
P
Tightness of terminals
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Ambient conditions (dustiness,
moisture, corrosion, temperature)
Cooling liquid pipe connections
Spare parts
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Spare part stock
Other
ABB-SACE Air circuit breaker
maintenance
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
ABB Contactors maintenance
1)
Replace CIO-module or reset fan counters, see CIO-01 I/O module for distributed I/O bus control user's manual
(3AXD50000126880 [English])
Symbols
I
Inspection (visual inspection and maintenance action if needed)
Performance of on/off-site work (commissioning, tests, measurements or other work)
Replacement
P
R
Maintenance and component replacement intervals are based on the assumption that the
equipment is operated within the specified ratings and ambient conditions. ABB recommends
annual drive inspections to ensure the highest reliability and optimum performance.
Maintenance 65
Note: Long term operation near the specified maximum ratings or ambient conditions may
require shorter maintenance intervals for certain components. Consult your local ABB Service
representative for additional maintenance recommendations.
Maintenance timers and counters
The control program has maintenance timers and counters that can be configured to generate
a warning when a pre-defined limit is reached. Each timer/counter can be set to monitor
any parameter. This feature is especially useful as a service reminder. For more information,
see the firmware manual.
Internal liquid-cooling system
For instructions on coolant replacement and checking the liquid-cooling system, see chapter
Power connections
￭ Retightening the power connections
WARNING!
Obey the safety instructions given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
If you ignore the safety instructions, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
you start the work.
2. Examine the tightness of the cable connections. Use the tightening torques given in the
technical data.
Fans
The lifespan of the cooling fans of the drive depends on the running time, ambient
temperature and dust concentration. See the firmware manual for the actual signal which
indicates the running time of the cooling fan. Reset the running time signal after fan
replacement.
Replacement fans are available from ABB. Do not use other than ABB specified spare parts.
￭ Replacing the fan in the 600 mm wide incoming cubicle
WARNING!
Read the safety instructions given in Safety instructions for ACS880
liquid-cooled multidrive cabinets and modules (3AXD50000048633
[English]). If you ignore them, injury or death, or damage to the equipment
can occur.
66 Maintenance
WARNING!
Wear protective gloves and long sleeves. Some parts have sharp edges.
you start the work.
2. Remove the shrouding in front of the fan (if any).
3. Disconnect the fan wiring. Remove the CIO module.
4. Remove the two screws and slide the fan unit out.
5. Remove the four screws to detach the fan from the fan unit.
6. Remove the eight screws surrounding the fan unit.
7. Install a new fan in reverse order.
5
4
6
Maintenance 67
￭ Replacing the cooling fan of a D8T supply module
WARNING!
Use the required personal protective equipment. Wear protective gloves and long
sleeves. Some parts have sharp edges.
2. Remove any shrouding in front of the cooling fan.
3. Remove the support bracket of the fan.
4. Disconnect the fan wiring.
5. Undo the two retaining screws.
6. Pull the fan outwards to separate it from the heat exchanger housing.
7. Install new fan in reverse order. Align the guide pins at the rear of the fan cowling with
the slots in the bottom guide, then reinstall the retaining screws.
7
5
4
3
68 Maintenance
Fuses
￭ Checking and replacing the AC fuses
WARNING!
Obey the safety instructions given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
If you ignore the safety instructions, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
WARNING!
Use the required personal protective equipment. Wear protective gloves and long
sleeves. Some parts have sharp edges.
1. Stop the motors connected to the drive.
3. Open the cubicle door.
4. Remove any shrouding in front of the fuses.
5. 2×D8T: For replacing lower module AC fuses, remove the DC fuse assemblies:
•
Remove the screws, nuts and washers (8 pcs) from the top and bottom of the DC
fuses. Write down the correct order of the washers.
•
•
Remove the screws and nuts from the L-shaped busbars.
Remove the DC fuses and the L-shaped busbars.
6. Remove the screw, nut and washer in the middle.
7. Remove the screws (3 pcs, 1 per each phase) from the L-shaped busbars above the
fuses.
8. Remove the screws that attach the L-shape busbars below the fuses to the module AC
busbars. There is one screw and busbar for each AC phase (3 pcs). Pull out the fuse
assemblies with the L-shaped busbars (above and below) attached.
9. Remove the screws, nuts and washers that attach the old fuses to the busbars, remove
the old fuses and attach the new fuses in reverse order. Make sure to keep the washers
Maintenance 69
6
7
9
8
5
4
￭ Checking and replacing the DC fuses
WARNING!
Obey the safety instructions given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
If you ignore the safety instructions, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
WARNING!
Use the required personal protective equipment. Wear protective gloves and long
sleeves. Some parts have sharp edges.
1. Stop the motors connected to the drive.
3. Open the cubicle door.
4. Remove any shrouding in front of the DC fuses.
5. Remove the screws, nuts and washers from the old fuses. Write down the correct order
of the washers. Pull the fuses out.
6. Install the new fuses in reverse order. Make sure that the washers are in the correct
order. If necessary, loosen the bolts of the L-shape busbars somewhat. Retighten, after
Maintenance 71
WARNING!
Use the required personal protective equipment. Wear protective gloves and long
sleeves. Some parts have sharp edges.
Keep the module in its package until you install it. After unpacking, protect the
module from dust, debris and moisture.
Lift/lower a heavy module with a lifting device. Use the designated lifting points.
See the dimension drawings. There is a lifting device available from ABB (order
code 3AXD50000047447).
Make sure that the drive cabinet is attached to the floor to prevent it from toppling
over. The cabinet has a high center of gravity. When you pull out heavy components
or power modules, there is a risk of overturning.
1. Stop the motors connected to the drive.
3. Open the cubicle door.
4. Close the inlet and outlet valve.
5. Lead the drain hoses into a suitable container. If necessary, extend the hoses. Open
the inlet and outlet drain valves. This will drain all modules in the cubicle.
6. After the cubicle has drained, disconnect the piping from the module.
7. 2×D8T module: If lower module needs to be replaced, remove the cooling fan (see the
fan replacement instructions).
8. Remove any shrouding above the module.
10. Disconnect the plug connector and fiber optic connectors in front of the module.
11. Remove the L-shaped busbars (3 pcs above the module).
12. Remove the module fastening screws (4 pcs).
13. Install the module lifting device to the cabinet. See Converter module lifting device for
drive cabinets hardware manual (3AXD50000210268 [English]).
14. Attach one lifting hook to the front lifting eye of the module and pull the module out 10
centimeters. Keep the lifting chain tight.
15. Attach the second lifting hook to the rear lifting eye, and pull the module completely out
of the cabinet. Keep the weight constantly on the lifting device.
72 Maintenance
16. Lower the module on a pallet. Keep the lifting chain attached to the module and attach
the module safely to the pallet.
17. Remove the lifting chains from the old module and move the pallet out of the way.
18. Install the new module:
a. Attach the lifting hooks to the module, lift the module and place it on the module
guide plate. Keep the weight on the lifting device.
b. Push the module into cabinet.
c. Fasten the module fastening screws.
d. Remove the lifting chains.
e. Reinstall the DC busbars and fuses above the module.
f. Connect the plug connector and fiber optic connectors.
g. Reconnect the coolant pipes to the module.
h. Fill up the cooling system.
i. Reinstall all shrouds removed earlier.
j. Remove the lifting device.
9
8
Maintenance 73
11
12
10
6
12
74 Maintenance
14
15
Control panel
For detailed information on the control panel, see ACx-AP-x assistant control panels user’s
manual (3AUA0000085685 [English]).
￭ Cleaning the control panel
Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could scratch
the display window.
￭ Replacing the control panel battery
For instructions on how to replace the control panel battery, see ACx-AP-x assistant control
panels user’s manual (3AUA0000085685 [English]).
Maintenance 75
Control unit
￭ Replacing the memory unit
After replacing a control unit, you can keep the existing parameter settings by transferring
the memory unit from the defective control unit to the new control unit.
WARNING!
Do not remove or insert the memory unit when the control unit is powered.
you start the work.
2. Make sure that the control unit is not powered.
3. Remove the fastening screw and pull the memory unit out.
4. Install a memory unit in reverse order.
￭ Replacing the BCU control unit battery
Replace the real-time clock battery if the BATT OK LED is not illuminated when the control
unit is powered.
you start the work.
2. Undo the fastening screw and remove the battery.
3. Replace the battery with a new BR2032 battery.
76 Maintenance
4. Dispose of the old battery according to local disposal rules or applicable laws.
5. Set the real-time clock.
LEDs and other status indicators
This section instructs how to interpret the status indications of the diode supply unit.
Warnings and faults reported by the control program are displayed on the control panel on
the cabinet door. For further information, see the firmware manual.
￭ Control panel and panel platform/holder LEDs
The ACS-AP-… control panel has a status LED. The control panel mounting platform or
holder has two status LEDs. For their indications, see the following table.
Location
LED
Indication
Control panel
Continuous green
Flickering green
The unit is functioning normally.
Data is transferred between the PC and the unit through the USB
connection of the control panel.
Blinking green
Continuous red
Blinking red
There is an active warning in the unit.
There is an active fault in the unit.
There is a fault that requires the stopping and restarting of the
drive/converter/inverter.
Blinking blue (ACS- The Bluetooth interface is enabled, in discoverable mode, and
AP-W only)
ready for pairing.
Flickering blue
(ACS-AP-W only)
Data is being transferred through the Bluetooth interface of the
control panel.
Control panel
mounting platform or
holder (with the
control panel
Red
There is an active fault in the unit.
Green
Power supply for the control unit is OK.
removed)
Maintenance 77
￭ Control unit LEDs
LED
Color
Indication
BATT OK
Green
Battery voltage of the real-time clock is OK (higher than 2.8 V).
When the LED is not lit,
• battery voltage is below 2.8 V,
• the battery is missing, or
• the control unit is not powered.
PWR OK
FAULT
Green
Red
Internal voltage OK
The control program indicates that the equipment is faulty. See
the appropriate firmware manual.
WRITE
Yellow
Writing to SD card in progress.
78
Internal cooling circuit 79
8
Internal cooling circuit
Contents of this chapter
The cooling system of a liquid-cooled drive consists of two circuits: the internal cooling circuit
and the external cooling circuit. The internal cooling circuit covers the heat-generating
electrical components of the drive and transfers the heat to the cooling unit. In the cooling
unit, the heat is transferred to the external cooling circuit which is usually part of a larger
external cooling system. This chapter deals with the internal cooling circuit.
Applicability
The information in this chapter is applicable to cabinet-built ACS880 liquid-cooled drives.
Except where otherwise indicated, the information is also applicable to drives built out of
ACS880 liquid-cooled multidrive modules.
Internal cooling system
Each cubicle has an inlet and an outlet manifold, fitted with a stop valve and a drain valve.
The stop valves can be closed to isolate all modules in the cubicle from the main cooling
circuit.
In cabinet line-ups built by ABB, valves are color-coded:
•
•
Blue – Open during operation
Red – Closed during operation
The following diagram shows the coolant pipe connections in a drive system consisting of
a supply unit and an inverter unit.
80 Internal cooling circuit
2
2
A/L
A/L
A/L
1
HS
HS
HS
A/L
A/L
d
HS
a
c
a
c
b
d
b
3
1
Supply modules. The drawing shows the configuration of a diode supply unit, ie. there is a common
air-to-liquid exchanger in the cubicle. With an IGBT supply unit, each module has a dedicated air-to-
liquid exchanger as shown for item 2.
2
3
Inverter modules
To/From cooling unit
Air-to-liquid heat exchanger
Heat sink
A/L
HS
a
Inlet valve
b
Inlet-side drain valve
Outlet valve
c
d
Outlet-side drain valve
The coolant used with ACS880 liquid-cooled drive systems is Antifrogen® L 25% or 50%
Internal cooling circuit 81
Connection to a cooling unit
￭ Connection to an ACS880-1007LC cooling unit
Refer to ACS880-1007LC cooling unit user’s manual (3AXD50000129607 [English]).
￭ Connection to a custom cooling unit
General requirements
Equip the system with an expansion vessel to damp pressure rise due to volume changes
when the temperature varies. Equip the system with a pump that provides a nominal flow
Install a pressure regulator to make sure that the maximum permissible operating pressure
is not exceeded.
Install a bleed valve at the highest point of the cooling circuit, and a drain valve at the lowest
point.
Coolant temperature control
The temperature of the coolant in the internal cooling circuit must be kept within the limits
ambient temperature and relative humidity.
82 Internal cooling circuit
Filling up and bleeding the internal cooling circuit
Both the drive and coolant must be at room temperature before filling up the cooling circuit.
WARNING!
Make sure that the maximum permissible operating pressure is not exceeded.
When necessary regulate the pressure to appropriate level by draining excess
coolant out of the system.
WARNING!
Bleeding of the cooling circuit is very important and has to be done with great care.
Air bubbles in the cooling circuit may reduce or completely block coolant flow and
lead to overheating. Let the air out of the cooling system while filling in coolant
and, eg. after any power module replacements.
￭ Drive line-ups with an ACS880-1007LC cooling unit
Follow the filling up and bleeding instructions in ACS880-1007LC cooling unit user's manual
(3AXD50000129607 [English]).
￭ Drive line-ups with a custom cooling unit
Note:
•
In filling up the system, the drain valves in the line-up are used only to vent the air from
the circuit so that it can be displaced by the coolant. The actual bleeding of the circuit
must be done via an external bleed valve installed at the highest point of the cooling
circuit. The most practical location for the valve is usually near or at the cooling unit.
•
•
Observe the instructions given by the manufacturer of the cooling unit. Pay special
attention to filling up and bleeding the pumps properly as they may be damaged if
operated when dry.
Draining coolant into the sewer system is not allowed.
1. Open the bleed valve at the cooling unit.
2. Open the inlet valve and the outlet-side drain valve of one cubicle. Keep the outlet valve
and the inlet-side drain valve closed.
3. Attach a hose to the outlet-side drain valve and lead it into a suitable container.
Note: To minimize foaming, do not exceed the filling flow rate of 5 l/min
(1.3 US gallon/min).
5. As the piping and modules in the cubicle fills up, coolant starts to flow from the hose.
Let some coolant flow out, then close the drain valve.
6. Close the inlet valve.
7. Repeat steps 2 to 6 for all cubicles in the line-up.
8. Open the inlet and outlet valves in all cubicles. Let any air remaining in the system out
through the bleed valve at the cooling unit.
9. Close the bleed valve at the cooling unit.
10. Continue to fill in coolant until a base pressure of 100…150 kPa is achieved.
11. Open the bleed valve of the pump to let out any air.
12. Re-check the pressure and add coolant if necessary.
Internal cooling circuit 83
13. Start the coolant pump. Let any air remaining in the system out through the bleed valve
at the cooling unit.
14. After one to two minutes, stop the pump or block the coolant flow with a valve.
15. Re-check the pressure and add coolant if necessary.
16. Repeat steps 13 to 15 a few times until all air is let out of the cooling circuit. Listen for
a humming sound and/or feel the piping for vibration to find out if there is still air left in
the circuit.
84 Internal cooling circuit
Draining the internal cooling circuit
The modules in each cubicle can be drained through the drain valves without draining the
whole internal cooling circuit.
WARNING!
Hot, pressurized coolant can be present in the cooling circuit. Do not work on the
cooling circuit before the pressure is released by stopping the pumps and draining
coolant.
1. Attach hoses to each drain valve in the cubicle to be drained. Lead the hoses into a
suitable container. Make sure the ends of the hoses are not immersed in coolant at any
point so that air can displace the coolant in the system.
2. Open the drain valves. Wait until all coolant has drained.
Note: Draining coolant into the sewer system is not allowed.
3. If required, dry the piping with compressed oil-free air of less than 6 bar.
4. If the drive is to be stored in temperatures below 0 °C (32 °F),
•
•
•
dry the cooling circuit with air,
drain the cooling circuit again.
Maintenance intervals
As a general rule, the quality of the coolant should be checked at intervals of two years.
sample is provided.
Technical data
￭ Coolant specification
Coolant type
from Clariant distributors and ABB Service representatives.
Note: Do not dilute the coolant. It is ready to use.
Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F).
Antifrogen® L 50% mixture is usable in storage temperatures down to -40 °C (-40 °F).
Note that operation below 0 °C (32 °F) is not allowed regardless of the freezing point of the
coolant.
WARNING!
The warranty does not cover damage occurring from use of improper coolant.
￭ Temperature limits
Ambient temperature: See the technical data of the drive/unit.
Freeze protection: The freezing point of the coolant is determined by the concentration of
heat transfer fluid in the mixture.
Internal cooling circuit 85
The higher the concentration of heat transfer fluid, the higher the viscosity of the coolant.
The nominal current ratings of drive system modules apply to an Antifrogen® L / water
solution of 25/75% (volume). With the Antifrogen® L concentration between 25% and 50%,
the drive output current must be derated by 1/3 percentage point per 1 p.p. increase in
Antifrogen® L concentration. The drawing below shows the derating factor (k) in relation to
Antifrogen® L concentration.
k
1.00
0.95
0.90
25%
30%
35%
40%
45%
50%
Antifrogen® L concentration
Incoming coolant temperature:
•
•
0…40 °C (32…104 °F): no drive output current derating required
40…45 °C (104…113 °F): drive output current must be derated by 2 percentage points
per 1 °C (1.8 °F) temperature increase, as shown by curve (a).
•
45…50 °C (113…122 °F):
•
If components with a maximum operating temperature of 55 °C (131 °F) are installed
in the same space as the drive modules, drive output current must be derated by
6 percentage points per 1 °C (1.8 °F) temperature increase, as shown by curve (c).
•
If there are no components with a maximum operating temperature of 55 °C (131 °F)
installed in the same space as the drive modules, drive output current must be
derated by 2 percentage points per 1 °C (1.8 °F) temperature increase, as shown
by curve (b).
The drawing below shows the derating factor (k) in relation to coolant temperature.
k
1.00
(a)
0.90
(b)
0.80
(c)
0.70
0.60
+40 °C
+45 °C
+50 °C
T
+104 °F
+113 °F
+122 °F
Condensation is not allowed. The minimum coolant temperature to avoid condensation (at
an atmospheric pressure of 1 bar) is shown below as a function of relative humidity (RH)
and ambient temperature (Tair).
Tair
Min. Tcoolant (°C)
RH = 65%
-0.9
(°C)
RH = 95%
RH = 80%
RH = 50%
RH = 40%
5
4.3
1.9
-4.5
-7.4
86 Internal cooling circuit
Tair
Min. Tcoolant (°C)
(°C)
RH = 95%
RH = 80%
6.7
RH = 65%
3.7
RH = 50%
-0.1
RH = 40%
-3.0
10
15
20
25
30
35
40
45
50
55
9.2
14.2
19.2
24.1
29.1
34.1
39.0
44.0
49.0
53.9
11.5
8.4
4.6
1.5
16.5
21.4
26.2
31.1
35.9
40.8
45.6
50.4
13.2
17.9
22.7
27.4
32.2
36.8
41.6
46.3
9.4
6.0
13.8
18.4
23.0
27.6
32.1
36.7
42.2
10.5
15.0
19.4
23.8
28.2
32.8
37.1
= Not allowed as standard but the coolant temperature must be 0 °C (32 °F) or above.
At an air temperature of 45 °C and relative humidity of 65% the coolant temperature may
not be below +36.8 °C
Example:
Maximum temperature rise: Depends on heat losses and mass flow. Typically 10 °C (18
°F) with nominal losses and flow.
￭ Pressure limits
Base pressure: 250 kPa (recommended); 300 kPa (maximum). “Base pressure” denotes
the pressure of the system compared with the atmospheric pressure when the cooling circuit
is filled with coolant.
Air counterpressure in expansion vessel (with ACS880-1007LC cooling unit): 80 kPa
Design pressure (PS): 600 kPa
Nominal pressure difference: 120 kPa with Antifrogen® L 25% coolant solution, 140 kPa
with Antifrogen® L 50% coolant solution. This has to be taken into account when
dimensioning the liquid cooling circuit.
Maximum pressure difference: 160 kPa
￭ Coolant flow rate limits
The maximum coolant flow rate for all drive equipment is 1.3 × nominal. See the technical
data chapter for nominal values.
￭ Cooling circuit materials
Materials used in the internal cooling circuit are listed below. These are also the only materials
that can be used in the external cooling circuit.
•
•
•
stainless steel AISI 316L (UNS 31603)
heavy gauge aluminum
plastic materials such as PA, PEX and PTFE
Note: PVC hoses are not suitable for use with antifreeze.
Internal cooling circuit 87
•
rubber gasketing NBR (nitrile rubber).
WARNING!
If connecting external piping to the internal cooling circuit, use only materials
that are specified above. Copper, brass or bronze must not be used under
any circumstances. Even minor dissolution of copper can cause copper
precipitation on aluminum and subsequent galvanic corrosion. The liquid
cooling system must not contain any zinc (eg. galvanized pipes).
If the plant incorporates normal iron pipes or cast iron accessories (eg. motor housings), a
cooling unit with a heat exchanger (such as the ACS880-1007LC) must be used to separate
the systems.
88
Technical data 89
9
Technical data
Contents of this chapter
This chapter contains the technical data.
The information is valid for ACS880-307LC…+A018 diode supply units.
Ratings
Supply unit
type
No overload use
Light overload Heavy-duty use
use
ACS880-
307LC-…
I1
I2
Imax_1
SN
Imax_2
PN
ILd
PLd
IHd
PHd
A (AC) A (DC) A (DC)
kVA
A (AC)
kW
A (DC)
kW
A (DC)
kW
(DC)
(DC)
(DC)
UN = 690 V
6-pulse
0490A-7+A018
0780A-7+A018
490
780
600
955
900
1430
1950
2700
3675
5505
7350
9180
11025
585
932
735
559
890
576
917
537
854
449
714
418
666
1170
1590
2205
3000
4500
6000
7500
9000
1060A-7+A018 1060
1470A-7+A018 1470
2000A-7+A018 2000
3000A-7+A018 3000
4000A-7+A018 4000
5000A-7+A018 5000
6000A-7+A018 6000
12-pulse
1300
1800
2450
3670
4900
6120
7350
1267
1757
2390
3585
4780
5979
7171
1211
1677
2283
3420
4566
5703
6849
1248
1728
2352
3523
4704
5875
7056
1163
1610
2192
3283
4383
5475
6575
972
906
1346
1833
2745
3665
4578
5498
1255
1708
2558
3415
4266
5123
0920A-7
920
1130
1695
1100
1380
1053
1085
1011
845
788
+A004+A018
90 Technical data
Supply unit
type
No overload use
Light overload Heavy-duty use
use
ACS880-
307LC-…
I1
I2
Imax_1
SN
Imax_2
PN
ILd
PLd
IHd
PHd
A (AC) A (DC) A (DC)
kVA
A (AC)
kW
A (DC)
kW
A (DC)
kW
(DC)
(DC)
(DC)
1470A-7
+A004+A018
1470
2000
2940
4000
6000
1800
2450
3600
4900
7350
2700
3675
5400
7350
11025
1757
2390
3514
4780
7171
2205
3000
4410
6000
9000
1677
2283
3355
4566
6849
1728
2352
3456
4704
7056
1610
2192
3220
4383
6575
1346
1833
2693
3665
5498
1255
1708
2509
3415
5123
2000A-7
+A004+A018
2940A-7
+A004+A018
4000A-7
+A004+A018
6000A-7
+A004+A018
Definitions
Nominal ratings
UN
I1
Continuous rms input (AC) current. No overload capability at the coolant
temperature of 40 °C (104 °F) and air temperature of 45 °C (113 °F).
I2
Continuous rms output (DC) current. No overload capability at the coolant
temperature of 40 °C (104 °F) and air temperature of 45 °C (113 °F).
Imax_1
Maximum output (DC) current. Available for 10 s at start, otherwise as long as
allowed by module temperature.
SN
Nominal apparent (AC) power
Maximum input (AC) current
Nominal output (DC) power
Imax_2
PN
Light-overload use (50% overload capability) ratings
ILd
Continuous current. 50% overload is allowed for one minute every 5 minutes.
Output power in light-overload use
PLd
Heavy-duty use (50% overload capability) ratings
IHd
Continuous current. 50% overload is allowed for one minute every 5 minutes.
Output power in heavy-duty use
PHd
Derating
￭ Surrounding air temperature derating
In the temperature range +45…55 °C (+113…131 °F), the rated output current is derated
by 0.5 percentage points for every added 1 °C (1.8 °F). The output current can be calculated
by multiplying the current given in the rating table by the derating factor (k):
Technical data 91
k
1.00
0.95
0.90
T
+45 °C
+55 °C
+113 °F
+131 °F
￭ Coolant temperature derating
￭ Antifreeze content derating
￭ Altitude derating
At altitudes 1000 … 2000 m (3281 … 6562 ft) above sea level, the output current derating
is 1 percentage point for every added 100 m (328 ft). For example, the derating factor for
1500 m (4921 ft) is 0.95. For altitudes above 2000 m (6562 ft), contact ABB.
For a more accurate derating, use the DriveSize PC tool.
Type equivalence table
Supply unit type
Basic module type
Frame
UN = 690 V
6-pulse
ACS880-307LC-0490A-7+A018
ACS880-307LC-0780A-7+A018
ACS880-307LC-1060A-7+A018
ACS880-307LC-1470A-7+A018
ACS880-307LC-2000A-7+A018
ACS880-307LC-3000A-7+A018
ACS880-307LC-4000A-7+A018
ACS880-307LC-5000A-7+A018
ACS880-307LC-6000A-7+A018
12-pulse
ACS880-304LC-0490A-7+A018
ACS880-304LC-0780A-7+A018
ACS880-304LC-1060A-7+A018
ACS880-304LC-0780A-7+A018
ACS880-304LC-1060A-7+A018
ACS880-304LC-1060A-7+A018
ACS880-304LC-1060A-7+A018
ACS880-304LC-1060A-7+A018
ACS880-304LC-1060A-7+A018
D8T
D8T
D8T
2×D8T
2×D8T
3×D8T
4×D8T
5×D8T
6×D8T
ACS880-307LC-0920A-7+A004+A018
ACS880-307LC-1470A-7+A004+A018
ACS880-307LC-2000A-7+A004+A018
ACS880-307LC-2940A-7+A004+A018
ACS880-307LC-4000A-7+A004+A018
ACS880-307LC-6000A-7+A004+A018
ACS880-304LC-0490A-7+A018
ACS880-304LC-0780A-7+A018
ACS880-304LC-1060A-7+A018
ACS880-304LC-0780A-7+A018
ACS880-304LC-1060A-7+A018
ACS880-304LC-1060A-7+A018
2×D8T
2×D8T
2×D8T
4×D8T
4×D8T
6×D8T
92 Technical data
Fuses
￭ Main circuit AC fuses
IEC
IN
Supply unit type
ACS880-307LC-…
Type
Pcs.
Size
A
UN = 690 V
6-pulse
0490A-7+A018
0780A-7+A018
1060A-7+A018
1470A-7+A018
2000A-7+A018
3000A-7+A018
4000A-7+A018
5000A-7+A018
6000A-7+A018
12-pulse
170M6413
170M6416
170M6413
170M6416
170M6413
170M6413
170M6413
170M6413
170M6413
3
3
900
size 3
1250
size 3
6
2 × 900
1250
2 × size 3
size 3
6
12
18
24
30
36
2 × 900
2 × 900
2 × 900
2 × 900
2 × 900
2 × size 3
2 × size 3
2 × size 3
2 × size 3
2 × size 3
0920A-7+A004+A018
1470A-7+A004+A018
2000A-7+A004+A018
2940A-7+A004+A018
4000A-7+A004+A018
6000A-7+A004+A018
170M6413
170M6416
170M6413
170M6416
170M6413
170M6413
6
900
size 3
size 3
6
1250
12
12
24
36
2 × 900
1250
2 × size 3
size 3
2 × 900
2 × 900
2 × size 3
2 × size 3
UL/CSA
IN
Supply unit type
ACS880-307LC-…
Type
Pcs.
Size
A
UN = 690 V
6-pulse
0490A-7+A018
0780A-7+A018
1060A-7+A018
1470A-7+A018
2000A-7+A018
3000A-7+A018
4000A-7+A018
5000A-7+A018
6000A-7+A018
12-pulse
170M6413
170M6416
170M6904
170M6416
170M6904
170M6904
170M6904
170M6904
170M6904
3
3
900
size 3
size 3
1250
1800
1250
1800
1800
1800
1800
1800
3
size 23
size 3
6
6
size 23
size 23
size 23
size 23
size 23
9
12
15
18
0920A-7+A004+A018
1470A-7+A004+A018
170M6413
170M6416
6
6
900
size 3
size 3
1250
Technical data 93
UL/CSA
IN
Supply unit type
ACS880-307LC-…
Type
Pcs.
Size
A
2000A-7+A004+A018
2940A-7+A004+A018
4000A-7+A004+A018
6000A-7+A004+A018
170M6904
170M6416
170M6904
170M6904
6
1800
1250
1800
1800
size 23
size 3
12
12
18
size 23
size 23
￭ Main circuit DC fuses
IEC
IN
Supply unit type
ACS880-307LC-…
Type
Pcs.
Size
A
UN = 690 V
6-pulse
0490A-7+A018
0780A-7+A018
1060A-7+A018
1470A-7+A018
2000A-7+A018
3000A-7+A018
4000A-7+A018
5000A-7+A018
6000A-7+A018
12-pulse
170M6549
170M6546
170M6549
170M6546
170M6549
170M6549
170M6549
170M6549
170M6549
2
4
1100
size 3
2 × 800
2 × 1100
2 × 800
2 × 1100
2 × 1100
2 × 1100
2 × 1100
2 × 1100
2 × size 3
2 × size 3
2 × size 3
2 × size 3
2 × size 3
2 × size 3
2 × size 3
2 × size 3
4
8
8
12
16
20
24
0920A-7+A004+A018
1470A-7+A004+A018
2000A-7+A004+A018
2940A-7+A004+A018
4000A-7+A004+A018
6000A-7+A004+A018
170M6549
170M6546
170M6549
170M6546
170M6549
170M6549
4
8
1100
size 3
2 × 800
2 × 1100
2 × 800
2 × 1100
2 × 1100
2 × size 3
2 × size 3
2 × size 3
2 × size 3
2 × size 3
8
16
16
24
UL/CSA
IN
Supply unit type
ACS880-307LC-…
Type
Pcs.
Size
A
UN = 690 V
6-pulse
0490A-7+A018
0780A-7+A018
1060A-7+A018
1470A-7+A018
2000A-7+A018
3000A-7+A018
170M6549
170M6792
170M6827
170M6792
170M6827
170M6827
2
2
2
4
4
6
1100
1600
2100
1600
2100
2100
size 3
size 23
size 23
size 23
size 23
size 23
94 Technical data
UL/CSA
IN
Supply unit type
ACS880-307LC-…
Type
Pcs.
Size
A
4000A-7+A018
170M6827
170M6827
170M6827
8
2100
2100
2100
size 23
size 23
size 23
5000A-7+A018
10
12
6000A-7+A018
12-pulse
0920A-7+A004+A018
1470A-7+A004+A018
2000A-7+A004+A018
2940A-7+A004+A018
4000A-7+A004+A018
6000A-7+A004+A018
170M6789
170M6792
170M6827
170M6792
170M6827
170M6827
4
4
1100
1600
2100
1600
2100
2100
size 3
size 23
size 23
size 23
size 23
size 23
4
8
8
12
Dimensions, weights and free space requirements
Note: The following dimensions and weights are applicable to diode supply module cubicle
only. Incoming and auxiliary control cubicles not included.
Height Width
Depth Weight
Supply unit type
ACS880-307LC-…
Basic module type
ACS880-304LC-…
Frame
mm
mm
mm
kg
6-pulse
0490A-7+A018
0780A-7+A018
1060A-7+A018
1470A-7+A018
2000A-7+A018
3000A-7+A018
4000A-7+A018
5000A-7+A018
6000A-7+A018
12-pulse
0490A-7+A018
0780A-7+A018
1060A-7+A018
0780A-7+A018
1060A-7+A018
1060A-7+A018
1060A-7+A018
1060A-7+A018
1060A-7+A018
D8T
D8T
2002
2002
2002
2002
2002
2002
2002
2002
2002
400
400
400
400
400
800
800
1200
1200
644
644
644
644
644
644
644
644
644
300
300
300
450
450
750
900
1200
1350
D8T
2xD8T
2xD8T
3xD8T
4xD8T
5xD8T
6xD8T
0920A-7+A004+A018
1470A-7+A004+A018
2000A-7+A004+A018
2940A-7+A004+A018
4000A-7+A004+A018
6000A-7+A004+A018
0490A-7+A018
0780A-7+A018
1060A-7+A018
0780A-7+A018
1060A-7+A018
1060A-7+A018
2xD8T
2xD8T
2xD8T
4xD8T
4xD8T
6xD8T
2002
2002
2002
2002
2002
2002
400
400
400
800
800
1200
644
644
644
644
644
644
450
450
450
900
900
1350
3AXD00000601909
Technical data 95
Cooling data and noise
Coolant volume
Coolant flow rate
Noise level
Pressure
Supply unit type
ACS880-307LC-…
Modules Modules + Modules Modules +
Average
loss
cabinet
cabinet
l
l
l/min
l/min
kPa
dB (A)
UN = 690 V
6-pulse
0490A-7+A018
0780A-7+A018
1060A-7+A018
1470A-7+A018
2000A-7+A018
3000A-7+A018
4000A-7+A018
5000A-7+A018
6000A-7+A018
12-pulse
0.6
0.6
0.6
1.2
1.2
1.8
2.4
3.0
3.6
3.5
3.5
14
14
14
28
28
42
56
70
84
20
20
20
34
34
54
68
88
102
120
120
120
120
120
120
120
120
120
65
65
65
65
65
67
67
68
68
3.5
4.2
4.2
7.7
8.4
11.9
12.6
0920A-7+A004+A018
1470A-7+A004+A018
2000A-7+A004+A018
2940A-7+A004+A018
4000A-7+A004+A018
6000A-7+A004+A018
1.2
1.2
1.2
2.4
2.4
3.6
4.2
4.2
28
28
28
56
56
84
34
34
120
120
120
120
120
120
67
67
67
68
68
68
4.2
34
8.4
68
8.4
68
12.6
102
Terminal and cable entry data for the input power cable
These drawings (from front, side and above) show the terminal and cable entry dimensions
for incoming cubicles. The dimensions are given in millimeters. Tightening torque for the
cable lug connection depends on the bolt size and type. See section Tightening
98 Technical data
Tightening torques
Unless a tightening torque is specified in the text, the following torques can be used.
￭ Electrical connections
Size
M3
Torque
Note
0.5 N·m (4.4 lbf·in)
1 N·m (9 lbf·in)
Strength class 4.6...8.8
Strength class 4.6...8.8
Strength class 8.8
Strength class 8.8
Strength class 8.8
Strength class 8.8
Strength class 8.8
Strength class 8.8
M4
M5
4 N·m (35 lbf·in)
9 N·m (6.6 lbf·ft)
22 N·m (16 lbf·ft)
42 N·m (31 lbf·ft)
70 N·m (52 lbf·ft)
120 N·m (90 lbf·ft)
M6
M8
M10
M12
M16
￭ Mechanical connections
Size
M5
Max. torque
6 N·m (53 lbf·in)
10 N·m (7.4 lbf·ft)
24 N·m (17.7 lbf·ft)
Note
Strength class 8.8
Strength class 8.8
Strength class 8.8
M6
M8
￭ Insulation supports
Size
M6
Max. torque
Note
5 N·m (44 lbf·in)
9 N·m (6.6 lbf·ft)
18 N·m (13.3 lbf·ft)
31 N·m (23 lbf·ft)
Strength class 8.8
Strength class 8.8
Strength class 8.8
Strength class 8.8
M8
M10
M12
￭ Cable lugs
Size
M8
Max. torque
15 N·m (11 lbf·ft)
32 N·m (23.5 lbf·ft)
50 N·m (37 lbf·ft)
Note
Strength class 8.8
Strength class 8.8
Strength class 8.8
M10
M12
Technical data 99
Typical power cable sizes
The tables below give current carrying capacity (ILmax) for aluminum and copper PVC/XLPE
insulated cables. A correction factor K = 0.70 is used. Time const is the temperature time
constant of the cable.
The cable sizing is based on max. 9 cables laid on the cable trays side by side, three ladder
type trays one on top of the other, ambient temperature 30 °C (EN 60204-1 and
IEC 60364-5-52).
Aluminum cable
PVC insulation
XLPE insulation
Conductor temperature 70 °C Conductor temperature 90 °C
Size
⌀ [mm]
ILmax [A]
Time const. [s] ILmax [A]
Time const. [s]
3 × 35 + 10 Cu
3 × 50 + 15 Cu
3 × 70 + 21 Cu
3 × 95 + 29 Cu
3 × 120 + 41 Cu
3 × 150 + 41 Cu
3 × 185 + 57 Cu
3 × 240 + 72 Cu
3 × 300 + 88 Cu
26
29
32
38
41
44
49
54
58
67
736
84
669
82
959
102
131
159
184
213
243
286
330
874
105
128
148
171
196
231
267
1182
1492
1776
2042
2422
2967
3478
1079
1376
1637
1881
2237
2740
3229
2 × (3 × 70 + 21 Cu)
2 × (3 × 95 + 29 Cu)
2 × (3 × 120 + 41 Cu)
2 × (3 × 150 + 41 Cu)
2 × (3 × 185 + 57 Cu)
2 × (3 × 240 + 72 Cu)
2 × (3 × 300 + 88 Cu)
2 × 32
2 × 38
2 × 41
2 × 44
2 × 49
2 × 54
2 × 58
210
256
297
343
392
462
533
1182
1492
1776
2042
2422
2967
3478
262
318
368
425
486
572
659
1079
1376
1637
1881
2237
2740
3229
3 × (3 × 150 + 41 Cu)
3 × (3 × 185 + 57 Cu)
3 × (3 × 240 + 72 Cu)
3 × (3 × 300 + 88 Cu)
3 × 44
3 × 49
3 × 54
3 × 58
514
588
693
800
2042
2422
2967
3478
638
728
859
989
1881
2237
2740
3229
4 × (3 × 185 + 57 Cu)
4 × (3 × 240 + 72 Cu)
4 × (3 × 300 + 88 Cu)
4 × 49
4 × 54
4 × 58
784
2422
2967
3478
971
2237
2740
3229
924
1145
1319
1067
5 × (3 × 185 + 57 Cu)
5 × (3 × 240 + 72 Cu)
5 × (3 × 300 + 88 Cu)
5 × 49
5 × 54
5 × 58
980
2422
2967
3478
1214
1431
1648
2237
2740
3229
1155
1333
6 × (3 × 240 + 72 Cu)
6 × (3 × 300 + 88 Cu)
6 × 54
6 × 58
1386
1600
2967
3478
1718
1978
2740
3229
7 × (3 × 240 + 72 Cu)
7 × (3 × 300 + 88 Cu)
7 × 54
7 × 58
1617
1867
2967
3478
2004
2308
2740
3229
8 × (3 × 240 + 72 Cu)
8 × (3 × 300 + 88 Cu)
8 × 54
8 × 58
1848
2133
2967
3478
2290
2637
2740
3229
9 × (3 × 240 + 72 Cu)
9 × (3 × 300 + 88 Cu)
9 × 54
9 × 58
2079
2400
2967
3478
2577
2967
2740
3229
10 × (3 × 240 + 72 Cu)
10 × (3 × 300 + 88 Cu)
10 × 54
10 × 58
2310
2667
2967
3478
2867
3297
2740
3229
100 Technical data
Copper cable
Size
PVC insulation
XLPE insulation
Conductor temperature 70 °C Conductor temperature 90 °C
⌀ [mm]
ILmax [A]
Time const. [s] ILmax [A]
Time const. [s]
3 × 1.5 + 1.5
3 × 2.5 + 2.5
(3 × 4 + 4)
13
14
16
18
21
23
24
26
29
32
38
41
44
50
55
58
13
85
16
67
18
121
23
88
24
175
30
133
3 × 6 + 6
30
251
38
186
3 × 10 + 10
3 × 16 + 16
3 × 25 + 16
3 × 35 + 16
3 × 50 + 25
3 × 70 + 35
3 × 95 + 50
3 × 120 + 70
3 × 150 + 70
3 × 185 + 95
3 × 240 + 120
3 × 300 + 150
42
359
53
268
56
514
70
391
71
791
89
598
88
1000
1308
1613
2046
2441
2820
3329
4073
4779
110
134
171
209
241
279
319
376
435
760
107
137
167
193
223
255
301
348
990
1230
1551
1859
2139
2525
3099
3636
2 × (3 × 70 + 35)
2 × (3 × 95 + 50)
2 × (3 × 120 + 70)
2 × (3 × 150 + 70)
2 × (3 × 185 + 95)
2 × (3 × 240 + 120)
2 × (3 × 300 + 150)
2 × 32
2 × 38
2 × 41
2 × 44
2 × 50
2 × 55
2 × 58
274
334
386
446
510
602
696
1613
2046
2441
2820
3329
4073
4779
342
418
482
558
638
752
869
1230
1551
1859
2139
2525
3099
3636
3 × (3 × 120 + 70)
3 × (3 × 150 + 70)
3 × (3 × 185 + 95)
3 × (3 × 240 + 120)
3 × (3 × 300 + 150)
3 × 41
3 × 44
3 × 50
3 × 55
3 × 58
579
669
765
903
1044
2441
2820
3329
4073
4779
723
1859
2139
2525
3099
3636
837
957
1128
1304
4 × (3 × 150 + 70)
4 × (3 × 185 + 95)
4 × (3 × 240 + 120)
4 × (3 × 300 + 150)
4 × 44
4 × 50
4 × 55
4 × 58
892
2820
3329
4073
4779
1116
1276
1504
1304
2139
2525
3099
3636
1020
1204
1391
5 × (3 × 185 + 95)
5 × (3 × 240 + 120)
5 × (3 × 300 + 150)
5 × 50
5 × 55
5 × 58
1275
1505
1739
3329
4073
4779
1595
1880
2173
2525
3099
3636
6 × (3 × 185 + 95)
6 × (3 × 240 + 120)
6 × (3 × 300 + 150)
6 × 50
6 × 55
6 × 58
1530
1806
2087
3329
4073
4779
1914
2256
2608
2525
3099
3636
7 × (3 × 240 + 120)
7 × (3 × 300 + 150)
7 × 55
7 × 58
2107
2435
4073
4779
2632
3043
3099
3636
8 × (3 × 240 + 120)
8 × (3 × 300 + 150)
8 × 55
8 × 58
2408
2783
4073
4779
3008
3477
3099
3636
Technical data 101
Electrical power network specification
Voltage (U1)
690 V units: 525…690 V AC 3-phase ± 10% (525…600 V AC ± 10% in UL/CSA
installations, or corner-grounded TN systems). This is indicated in the type desig-
nation label as typical input voltage levels (3~ 525/600/690 V AC).
Network type
Frequency
TN (grounded) and IT (ungrounded) systems
50/60 Hz, variation ± 5% of nominal frequency
Imbalance
Max. ± 3% of nominal phase-to-phase input voltage
Supply units with main circuit breaker (option +F255) and without grounding/earthing
Short-circuit withstand
strength (IEC/EN 61439-1) switch (without option +F259):
Rated peak withstand current (Ipk): 143 kA
Rated short-time withstand current (Icw): 65 kA/1 s
All other configurations:
Rated peak withstand current (Ipk): 105 kA
Rated short-time withstand current (Icw): 50 kA/1 s
Short-circuit current protec- The drive is suitable for use on a circuit capable of delivering not more than
tion (UL 508A, CSA C22.2 100,000 rms symmetrical amperes at 600 V maximum when the input cable is
No. 14-13)
protected with class T fuses.
Transformer specification Connection: Dy 11 d0 or Dyn 11 d0
for 12-pulse supply
Phase shift between secondaries: 30° electrical
(IEC 60076-1:2011)
Voltage difference between secondaries: < 0.5%
Short-circuit impedance of secondaries: > 5%
Short-circuit impedance difference between secondaries: ≤ 10% of the percentage
impedance
To avoid a potentially destructive DC voltage level in an earth fault situation,
grounding of the secondaries is not allowed. Static shielding is recommended.
Control unit (board) connection data
Auxiliary circuit current consumption
Auxiliary circuit current consumption varies depending on the actual drive configuration and
options. Contact ABB for the delivery-specific value.
Efficiency
Efficiency
98.2…98.8% at nominal power level depending on drive type
Protection classes
Degrees of protection
(IEC/EN 60529)
IP42 (standard), IP54 (option +B055)
Enclosure types (UL50) UL Type 1 (standard), UL Type 12 (option +B055). For indoor use only.
Overvoltage category
(IEC/EN 60664-1)
III, except for auxiliary power connections (fan, control, heating, lighting, cooling
unit pump etc) which are category II.
Protective class
I
(IEC/EN 61800-5-1)
102 Technical data
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.
Operation
Storage
Transportation
installed for stationary in the protective package in the protective package
use
Installation site altitude
0…2000 m (0…6562 ft)
above sea level. For alti-
tudes over 2000 m, contact
ABB.
-
-
Output derated above 1000
m (3281 ft).
Air temperature
0 … +45 °C
(+32 … +113 °F), no con-
densation allowed. Output
derated in the range
+45 … +55 °C
-40 to +70 °C (-
40 to +158 °F)
-40 to +70 °C (-
40 to +158 °F)
(+113 … +131 °F).
Relative humidity
Contamination
Max. 95%
Max. 95%
Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence
of corrosive gases.
IEC/EN 60721-3-3:2002:
Classification of environ-
mental conditions - Part 3-
3: Classification of groups
of environmental paramet-
ers and their severities -
Stationary use of weather
protected locations
IEC 60721-3-1:1997
IEC 60721-3-2:1997
Chemical gases: Class
1C2
Chemical gases: Class
2C2
Solid particles: Class 1S3 Solid particles: Class 2S2
(packing must support this,
otherwise 1S2)
Chemical gases: Class
3C2
Solid particles: Class 3S2.
No conductive dust al-
lowed.
Pollution degree
2
Vibration
IEC/EN 60721-3-3:2002 IEC/EN 60721-3-1:1997 IEC/EN 60721-3-2:1997
10…57 Hz: max. 0.075 mm 10…57 Hz: max. 0.075 mm 2…9 Hz: max. 3.5 mm
IEC/EN 61800-5-1
amplitude
amplitude
amplitude
9…200 Hz: 10 m/s2
(32.8 ft/s2)
IEC 60068-2-6:2007,
EN 60068-2-6:2008 Envir-
onmental testing Part 2:
Tests –Test Fc: Vibration
(sinusoidal)
57…150 Hz: 1 g
57…150 Hz: 1 g
Units with marine construc-
tion (option +C121): Max.
1 mm (0.04 in)
(5 … 13.2 Hz), max. 0.7 g
(13.2 … 100 Hz) sinusoidal
Shock
Not allowed
With packing max.
With packing max.
100 m/s2 (328 ft/s2) 11 ms 100 m/s2 (328 ft/s2) 11 ms
IEC 60068-2-27:2008, EN
60068-2-27:2009
Environmental testing -
Part 2-27: Tests - Test Ea
and guidance: Shock
Technical data 103
Materials
See ACS880 cabinet-installed drives Recycling instructions and environmental information
(3AXD50000153909 [English]).
Color
RAL 7035 and RAL 9017.
Package
￭ Vertical package
Cabinets are attached to the pallet with screws and braced at the top to the package walls
against swaying inside the package. Package elements are attached to each other with
screws.
Standard package
Timber, polyethylene sheet (thickness 0.15 mm), stretch film (thickness 0.023 mm),
PP tape, PET strap, sheet metal (steel).
For land and air transport when planned storage time is less than 2 months, or,
when storage can be arranged in clean and dry conditions, less than 6 months.
Can be used when product will not be exposed to corrosive atmosphere during
transport or storage.
Seaworthy package
(option +P912)
Timber, plywood, VCI sheet film (PE, thickness 0.10 mm), VCI stretch film (PE,
thickness 0.04 mm), VCI emitter bags, PP tape, PET strap, sheet metal (steel).
For sea transport with or without containerization.
For long storage periods in environments where roofed and humidity-controlled
storage cannot be arranged.
Container package
(option +P929)
Timber, VCI sheet film (PE, thickness 0.10 mm), VCI stretch film (PE, thickness
0.04 mm), VCI emitter bags, PP tape, PET strap, sheet metal (steel).
For sea transport in containers.
Recommended for land and air transport when storage time prior to installation
exceeds 6 months or storage is arranged in partially weather-protected conditions.
Disposal
The main parts of the drive can be recycled to preserve natural resources and energy.
Product parts and materials should be dismantled and separated.
Generally all metals, such as steel, aluminum, copper and its alloys, and precious metals
can be recycled as material. Plastics, rubber, cardboard and other packaging material can
be used in energy recovery. Printed circuit boards and large electrolytic capacitors need
selective treatment according to IEC 62635 guidelines. To aid recycling, plastic parts are
marked with an appropriate identification code.
Contact your local ABB distributor for further information on environmental aspects and
recycling instructions for professional recyclers. End of life treatment must follow international
and local regulations. See ACS880 cabinet-installed drives recycling instructions and
environmental information (3AXD50000153909 [English]).
Applicable standards
See ACS880 liquid-cooled multidrive cabinets and modules Electrical planning
(3AXD50000048634 [English]).
104 Technical data
Markings
See ACS880 liquid-cooled multidrive cabinets and modules Electrical planning
(3AXD50000048634 [English]).
Disclaimers
￭ Generic disclaimer
The manufacturer shall have no obligation with respect to any product which (i) has been
improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident;
(iii) has been used in a manner contrary to the manufacturer’s instructions; or (iv) has failed
as a result of ordinary wear and tear.
￭ Cybersecurity disclaimer
This product is designed to be connected to and to communicate information and data via
a network interface. It is Customer's sole responsibility to provide and continuously ensure
a secure connection between the product and Customer network or any other network (as
the case may be). Customer shall establish and maintain any appropriate measures (such
as but not limited to the installation of firewalls, application of authentication measures,
encryption of data, installation of anti-virus programs, etc) to protect the product, the network,
its system and the interface against any kind of security breaches, unauthorized access,
interference, intrusion, leakage and/or theft of data or information. ABB and its affiliates are
not liable for damages and/or losses related to such security breaches, any unauthorized
access, interference, intrusion, leakage and/or theft of data or information.
—
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and service
Product training
Providing feedback on ABB manuals
Your comments on our manuals are welcome. Navigate to
Document library on the Internet
You can find manuals and other product documents in PDF format on the Internet at
a1 (frozen)
PDF-A4
Created 2020-06-30, 09:37:26
www.abb.com/drives
3AXD50000579662A
© Copyright 2020 ABB. All rights reserved.
Specifications subject to change without notice.
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